Relevant bibliographies by topics / Engineering design Friction stir welding

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  1. Journal articles
  2. Dissertations / Theses
  3. Books
  4. Book chapters
  5. Conference papers

Academic literature on the topic 'Engineering design Friction stir welding'

Author: Grafiati
Published: 4 June 2021
Last updated: 8 February 2022

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Journal articles on the topic "Engineering design Friction stir welding"

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Palanivel, R., RF Laubscher, S. Vigneshwaran, and I. Dinaharan. "Prediction and optimization of the mechanical properties of dissimilar friction stir welding of aluminum alloys using design of experiments." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 8 (September 6, 2016): 1384–94. http://dx.doi.org/10.1177/0954405416667404.

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Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face–centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351–AA5083. Three weld parameters that influence weld quality were considered, namely, tool shoulder profile (flat grooved, partial impeller and full impeller), rotational speed and welding speed. Experimental results detailing the variation of the ultimate tensile strength as a function of the friction stir welding process parameters are presented and analyzed. An empirical model that relates the friction stir welding process parameters and the ultimate tensile strength was obtained by utilizing a design of experiments technique. The models developed were validated by an analysis of variance. In general, the full impeller shoulder profile displayed the best mechanical properties when compared to the other profiles. Electron backscatter diffraction maps were used to correlate the metallurgical properties of the dissimilar joints with the joint mechanical properties as obtained experimentally and subsequently modeled. The optimal friction stir welding process parameters, to maximize ultimate tensile strength, are identified and reported.
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Jagadeesha, C. B. "Analysis and design of friction stir welding tool." Journal of the Mechanical Behavior of Materials 25, no. 5-6 (December 20, 2016): 179–82. http://dx.doi.org/10.1515/jmbm-2017-0006.

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AbstractSince its inception no one has done analysis and design of FSW tool. Initial dimensions of FSW tool are decided by educated guess. Optimum stresses on tool pin have been determined at optimized parameters for bead on plate welding on AZ31B–O Mg alloy plate. Fatigue analysis showed that the chosen FSW tool for the welding experiment has not ∞ life and it has determined that the life of FSW tool is 2.66×105 cycles or revolutions. So one can conclude that any arbitrarily decided FSW tool generally has finite life and cannot be used for ∞ life. In general, one can determine the suitability of tool and its material to be used in FSW of the given workpiece materials in advance by this analysis in terms of fatigue life of the tool.
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Hsieh, H. T., and J. L. Chen. "Using TRIZ methods in friction stir welding design." International Journal of Advanced Manufacturing Technology 46, no. 9-12 (July 11, 2009): 1085–102. http://dx.doi.org/10.1007/s00170-009-2172-y.

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Sharma, Nidhi, Zahid A. Khan, Arshad Noor Siddiquee, and Mohd Atif Wahid. "Multi-response optimization of friction stir welding process parameters for dissimilar joining of Al6101 to pure copper using standard deviation based TOPSIS method." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 18 (July 23, 2019): 6473–82. http://dx.doi.org/10.1177/0954406219858628.

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Friction stir welding is a new and effective solid-state welding process for joining dissimilar materials such as aluminum (Al) and copper (Cu). Joint quality of the friction stir welded materials gets influenced by the welding strategy and different friction stir welding process parameters, i.e. rotational speed, welding speed, tool design, tool pin offset, and tilt angle. In this paper, the effect of combination of different friction stir welding process parameters during joining of Al-6101 and pure copper is studied using Taguchi L18 orthogonal array. Four friction stir welding process parameters, i.e. shoulder diameter (A), pin offset (B), welding speed (C), and rotational speed (D) each at three levels except shoulder diameter, which is at two levels are selected. The effect of different combinations of these parameters on ultimate tensile strength and micro-hardness of the joints is investigated. Subsequently, single response optimization for ultimate tensile strength and micro-hardness and multi-response optimization of ultimate tensile strength and micro-hardness taken together is carried out to obtain the optimal combination of the friction stir welding process parameters. Taguchi method is used for single response optimization, whereas Taguchi-based TOPSIS method is employed for multi-response optimization. For single optimization, the optimum combination of the friction stir welding parameters yielding maximum strength and micro-hardness are A1B1C2D2 and A2B1C2D3, respectively. The optimum combination of the process parameters for multi-response optimization is A2B1C2D2. From the results of the study for single- and multi-response optimization, it is revealed that the rotational speed is the most significant process parameter affecting the tensile strength and micro-hardness of the joints followed by the welding speed. Further, the macro/microstructure and micro-hardness profile of the joint obtained at the optimal combination of the multi-response optimization are given and discussed for better understanding of material mixing and joining.
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Wu, Jiafeng, Rui Zhang, and Guangxin Yang. "Design and experiment verification of a new heavy friction-stir-weld robot for large-scale complex surface structures." Industrial Robot: An International Journal 42, no. 4 (June 15, 2015): 332–38. http://dx.doi.org/10.1108/ir-01-2015-0009.

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Purpose – This paper aims to present a new friction-stir-weld robot for large-scale complex surface structures, which has high stiffness and good flexibility. Design/methodology/approach – The robot system is designed according to manufacturability of large aluminum products in aeronautic and astronautic area. The kinematic model of the robot is established, and a welding trajectory planning method is also developed and verified by experiments. Findings – Experimental results show that the robot system can meet the requirements of friction stir welding (FSW) for large-scale complex surface structures. Practical implications – Compared with other heavy robotic arm and machine tool welding devices, this robot has better working quality and capability, which can greatly improve the manufacturability for large-scale complex surface structures. Originality/value – The friction-stir-weld robot system is a novel solution for welding large-scale complex surface structures. Its major advantages are the high stiffness, good flexibility and high precision of the robot body, which can meet the requirements of FSW. Besides, a welding trajectory planning method based on iterative closest point (ICP) algorithm is used for welding trajectory.
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Yavuz, Hakan. "Function-oriented design of a friction stir welding robot." Journal of Intelligent Manufacturing 15, no. 6 (December 2004): 761–75. http://dx.doi.org/10.1023/b:jims.0000042662.79454.c5.

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van der Laan, A. H., R. Curran, M. J. L. van Tooren, and C. Ritchie. "Integration of friction stir welding into a multi-disciplinary aerospace design framework." Aeronautical Journal 110, no. 1113 (November 2006): 759–66. http://dx.doi.org/10.1017/s0001924000001627.

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Abstract Multidisciplinary design and innovative highly automated manufacturing methods are increasingly important to today’s aircraft industry: multidis-ciplinary design because it reduces lead-time and results in a better design, and automated manufacturing methods because they are more capable and reduce manufacturing cost. In this paper a cost estimation model is presented that integrates the manufacturing cost of friction stir welded connections within a multidisciplinary design decision tool. Due to the fact that friction stir welding is a new manufacturing method, the cost estimation model is based on the actual process physics, meaning what the process looks like in terms of processing speeds and characteristics. As an integral part of a multidisciplinary design framework, the developed cost estimation model contributes to a design support tool that assesses not only manufacturing but also structural and aerodynamic issues. It is shown that the cost model developed can be integrated into this more holistic design process support architecture. The predicted costs are accurate to the historical data and allow tradeoff of manufacturing and economic considerations within the context of the multidisciplinary design tool. The tradeoff capability is highlighted through a presented case study that compares the friction stir welding process as an alternative solution to more tradition riveting. Most importantly, this results in a quantitative tradeoff between two processes that shows the manufacturing cycle time of friction stir welding to be reduced by 60% and the recurring assembly cost by 20%.
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Wang, Xi Jing, Bo Qiang Li, and Chang Qing Zhang. "Study of Friction Stir Spot Welding of Steel/ Magnesium." Advanced Materials Research 239-242 (May 2011): 417–21. http://dx.doi.org/10.4028/www.scientific.net/amr.239-242.417.

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Dissimilar metal of Steel and Magnesium alloy by friction stir spot welding is studied. Based on using orthogonal test method to optimize the process parameters and get satisfactory joint, SEM is used to observe the features of joint, fracture morphology, and XRD is used to determine the joint phase, and the results show that: the design of rotating tool without pin is reasonable and it can form satisfactory joints without keyhole for spot welding; spot welding nugget zone on the magnesium side shows the phenomenon of melting and solidification in the range of hundreds microns, and its microstructure appears a structure of dendrites; The fracture mode of spot welding joint is a mixed mode of cleavage and dimpled rupture.
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Santiago, Diego, Santiago Urquiza, Guillermo Lombera, and Luis de Vedia. "3D modeling of material flow and temperature in Friction Stir Welding." Soldagem & Inspeção 14, no. 3 (September 2009): 248–56. http://dx.doi.org/10.1590/s0104-92242009000300008.

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The process of Friction Stir Welding (FSW) is a welding method developed by the "The Welding Institute" (TWI) of England in 1991. The welding equipment consists of a tool that rotates and progresses along the joint of two restrained sheets. The joint is produced by frictional heating which causes the softening of both components into a viscous-plastic condition and also by the resultant flow between the sheets to be joined. Numerical Modeling of the process can provide realistic prediction of the main variables of the process, reducing the number of experimental tests, thus accelerating the design processes while reducing costs and optimizing the involved technological variables. In this study the friction stir welding process is modeled using a general purpose finite element based program, reproducing the material thermal map and the corresponding mass flow. Numerical thermal results are compared against experimental thermographic maps and numerical material flow results are compared with material flow visualization techniques, with acceptable concordance.
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De Backer, Jeroen, and Gunnar Bolmsjö. "Deflection model for robotic friction stir welding." Industrial Robot: An International Journal 41, no. 4 (June 10, 2014): 365–72. http://dx.doi.org/10.1108/ir-01-2014-0301.

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Purpose – This paper aims to present a deflection model to improve positional accuracy of industrial robots. Earlier studies have demonstrated the lack of accuracy of heavy-duty robots when exposed to high external forces. One application where the robot is pushed to its limits in terms of forces is friction stir welding (FSW). This process requires the robot to deliver forces of several kilonewtons causing deflections in the robot joints. Especially for robots with serial kinematics, these deflections will result in significant tool deviations, leading to inferior weld quality. Design/methodology/approach – This paper presents a kinematic deflection model, assuming a rigid link and flexible joint serial kinematics robot. As robotic FSW is a process which involves high external loads and a constant welding speed of usually below 50 mm/s, many of the dynamic effects are negligible. The model uses force feedback from a force sensor, embedded on the robot, and predicts the tool deviation, based on the measured external forces. The deviation is fed back to the robot controller and used for online path compensation. Findings – The model is verified by subjecting an FSW tool to an external load and moving it along a path, with and without deviation compensation. The measured tool deviation with compensation was within the allowable tolerance for FSW. Practical implications – The model can be applied to other robots with a force sensor. Originality/value – The presented deflection model is based on force feedback and can predict and compensate tool deviations online.
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Dissertations / Theses on the topic "Engineering design Friction stir welding"

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Bagaitkar, Harish. "Design for manufacturing for friction stir welding." Diss., Rolla, Mo. : Missouri University of Science and Technology, 2008. http://scholarsmine.mst.edu/thesis/pdf/Bagaitkar_09007dcc805a2c42.pdf.

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Thesis (M.S.)--Missouri University of Science and Technology, 2008.
Vita. The entire thesis text is included in file. Title from title screen of thesis/dissertation PDF file (viewed December 2, 2008) Includes bibliographical references.
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Erickson, Jonathan David. "Design and Characterization of a Plunge-Capable Friction Stir Welding Temperature Feedback Controller." BYU ScholarsArchive, 2018. https://scholarsarchive.byu.edu/etd/7461.

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Temperature control in friction stir welding (FSW) is of interest because of the potential to improve the mechanical and microstructure characteristics of a weld. Two types of active temperature control have been previously implemented for steady-state friction stir welding conditions: PID Feedback Control and Model Predictive Control. The start-up portion of a weld is an obstacle for these types of active control.To date, only minimal exploratory research has been done to develop an active temperature controller for the start-up portion of the weld. The FSW temperature controller presented in this thesis, a Position-Velocity-Acceleration (PVA) controller implemented with gain-scheduling, is capable of active control during the start-up portion of a weld. The objectives of the controller are (1) to facilitate fully-automated active temperature control during the entire welding process, (2) to minimize the rise time, the settling time, the percentage maximum post-rise error (overshoot calculated as a percentage of the settling band half-width), and the post-settled root-mean-square (RMS) of the temperature error, and (3) to maintain the steady state performance of previous control methods.For welds performed in 6.35 mm plates of 7075-T651 Aluminum with controller gains identified through a manual tuning process, the mean controller performance is a rise time of 10.82 seconds, a settling time of 11.35 seconds, a percentage maximum post-rise error of 69.86% (as a percentage of the 3◦C settling band half-width), and a post-settled RMS error of 0.92◦C.Tuning of the start-up controller for operator-specified behavior can be guided through construction of regression models of the weld settling time, rise time, percent maximum post-rise error, and post-settled RMS error. Characterization of the tuning design space is performed through regression modeling. The effects of the primary controller tuning parameters and their interactions are included. With the exception of the post-settled RMS error model, these models are inadequate to provide useful guidance of the controller tuning, as significant curvature is present in the design space. Exploration of higher-order models is performed and suggests that regression models including quadratic terms can adequately characterize the design space to guide controller tuning for operator-specified behavior.
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Covington, Joshua L. "Experimental and Numerical Investigation of Tool Heating During Friction Stir Welding." Diss., CLICK HERE for online access, 2005. http://contentdm.lib.byu.edu/ETD/image/etd961.pdf.

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Stahl, Aaron L. "Experimental Measurements of Longitudinal Load Distributions on Friction Stir Weld Pin Tools." Diss., CLICK HERE for online access, 2005. http://contentdm.lib.byu.edu/ETD/image/etd1018.pdf.

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Record, Jonathan H. "Statistical Investigation of Friction Stir Processing Parameter Relationships." Diss., CLICK HERE for online access, 2005. http://contentdm.lib.byu.edu/ETD/image/etd732.pdf.

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Zhou, Xingguo. "Friction stir welding simulation, optimization and design." Thesis, University of Strathclyde, 2013. http://oleg.lib.strath.ac.uk:80/R/?func=dbin-jump-full&object_id=25244.

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Friction stir welding is an advanced welding technology mainly used to join aluminum alloys but with potential for other materials like steel, titanium and its alloys. The aim of this work is to provide a combination of numerical and experiment tools to understand the mechanisms of friction stir welding, optimizing the friction stir welds and characterizing the material properties for welds. The thesis is broadly divided into three themes. In the first theme, an automatic procedure to estimate friction stir welding model parameters, particularly those difficult to measure directly, is proposed and developed. The proposed methodology is seen to predict heat input power from the welding tool and contact conductivity between the workpiece and its supporting plate in good agreement with experimental temperature history data. In the second theme, discontinuous and distributed cooling methods, which use periodical and non-uniformly distributed cooling medium flow to cool the welding workpieces, are proposed to reduce the residual stress of friction stir welds and investigated using multi-physics numerical simulation to predict transient temperature field, residual stress and mechanical performance of welds. The discontinuous cooling method is found to be more effective than conventional active cooling, leading to a lower drop in induced welding temperature and reduced residual stress. The distributed cooling provides another method to balance residual stress and welding temperature for butt welding. The effect of discontinuous cooling on microstructure is evaluated using the multi-physics model. The third part presents small punch beam testing method to characterize material properties of base material, welded material and material property distribution. The small punch beam test utilizes miniaturized specimen and is therefore suited to measuring material properties in local regions of structure, such as the friction stir welding nugget.
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Pehkonen, Henri. "Design of Gas Shield for Friction Stir Welding Machine." Thesis, Linköpings universitet, Maskinkonstruktion, 2014. http://urn.kb.se/resolve?urn=urn:nbn:se:liu:diva-126605.

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The research and development of the final disposal of the nuclear waste produced by the nuclear power plants is an important work done by The Swedish Nuclear Fuel & Waste Management Co. (SKB). As the demands on a final disposal increase the laboratory equipment has to be better in order to do valid experiments. Research on how the copper canister for the spent fuel will be manufactured and handled is done at the Canister laboratory in Oskarshamn, Sweden. The work presented in this report was to design a new gas shield for the friction stir welding machine at the laboratory. The welding machine seals the canisters containing the spent fuel which are then transported to the final disposal 500 meter down in basement rock. To minimize the amount of oxide particles in the weld zone SKB have to design a better gas shield that should deliver the required atmosphere around the welding area. The work contains a pre study phase where the important things to consider when designing are collected. Then ideas are generated and concepts created for a new gas shield. These concepts are evaluated by a pair wise comparison method in order to find the most promising concept. The concept chosen is then detail designed to come as close to a manufacturable design as possible.
Utvecklingen av ett slutförvar för det urbrända kärnbränslet som blir avfallsprodukten vid framställning av energi via kärnkraft är ett viktigt arbete som drivs av Svensk Kärnbränslehantering AB. Då kraven och bevisningen på huruvida ett slutförvar ska utföras på ett säkert sätt måste experimenten och försöksutrustningen bli bättre för att generera tillförlitliga resultat. Forskning om hur kopparkapseln för det urbrända kärnbränslet ska konstrueras och hanteras pågår vid Kapsellaboratoriet i Oskarshamn. Arbetet som presenteras i denna rapport tar upp konstruktionen av ett nytt gasskydd till friktionsomrörningssvetsningsmaskinen på Kapsellaboratoriet. Svetsmaskinen försluter kapslarna med radioaktivt avfall vilka sedan transporteras 500 meter ner i det svenska urberget. För att minska mängden oxidpariklar kring svetsområdet måste SKB tillverka ett nytt gasskydd vilket bör uppfylla de krav på atmosfären kring svetsområdet som finns. Arbetet består av en forsknings- och informationssamlingsfas där viktiga aspekter och problemområden hittas. Sedan genereras idéer och nya koncept på gasskydd fås fram. Koncepten utvärderas parvis med metoden ”pair wise comparison” för att hitta det mest lovande konceptet. Konceptet detaljkonstrueras och tillslut fås en design vilken är så nära tillverkningsbar som möjligt.
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Liechty, Brian C. "Material Flow Behavior in Friction Stir Welding." Diss., CLICK HERE for online access, 2008. http://contentdm.lib.byu.edu/ETD/image/etd2403.pdf.

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Blignault, Calvin. "Design, development and analysis of the friction stir welding process." Thesis, Port Elizabeth Technikon, 2002. http://hdl.handle.net/10948/1350.

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The development of a CNC-based technology FSW machine to accurately produce friction stir weld samples that can be analyzed for research purposes is implemented and discussed. A process diagnosis and control scheme to improve the process monitoring and weld evaluation capabilities of an FSW machine are proposed and implemented. Basic CNC-based hardware implementation such as optical encoders and inverters for process control are explained and verified. The control scheme and framework of interfaces to the digital I/O cards for PC user interface are explained. An advanced monitoring system which senses process performance parameters such as tool temperature, 3-axis tool forces, torque and spindle speed are explained. Mechanical designs and manufacturing techniques such as tool, clamp and backing plate designs are explained and verified. The process parameters for quality optimization are investigated and optimized by making use of Correlation and Regression Analysis. The statistical data and analytical relationships between welding parameters (independent) and each of the performance parameters (dependent) are obtained and used to simulate the machining process. The weld research samples are tested for strength and integrity making use of various scientific testing techniques. The reliability of the samples are also evaluated and compared to that of other institutions. Process variables and the optimum operating range of the Friction Stir Welding machine is determined and a framework for further research into weld quality optimization is set.
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Tipaji, Pradeep Kumar. "E-design tools for friction stir welding: cost estimation tool." Diss., Rolla, Mo. : University of Missouri-Rolla, 2007. http://scholarsmine.mst.edu/thesis/pdf/Tipaji_09007dcc8043f642.pdf.

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Thesis (M.S.)--University of Missouri--Rolla, 2007.
Vita. The entire thesis text is included in file. Title from title screen of thesis/dissertation PDF file (viewed February 5, 2008) Includes bibliographical references (p. 29-31).
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Books on the topic "Engineering design Friction stir welding"

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Welding & joining & fastening & friction stir welding, 2007. Warrendale, PA: SAE International, 2007.

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Engineers, Society of Automotive, and SAE World Congress (2007 : Detroit, Mich.), eds. Welding & joining & fastening & friction stir welding, 2007. Warrendale, Pa: Society of Automotive Engineers, 2007.

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Friction Stir Welding and Processing: Science and Engineering. Springer, 2014.

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Book chapters on the topic "Engineering design Friction stir welding"

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Zhang, Qian, and Xiaoxiao Liu. "Optimisation in Friction Stir Welding: Modelling, Monitoring and Design." In Management and Industrial Engineering, 299–329. Cham: Springer International Publishing, 2018. http://dx.doi.org/10.1007/978-3-030-01641-8_11.

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Prem, B. Raghu, Kundan K. Singh, and Ravi Shanker Vidyarthy. "Influence of Workpiece Mating Gap on Friction Stir Welding of 316L for Fixture Design on a Machine." In Lecture Notes in Mechanical Engineering, 285–95. Singapore: Springer Singapore, 2021. http://dx.doi.org/10.1007/978-981-16-1769-0_26.

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Banik, Abhijit, John Deb Barma, Ram Singh, and S. C. Saha. "A Study on the Effect of Varying Revolution Pitch for Different Tool Design: Friction Stir Welding of AA 6061-T6." In Lecture Notes in Mechanical Engineering, 505–13. Singapore: Springer Singapore, 2019. http://dx.doi.org/10.1007/978-981-13-6412-9_49.

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Akinlabi, Esther Titilayo, and Rasheedat Modupe Mahamood. "Friction Stir Welding." In Mechanical Engineering Series, 39–73. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-37015-2_3.

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Akinlabi, Esther Titilayo, and Rasheedat Modupe Mahamood. "Introduction to Friction Welding, Friction Stir Welding and Friction Stir Processing." In Mechanical Engineering Series, 1–12. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-37015-2_1.

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Chaturvedi, Mukti, and S. Arungalai Vendan. "Friction Stir Welding and Design." In Advanced Welding Techniques, 133–65. Singapore: Springer Singapore, 2021. http://dx.doi.org/10.1007/978-981-33-6621-3_6.

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Akinlabi, Esther Titilayo, and Rasheedat Modupe Mahamood. "Future Research Direction in Friction Welding, Friction Stir Welding and Friction Stir Processing." In Mechanical Engineering Series, 131–42. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-37015-2_7.

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Akinlabi, Esther Titilayo, and Rasheedat Modupe Mahamood. "Friction Stir Welding and Friction Stir Processing: Case Studies." In Mechanical Engineering Series, 103–13. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-37015-2_5.

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Mistry, Hiten J., Piyush S. Jain, and J. Vaghela Tinej. "Experimental Comparison Between Friction Stir Welding and Underwater Friction Stir Welding on Al6061 Alloys." In Advances in Mechanical Engineering, 169–77. Singapore: Springer Singapore, 2020. http://dx.doi.org/10.1007/978-981-15-3639-7_20.

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Kumar, Sudhir, Tanmoy Medhi, and Barnik Saha Roy. "Friction Stir Welding of Thermoplastic Composites." In Lecture Notes in Mechanical Engineering, 221–35. Singapore: Springer Singapore, 2019. http://dx.doi.org/10.1007/978-981-13-6412-9_21.

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Conference papers on the topic "Engineering design Friction stir welding"

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Aadhari, Santhosh, and Devaiah Malkapuram. "Friction Stir Welding of Aluminum 6082." In International Conference on Advances in Design, Materials, Manufacturing and Surface Engineering for Mobility. 400 Commonwealth Drive, Warrendale, PA, United States: SAE International, 2018. http://dx.doi.org/10.4271/2018-28-0051.

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Bagaitkar, Harish, and Venkat Allada. "E-Design Tool for Friction Stir Welding." In ASME 2008 International Manufacturing Science and Engineering Conference collocated with the 3rd JSME/ASME International Conference on Materials and Processing. ASMEDC, 2008. http://dx.doi.org/10.1115/msec_icmp2008-72207.

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This paper describes efforts to develop a web-based E-Design tool for the Friction Stir Welding (FSW) technique. The input parameters to the E-Design tool are the joint specifications. The output parameters of the E-Design tool are process parameters such as tool geometry details, tool rpm, and plunge depth. The heart of the E-Design tool is the FSW database. The FSW database contains mappings of various input parameters and output parameters that are captured by referring to various experimental studies cited in the literature. The proposed E-Design tool deals with lap joints and butt joints between similar aluminum alloys.
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Park, Kwanghyun, Gap-Yong Kim, and Jun Ni. "Design and Analysis of Ultrasonic Assisted Friction Stir Welding." In ASME 2007 International Mechanical Engineering Congress and Exposition. ASMEDC, 2007. http://dx.doi.org/10.1115/imece2007-44007.

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This paper presents ultrasonic assisted friction stir welding (UaFSW), which is suggested to improve the weld quality and efficiency as a hybrid welding system. Ultrasonic-assisted processes have been coupled with tooling in various manufacturing processes to enhance the performance of conventional machining and bonding processes. For successful and effective implementation of the UaFSW, we must first consider how to integrate ultrasonics into the friction stir welding equipment. To solve this problem, we designed an ultrasonic horn to vibrate the FSW tool and transmit ultrasonic energy into the workpiece. Using a numerical modal and harmonic analysis, we fabricated and analyzed the ultrasonic horn under specific design considerations. Force was measured and compared during ultrasonic assisted and conventional friction stir welding. The mechanical properties of the workpieces were also investigated.
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Fratini, Livan, and Mario Piacentini. "Friction Stir Welding of 3D Industrial Parts: Joint Strength Analysis." In ASME 8th Biennial Conference on Engineering Systems Design and Analysis. ASMEDC, 2006. http://dx.doi.org/10.1115/esda2006-95382.

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In the recent years Friction Stir Welding (FSW) has become an important joining technique since it allows to weld light weight alloys rather difficult to be welded or even “un-weldable” with the classic fusion welding operations. In the paper the authors present the application of the FSW process to the joining of 3D complex shapes typical of the industrial environment. In particular the research was aimed to highlight the joint mechanical strength at the varying of the 3D geometry of the welding line.
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Zhao, Xin, Prabhanjana Kalya, Robert G. Landers, and K. Krishnamurthy. "Empirical Dynamic Modeling of Friction Stir Welding Processes." In ASME 2007 International Manufacturing Science and Engineering Conference. ASMEDC, 2007. http://dx.doi.org/10.1115/msec2007-31047.

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Current Friction Stir Welding (FSW) process modeling research is concerned with the detailed analysis of local effects such as material flow, heat generation, etc. These detailed thermo-mechanical models are typically solved using finite element or finite difference schemes and require substantial computational effort to determine temperature, forces, etc. at a single point in time. Dynamic models describing the total forces acting on the tool throughout the entire welding process are required for the design of feedback control strategies and improved process planning and analysis. In this paper, empirical models relating the process parameters (i.e., plunge depth, traverse rate, and rotation speed) to the process variables (i.e., axial, traverse, and lateral forces) are developed to understand their dynamic relationship. First, the steady-state relationship between the process parameters and variables is constructed, and the relative importance of each process parameter on each process variable is determined. Next, the dynamic process response characteristics are determined using Recursive Least-Squares. The results indicate that the steady-state relationship between the process parameters and variables is well characterized by a nonlinear power relationship, and the dynamic responses are well characterized by low-order linear equations. Experiments are conducted that validate the developed FSW dynamic models.
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6

Mantegh, Iraj. "Thermal Modeling for Control of Friction Stir Welding Process in Automated Manufacturing." In ASME 2011 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. ASMEDC, 2011. http://dx.doi.org/10.1115/detc2011-48774.

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Friction stir welding is a patented joining process invented in 1991 at The Welding Institute in Cambridge, UK, and further developed to the stage suitable for production. In this process, a wear resistant rotating tool is used to join sheet and plate with different materials such as aluminum, copper, lead, magnesium, zinc, and titanium. This work studies the thermal characteristics of this process and provides a modeling technique based on Neural Network that can be used for real-time control. A thermal feed-back control method is presented to control the process. Using some thermal modeling for the heat distribution during friction stir welding process, this paper displays the complexity of obtaining an accurate design for the thermal feed back control. A three-dimensional transient heat transfer model is developed here for a sequential joining process (Friction Stir Welding-FSW) applied on aluminum parts. A neural network is created based on a set of experiments to predict the spatial and temporal variations in the temperature over the weld seam for different set of input variables. The model includes the dynamic and friction behavior of the rotating spindle and the thermal behaviors of the weld components involved. The significance of this modeling approach is that it captures the movement of the spindle, simulating a sequential joining process along a continuous weld seam. The modeling results are compared with experimental data obtained by thermocouples and infrared camera, and accurately predict the trend of variations in weld temperature. A fuzzy-logic based controller is proposed to regulate the FSW process parameters to maintain the weld temperature within the margin required to ensure the weld quality. This modeling and control system can have applications in manufacturing aluminum parts in automotive and aerospace industry.
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Payton, Lewis N., Vishnu Vardhan Chandrasekaran, and Wesley S. Hunko. "Dimensional Analysis of Thermal Fields Surrounding Friction Stir Welding Process." In ASME 2014 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2014. http://dx.doi.org/10.1115/imece2014-37035.

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A dimensionless correlation is developed based on Buckingham’s Pi-Theorem to estimate the temperature fields generated by the movement of a tool during the Friction Stir Welding of an aluminum alloy (6061-T6). Symmetrical thermocouple measurements are taken during a statistically designed experiment using different factor levels (RPM, Traverse, etc). Analytical comparison (using multivariate ANOVA) validates the predicted dimensionless correlation including the often-reported difference between the advancing versus retreating side of the Friction Stir Tool.
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8

Iliopoulos, Athanasios P., John G. Michopoulos, and Samuel Lambrakos. "Reduced Order Modeling for Inverse Parameter Identification of Ti-5111 Friction Stir Welding." In ASME 2016 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/detc2016-59890.

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Forward and inverse modeling of the friction stir welding (FSW) process is an important endeavor, which can be used to optimize process parameters that can play a significant role on achieving specification requirements of manufactured parts. In this work a Reduced Order Modeling (ROM) approach is presented with the aim to reduce the forward step evaluation of an optimization loop that implements the solution of the relevant inverse problem. This is done in order to reduce the overall computational time required. The feasibility and efficiency of this approach is demonstrated through its implementation and the comparison between the full and the reduced order model implementations.
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Michopoulos, John G., Samuel Lambrakos, and Athanasios Iliopoulos. "Friction Stir Welding Process Parameter Effects on Workpiece Warpage due to Residual Strains." In ASME 2011 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. ASMEDC, 2011. http://dx.doi.org/10.1115/detc2011-47763.

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An important performance measure of the quality of a weld is the permanent deformation developed during welding processes due to the thermally activated residual strains. This paper presents the results of a sensitivity analysis that determines the effects of processing parameters — such as the speed of rotation and the traveling speed of a rotating friction stir welding (FSW) tool — on the resulting residual strain fields. The problem has been modeled as a thermostructurally coupled problem via Finite Element Analysis of an elastoplastic workpiece under the influence of heat generated from the stirring process and taking into account the temperature dependent yield strength of the material. Results are presented and discussed in the context of our future plans.
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10

Canales, D., Ch Ghnatios, A. Leygue, F. Chinesta, I. Alfaro, E. Cueto, E. Feulvarch, and J. M. Bergheau. "Numerical Simulation of Friction Stir Welding by an Efficient 3D Updated Lagrangian Technique." In ASME 2014 12th Biennial Conference on Engineering Systems Design and Analysis. American Society of Mechanical Engineers, 2014. http://dx.doi.org/10.1115/esda2014-20285.

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Friction Stir Welding (FSW) is a welding technique which since its invention in 1991 is of great interest to the industry for its many advantages. Despite being widely used, its physical foundations and its relation to the technological parameters of the process are not known in detail. Numerical simulations are a powerful tool to achieve a greater understanding of the physics of the problem. Although several approaches can be found in the literature for FSW, all of them present different limitations that restrict their applicability to the industry. This paper presents a new solution strategy that combines a meshless method, the Natural Element Method (NEM), with a solution separated representation making use of the Proper Generalized Decomposition (PGD), for creating a new powerful updated-Lagrangian method for addressing the 3D model while maintaining a 2D computational complexity.
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