Relevant bibliographies by topics / Robotic friction stir welding

Academic literature on the topic 'Robotic friction stir welding'

Author: Grafiati
Published: 4 June 2021
Last updated: 16 February 2022

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

Journal articles on the topic "Robotic friction stir welding":

1

Cook, George E., Reginald Crawford, Denis E. Clark, and Alvin M. Strauss. "Robotic friction stir welding." Industrial Robot: An International Journal 31, no. 1 (February 2004): 55–63. http://dx.doi.org/10.1108/01439910410512000.

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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.
3

Mendes, N., P. Neto, M. A. Simão, A. Loureiro, and J. N. Pires. "A novel friction stir welding robotic platform: welding polymeric materials." International Journal of Advanced Manufacturing Technology 85, no. 1-4 (June 12, 2014): 37–46. http://dx.doi.org/10.1007/s00170-014-6024-z.

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Crawford, Reginald, George E. Cook, Alvin M. Strauss, and Daniel A. Hartman. "Modelling of friction stir welding for robotic implementation." International Journal of Modelling, Identification and Control 1, no. 2 (2006): 101. http://dx.doi.org/10.1504/ijmic.2006.010087.

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De Backer, Jeroen, Anna‐Karin Christiansson, Jens Oqueka, and Gunnar Bolmsjö. "Investigation of path compensation methods for robotic friction stir welding." Industrial Robot: An International Journal 39, no. 6 (October 12, 2012): 601–8. http://dx.doi.org/10.1108/01439911211268813.

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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.
7

Callegari, Massimo, Archimede Forcellese, Matteo Palpacelli, and Michela Simoncini. "Robotic Friction Stir Welding of AA5754 Aluminum Alloy Sheets at Different Initial Temper States." Key Engineering Materials 622-623 (September 2014): 540–47. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.540.

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Robotic friction stir welding experiments were performed on AA5754 aluminium alloy sheets, 2.5 mm in thickness, in two different temper states (H111 and O-annealed). A six axes robot with a hybrid structure, characterised by an arm with parallel kinematics and a roll-pitch-roll wrist with serial kinematics, was used. The effect of the process parameters on the macro-and micro-mechanical properties and microstructure of joints was widely analysed. It was shown that, under the same process condition, the mechanical properties of the joints are strongly influenced by the initial temper state of the alloy. In particular, as AA5754-H111 is welded, the ultimate tensile strength is not significantly affected by the process parameters whilst the ultimate elongation significantly depends on the welding speed. In AA5754-O, both ultimate values of tensile strength and elongation are affected by the welding speed whilst a negligible effect of the rotational speed can be observed. Irrespective of the welding parameters, the H111 temper state leads to mechanical properties higher than those given by the O-annealed state. An investigation has been also carried out in order to evaluate the micro-hardness profiles and microstructure of the FSWed joints in order to understand the mechanisms operating during robotic friction stir welding.
8

De Backer, Jeroen, Gunnar Bolmsjö, and Anna-Karin Christiansson. "Temperature control of robotic friction stir welding using the thermoelectric effect." International Journal of Advanced Manufacturing Technology 70, no. 1-4 (September 14, 2013): 375–83. http://dx.doi.org/10.1007/s00170-013-5279-0.

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9

Qin, Jinna, Francois Leonard, and Gabriel Abba. "Real-Time Trajectory Compensation in Robotic Friction Stir Welding Using State Estimators." IEEE Transactions on Control Systems Technology 24, no. 6 (November 2016): 2207–14. http://dx.doi.org/10.1109/tcst.2016.2536482.

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Kolegain, Komlan, François Leonard, Sandra Chevret, Amarilys Ben Attar, and Gabriel Abba. "Off-line path programming for three-dimensional robotic friction stir welding based on Bézier curves." Industrial Robot: An International Journal 45, no. 5 (August 20, 2018): 669–78. http://dx.doi.org/10.1108/ir-03-2018-0038.

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Purpose Robotic friction stir welding (RFSW) is an innovative process which enables solid-state welding of aluminum parts using robots. A major drawback of this process is that the robot joints undergo elastic deformation during the welding, because of the high forces induced by the process. This leads to tool deviation and incorrect orientation. There is currently no computer-aided manufacturing/computer-aided design (CAD) software for generating off-line paths which integrates robot deflections, and the main purpose of this study is to propose an off-line methodology to plan a path for RFSW with the integration of the deflections. Design/methodology/approach The approach is divided into two steps. The first step consists of extracting position and orientation data from CAD models of the workpieces and adding the deflections calculated with a deflection model to generate a suitable path for performing RFSW. The second step consists of the smooth fitting of the suitable path using Bézier curves. Findings The method is experimentally validated by welding a curved workpiece using a Kuka KR500-2MT robot. A suitable tool position and orientation were calculated to perform this welding, an experimental procedure was set up, a defect-free weld was performed and a high accuracy was achieved in terms of position and orientation. Practical implications This method can help manufacturers to easily perform RFSW for three-dimensional workpieces regardless of the lateral tool deviation, loss of the right orientation and control force stability. Originality/value The originality of this method lies in compensating for robot deflections without using expensive sensors, which is the most commonly used method for compensating for robot deflection. This off-line method can lead to a reduction in programming time in comparison with teach programming method and leads to reduced investment costs in comparison with commercial off-line programming packages.
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Journal articles Dissertations / Theses Books

Dissertations / Theses on the topic "Robotic friction stir welding":

1

De, Backer Jeroen. "Feedback Control of Robotic Friction Stir Welding." Doctoral thesis, Högskolan Väst, Avd för automationssystem, 2014. http://urn.kb.se/resolve?urn=urn:nbn:se:hv:diva-6043.

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The Friction Stir Welding (FSW) process has been under constant developmentsince its invention, more than 20 years ago. Whereas most industrial applicationsuse a gantry machine to weld linear joints, there are applications which consistof complex three-dimensional joints, requiring more degrees of freedom fromthe machines. The use of industrial robots allows FSW of materials alongcomplex joint lines. There is however one major drawback when using robotsfor FSW: the robot compliance. This results in vibrations and insufficient pathaccuracy. For FSW, path accuracy is important as it can cause the welding toolto miss the joint line and thereby cause welding defects.The first part of this research is focused on understanding how welding forcesaffect the FSW robot accuracy. This was first studied by measuring pathdeviation post-welded and later by using a computer vision system and laserdistance sensor to measure deviations online. Based on that knowledge, a robotdeflection model has been developed. The model is able to estimate thedeviation of the tool from the programmed path during welding, based on thelocation and measured tool forces. This model can be used for online pathcompensation, improving path accuracy and reducing welding defects.A second challenge related to robotic FSW on complex geometries is thevariable heat dissipation in the workpiece, causing great variations in the weldingtemperature. Especially for force-controlled robots, this can lead to severewelding defects, fixture- and machine damage when the material overheats.First, a new temperature method was developed which measures thetemperature at the interface of the tool and the workpiece, based on the thermoelectriceffect. The temperature information is used as input to a closed-looptemperature controller. This modifies primarily the rotational speed of the tooland secondarily the axial force. The controller is able to maintain a stablewelding temperature and thereby improve the weld quality and allow joining ofgeometries which were impossible to weld without temperature control.Implementation of the deflection model and temperature controller are twoimportant additions to a FSW system, improving the process robustness,reducing the risk of welding defects and allowing FSW of parts with highlyvarying heat dissipation.
2

Zhang, Cheng. "Robotic 3D friction stir welding : T-butt joint." Thesis, Högskolan Väst, Avd för automationssystem, 2015. http://urn.kb.se/resolve?urn=urn:nbn:se:hv:diva-8250.

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This Master Thesis was performed in terms of robotic three dimensional friction stir welding with T-butt joint. Friction stir welding (FSW) is a solid state welding method that achieves the weld temperature by friction of a rotating non-consumable tool with the workpiece. Science and technology fast developing requires for higher seam quality and more complex welding joint geometry like 3D welds. In order to acquire high productivity, capacity and flexibility with acceptable cost, robotic FSW solution have been proposed. Instead of the standard FSW machine, using a robot to perform complicated welds such as, three-dimensional. In this report, a solution for weld a 3D T-butt joint, which located in an aluminium cylinder with 1.5 mm thickness using a robot, was developed. Moreover, two new paths were investigated in order to avoid the use of two welds to perform this type of joint. The paths were tested on 2D and on 3D (with a 5050 curvature radius) geometries. Both paths had good results. What is more, the parameter developing methods of FSW process, which is composed of necessary parameter setting, positional compensation was introduced. Specially,the study demonstrates how complicate geometry can be welded using a robot. Also,it shows that TWT temperature control is able to acquire high quality 3D welds. In addition, an analysis of the 2D welding and 3D welding was performed, which exposed that, keeping exactly the same welding conditions, higher lateral forces on the tool were found during 3D welding. Basis on the special case in this paper, when the tool goes like "climbing" the sample, the suffering force of tool decreasing with increasing the height(Z position); nevertheless, when the tool goes like "downhill", the suffering force of tool decreasing with decreasing the height (Z position). What is more, in 2D weld, increasing the downforce (Fz) results increasing the lateral forces which can be Fx and/or Fy. Finally, the future works suggestions were presented in terms of (1) performing the new paths into a real cylinder, (2) performing tensile test on the paths and comparing it with conventional path which weld twice, (3) researching how the downforce (Fz) influence the Fx and Fy during welding of different 3D geometries, (4) how the cooling rate of backing bar influence the seam quality when it is use the same welding parameters and (5) the effect of performing welds in the same welding temperature achieved with different combination of the tool rotational speed and downforce on the material properties
3

De, Backer Jeroen, and Bert Verheyden. "Robotic Friction Stir Welding for Automotive and Aviation Applications." Thesis, University West, Division of Production Engineering, 2010. http://urn.kb.se/resolve?urn=urn:nbn:se:hv:diva-2171.

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Friction Stir Welding (FSW) is a new technology which joins materials by using frictional heat. Inthe first part of this thesis, a profound literature study is performed. The basic principles, therobotic implementation and possibilities to use FSW for high strength titanium alloys areexamined. In the next phase, a FSW-tool is modelled and implemented on an industrial robot in arobot simulation program. Reachability tests are carried out on car body parts and jet engineparts. By using a simulation program with embedded collision detection, all possible weldinglocations are determined on the provided parts. Adaptations like a longer FSW-tool and amodified design are suggested in order to get a better reachability. In different case studies, thenumber of required robots and the reduction of weight and time are investigated and comparedto the current spot welding process.

4

Magalhães, Ana. "Thermo-electric temperature measurements in friction stir welding : Towards feedback control of temperature." Licentiate thesis, Högskolan Väst, Avdelningen för produktionssystem (PS), 2016. http://urn.kb.se/resolve?urn=urn:nbn:se:hv:diva-9982.

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Friction Stir Welding has seen a fast uptake in many industry segments. Mechanical properties superior to fusion welding, the ability to weld "unweldable" aluminium alloys and low distortion are often described as the main reasons for the fast industrial implementation of FSW. Most existing applications consist of long straight welding joints. Applications with complex weld geometries, however, are rarely produced by FSW. These geometries can induce thermal variations during the welding process, thus making it challenging to maintain a consistent weld quality. In-process adaptation of weld parameters to respond to geometrical variations and other environmental variants allow new design opportunities for FSW. Weld quality has been shown to be reliant on the welding temperature. However, the optimal methodology to control the temperature is still under development.The research work presented in this thesis focuses on some steps to take in order to reach the improvement of the FSW temperature controller, thus reach a better and consistent weld quality. In the present work different temperature methods were evaluated. Temperature measurements acquired by the tool-workpiece thermocouple (TWT) method were accurate and fast, and thereby enhanced suitable for the controller. Different environmental conditions influencing the material heat dissipation were imposed in order to verify the controller effect on the joint quality. In comparison with no controlled weld, the use of the controller enabled a fast optimization of welding parameters for the different conditions, leading to an improvement of the mechanical properties of the joint.For short weld lengths, such as stitch welds, the initial plunge and dwell stages occupy a large part of the total process time. In this work temperature control was applied during these stages. This approach makes the plunge and dwell stages more robust by preventing local material overheating, which could lead to a tool meltdown. The TWT method was demonstrated to allow a good process control during plunging and continuous welding. The approach proposed for control offers weld quality consistency and improvement. Also, it allows a reduction of the time required for the development of optimal parameters, providing a fast adaptation to disturbances during welding and, by decreasing the plunge time, provides a significant decrease on the process time for short welds.
5

Guillo, Mario. "Commande en effort robuste et compensation de trajectoire en temps réel pour les robots industriels sous fortes charges : application au soudage par friction malaxage robotisé (RFSW)." Thesis, Rennes, INSA, 2014. http://www.theses.fr/2014ISAR0020/document.

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Le soudage par friction malaxage (FSW) est un procédé de soudage innovant pour les matériaux à bas point de fusion (aluminium, cuivre…). Il a été breveté en 1992 par l’organisme anglais The Welding Institute (TWI). Depuis plusieurs années, celui-ci se développe dans l’industrie en cherchant à réduire son coût d’investissement. Le principe du FSW est de réaliser un cordon de soudure grâce à un outil animé d’un mouvement de rotation et d’avance. Les niveaux d’efforts et de précision requis contraignent à l’utilisation de machines cartésiennes de grande envergure. L’utilisation des robots industriels est un moyen de réduire les coûts, mais ils ne sont pas conçus pour ce genre d’applications et leur inconvénient majeur réside dans leur manque de rigidité. Ainsi, lorsque l’outil entre en contact avec les pièces à assembler, celui-ci peut dévier de plusieurs millimètres dans différentes directions de l’espace, rendant la mise en oeuvre d’une compensation de la trajectoire du robot obligatoire afin d’obtenir des soudures sans défauts. Le but de cette thèse a été de développer un procédé robotisé robuste. Le premier objectif est la mise en oeuvre d’une commande en effort robuste. En effet, en FSW, le maintien d’un effort axial constant est obligatoire. Le contrôle de cet effort permet de compenser la déviation axiale de l’outil et les défauts de mise en position des pièces à souder. Ainsi, une démarche d’identification et de modélisation afin de créer une commande en effort a été mise en oeuvre. La commande est définie de manière robuste afin d’éviter les réglages de l’asservissement lorsque les outils, les paramètres de soudage ou les trajectoires du robot changent. Une validation expérimentale complète a été réalisée dans le contexte du FSW. Le second objectif de cette thèse a été de développer une compensation de la déviation latérale de l’outil. Contrairement à l’objectif précédent, il n’y a pas d’effort à maintenir pour compenser cette déviation latérale. Dans l’industrie, cette déviation peut être compensée à l’aide d’un système de vision, mais ce dernier comporte de nombreux inconvénients en FSW (réflexion de l’aluminium, non visibilité du joint, coût, mise en oeuvre complexe). Ainsi, dans cette partie, un algorithme de compensation temps réel de la déviation latérale de l’outil a été mis en oeuvre. Celui-ci repose sur l’identification d’un modèle élasto-statique du robot. L’algorithme de compensation de la déviation latérale de l’outil a été couplé à la commande en effort et validé expérimentalement en FSW. La différence avec la majorité des travaux de recherche dans ce domaine est que les procédures d’identification n’utilisent pas de système de mesure 3D (photogrammétrie CCD ou laser de poursuite) dont le coût est un frein indéniable pour beaucoup d’industriels. La démarche est simple à mettre en oeuvre sur un robot industriel du marché actuel, et applicable pour d’autres procédés à contact comme l’usinage ou le polissage
Friction Stir Welding (FSW) is an innovative welding process for materials with a low melting point (aluminium, copper…). It was patented in 1992 by the English organization The Welding Institute (TWI). For many years, an effort is done to reduce the investment cost for industrial applications. FSW process involves a rotating tool advancing along a path. Currently, gantry-type CNC systems are using for FSW manufacturing. These machines offer a high stiffness and can tolerate the forces during FSW in order to carry out a good weld quality. Industrials robots can reduce the investment cost; however they are not design for these applications. The main limitation is the low stiffness of the robot structure. Consequently, the robot deformation under the high process forces causes tool deviations about several millimeters. The robot path has to be compensated in order to obtain a good weld quality. The aim of this thesis is to develop a robust robotized process. The first goal is to realize a robust force control. During FSW, a constant axial forging force should be applied. Axial tool deviation is compensated with the force control approach. In this way, a modeling and identification method is done in order to design a force controller. The force controller is robust because no tuning is required, even if welding parameters or robot paths change. An experimental validation in FSW is done. The second goal is to realize a compensation of the lateral tool deviation. Unlike the axial deformation, there is no force to maintain for compensate this deviation. In industry, the lateral tool deviation could be compensated with a camera or laser sensor in order to track the weld seam path during welding. However, the cost of a seam tracking device, the aluminium reflexion and the lack of visibility in lap joint configuration are significant drawbacks. In this chapter, a compensation algorithm is designed. An elastostatic model of the robot is used to estimate in real time the deflection of the robot TCP. The compensation algorithm is coupled with the force controller defined previously. Compare with others research works about this topic, identification methods don’t need a 3D measurement system (CCD camera or laser tracker). The cost of such system is a main drawback for industrial applications. In this thesis, identification methods are easy to implement in an industrial robot and available for others processes like machining or polishing
6

Colegrove, Paul Andrew. "Modelling of friction stir welding." Thesis, University of Cambridge, 2004. https://www.repository.cam.ac.uk/handle/1810/240576.

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This thesis investigates the modelling of friction stir welding (FSW). FSW is a relatively new welding process where a rotating non-consumable tool is used to join two materials through high temperature deformation. The aim of the thesis is the development of a numerical model to improve process understanding and to assist in the design of new tools. The early part of the thesis describes the process, defines the modelling problem and describes why a computational fluid dynamics package (FLUENT) was selected for the subsequent work. A systematic series of friction stir welding experiments in 7075 aluminium alloy, used to provide validation data for a numerical model of the process, are described in chapter 2. The trials examined how the welding conditions and tool type affected the weld temperature and heat input. From this data a thermal model of the welds was developed that included the convective heat flow due to material mixing. Chapters 3 to 6 describe the model development, from a preliminary model of a standard tool, to a detailed analysis of 2 dimensional profiles incorporating a novel slip boundary condition, and finally to a full 3 dimensional model of a new tool design, including material slip. The preliminary model with a standard tool assumed that the material stuck to the tool surface and included features such as the tool tilt, heat generation and heat flow. The model captured many of the real process characteristics, but gave poor predictions of the welding forces and heat generation. This identified the need for a more complex treatment of the tool-material interface that allowed material slip. The slip model was first implemented in a 2 dimensional study of flow around profiled tooling (chapter 4). This enabled a first order visualisation of the flow and the quantitative comparison of different 2 dimensional pin profiles. In chapter 5 an optimised 2 dimensional pin profile was determined by selecting the shape that minimised the traversing force. Two prototype tools based on this profile were manufactured: the plain 'Trivex™' and the threaded 'MX-Trivex™'. These were tested against a conventional 'MX-Triflute™' tool with the results showing that the traversing force was reduced by 18-25%. Chapter 6 describes 3 dimensional models of the 'Trivex™' and 'Triflute™' tools, which extended the slip model to 3 dimensions. The model correctly predicted that the Trivex™ tool had lower traversing and down forces than its Triflute™ counterpart, as observed experimentally. The thesis successfully demonstrates the application of fluid dynamics modelling to friction stir welding, enhancing visualisation of the flow, and guiding the development of new tooling.
7

Badarinarayan, Harsha. "Fundamentals of friction stir spot welding." Diss., Rolla, Mo. : Missouri University of Science and Technology, 2009. http://scholarsmine.mst.edu/thesis/pdf/Badarinarayan_2009_09007dcc807d7f97.pdf.

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Thesis (Ph. D.)--Missouri University of Science and Technology, 2009.
Vita. The entire thesis text is included in file. Title from title screen of thesis/dissertation PDF file (viewed July 16, 2010) Includes bibliographical references (p. 175-181).
8

Wang, Tianhao. "Friction Stir Welding of Dissimilar Metals." Thesis, University of North Texas, 2018. https://digital.library.unt.edu/ark:/67531/metadc1404577/.

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Dissimilar metals joining have been used in many industry fields for various applications due to their technique and beneficial advantages, such as aluminum-steel and magnesium-steel joints for reducing automobile weight, aluminum-copper joint for reducing material cost in electrical components, steel-copper joints for usage in nuclear power plant, etc. The challenges in achieving dissimilar joints are as below. (1) Big difference in physical properties such as melting point and coefficient of thermal expansion led to residual stress and defects. (2) The miscibility issues resulted in either brittle intermetallic compound layer at the welded interface for miscible combinations (such as, aluminum-steel, aluminum-copper, aluminum-titanium, etc.) or no metallurgical bonding for immiscible combinations (such as magnesium-copper, steel-copper, etc.). For metallurgical miscible combinations, brittle intermetallic compounds formed at the welded interface created the crack initiation and propagation path during deformational tests. (3) Stress concentration appeared at the welded interface region during tensile testing due to mismatch in elastic properties of dissimilar materials. In this study, different combinations of dissimilar metals were joined with friction stir welding. Lap welding of 6022-T4 aluminum alloy/galvanized mild steel sheets and 6022-T4 aluminum alloy/DP600 steel sheets were achieved via friction stir scribe technology. The interlocking feature determining the fracture mode and join strength was optimized. Reaction layer (intermetallic compounds layer) between the dissimilar metals were investigated. Butt welding of 5083-H116 aluminum alloy/HSLA-65 steel, 2024-T4 aluminum alloy/316 stainless steel, AZ31/316 stainless steel, WE43/316 stainless steel and 110 copper/316 stainless steel were obtained by friction stir welding. The critical issues in dissimilar metals butt joining were summarized and analyzed in this study including IMC and stress concentration.
9

Reilly, Aidan. "Modelling of friction stir spot welding." Thesis, University of Cambridge, 2013. https://www.repository.cam.ac.uk/handle/1810/244946.

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Friction stir spot welding (FSSW) is a solid-state welding process which is especially useful for joining precipitation-hardened aluminium alloys that undergo adverse property changes during fusion welding. It also has potential as an effective method for solid-state joining of dissimilar alloys. In FSSW, heat generation and plastic flow are strongly linked, and the scale of the process in time and space is such that it is difficult to separate and control the influence of all the relevant input parameters. The use of modelling is well-established in the field of welding research, and this thesis presents an analysis of the thermal and mechanical aspects of FSSW, principally using the finite element (FE) technique. Firstly, a thermal FE model is shown, which is subsequently validated by reference to experimental temperature data in both aluminium-to-aluminium and aluminium-to-steel welds. Correlations between high-quality welds and temperature fields are established, and predictions are made for peak temperatures reached under novel welding conditions. Deformation and heating are strongly linked in FSSW, but existing modelling tools are poorly suited to modelling flow processes in the conditions extant in FSSW. This thesis discusses the development and optimisation of two novel techniques to overcome the limitations of current approaches. The first of these uses greatly simplified constitutive behaviour to convert the problem into one defined purely by kinematics. In doing so, the boundary conditions reduce to a small number of assumptions about the contact conditions between weld material and tool, and the model calculation time is very rapid. This model is used to investigate changes in the slip condition at the tool to workpiece interface without an explicit statement of the friction law. Marker experiments are presented which use dissimilar composition but similar strength alloys to visualise flow patterns. The layering behaviour and surface patterns observed in the model agree well with observations from these experiments. The second approach extends the FE method to include deformation behaviour without the need for a fully-coupled approach, guided by the kinematic model. This is achieved using an innovative sequential small-strain analysis method in which thermal and deformation analyses alternate, with each running at a very different timescale. This technique avoids the requirement to either remesh the model domain at high strains or to use an explicit integration scheme, both of which impose penalties in calculation time and model complexity. The method is used to relate the purely thermal analysis developed in the work on thermal modelling to welding parameters such as tool speed. The model enables predictions of the spatial and temporal evolution of heat generation to be made directly from the constitutive behaviour of the alloy and the assumed velocity profile at the tool-workpiece interface. Predictions of the resulting temperature history are matched to experimental data and novel conditions are simulated, and these predictions correlate accurately with experimental results. Hence, the model is used to predict welding outcomes for situations for which no experimental data exists, and process charts are produced to describe optimum welding parameters. The methods and results presented in this thesis have significant implications for modelling friction stir spot welding, from optimising process conditions, to integration with microstructural models (to predict softening in the heat-affected zone, or the formation of intermetallics at the interface in dissimilar welds). The technique developed for sequential small strain finite element analysis could also be investigated for use in other kinematically constrained solid-state friction joining processes.
10

Merry, Joshua D. "Performance evaluation of discontinuous friction stir welding." Thesis, Wichita State University, 2011. http://hdl.handle.net/10057/5188.

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Friction stir welding has been shown by previous investigators to have many advantages over traditional metal joining practices. Friction stir lap welds and friction stir spot welds have been shown to be stronger than rivets when joining materials of the same thickness. Substructures containing continuous lap welded joints have demonstrated increased load carrying capabilities over their riveted counterparts. In full-scale structures, however, continuous welds are not always an option. Welds may be interrupted by fixturing limitations, tooling restrictions, or stiffening members that cross the weld path. In these situations, a discontinuous lap weld would be necessary. The principal problem with a discontinuous weld is that the tool plunge and exit locations cannot be eliminated with a run-off tab, as in continuous welded structures. These plunge and exit locations are then subjected to operational loads. In fatigue applications, it has been demonstrated that cracks will initiate in the exit hole of a discontinuous weld. The purpose of this study was to investigate techniques to terminate a lap weld without compromising the structure by leaving an unprotected exit hole.
Thesis (M.S.)--Wichita State University, College of Engineering, Dept. of Aerospace Engineering.
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Books on the topic "Robotic friction stir welding":

1

Völlner, Georg. Rührreibschweissen mit Schwerlast-Industrierobotern. München: Herbert Utz Verlag, 2010.

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Engineers, Society of Automotive. Welding & joining & fastening & friction stir welding. Warrendale, PA: SAE International, 2006.

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Akinlabi, Esther Titilayo, and Rasheedat Modupe Mahamood. Solid-State Welding: Friction and Friction Stir Welding Processes. Cham: Springer International Publishing, 2020. http://dx.doi.org/10.1007/978-3-030-37015-2.

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Mishra, Rajiv Sharan, Partha Sarathi De, and Nilesh Kumar. Friction Stir Welding and Processing. Cham: Springer International Publishing, 2014. http://dx.doi.org/10.1007/978-3-319-07043-8.

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Mubiayi, Mukuna Patrick, Esther Titilayo Akinlabi, and Mamookho Elizabeth Makhatha. Current Trends in Friction Stir Welding (FSW) and Friction Stir Spot Welding (FSSW). Cham: Springer International Publishing, 2019. http://dx.doi.org/10.1007/978-3-319-92750-3.

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Mishra, Rajiv, Murray W. Mahoney, Yutaka Sato, Yuri Hovanski, and Ravi Verma, eds. Friction Stir Welding and Processing VII. Cham: Springer International Publishing, 2016. http://dx.doi.org/10.1007/978-3-319-48108-1.

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Mishra, Rajiv S., Murray W. Mahoney, Yutaka Sato, and Yuri Hovanski, eds. Friction Stir Welding and Processing VIII. Cham: Springer International Publishing, 2016. http://dx.doi.org/10.1007/978-3-319-48173-9.

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Hovanski, Yuri, Rajiv Mishra, Yutaka Sato, Piyush Upadhyay, and David Yan, eds. Friction Stir Welding and Processing X. Cham: Springer International Publishing, 2019. http://dx.doi.org/10.1007/978-3-030-05752-7.

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Mishra, Rajiv, Murray W. Mahoney, Yutaka Sato, Yuri Hovanski, and Ravi Verma, eds. Friction Stir Welding and Processing VII. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2013. http://dx.doi.org/10.1002/9781118658345.

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Mishra, Rajiv, Murray W. Mahoney, Yutaka Sato, Yuri Hovanski, and Ravi Verma, eds. Friction Stir Welding and Processing VI. Hoboken, NJ, USA: John Wiley & Sons, Inc., 2011. http://dx.doi.org/10.1002/9781118062302.

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Book chapters on the topic "Robotic friction stir welding":

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Luo, Haitao, Jia Fu, Min Yu, Changshuai Yu, Tie Liu, Xiaofang Du, and Guangming Liu. "Simulation analysis of welding precision on friction stir welding robot." In Advances in Energy Science and Equipment Engineering II, 1537–43. Taylor & Francis Group, 6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742: CRC Press, 2017. http://dx.doi.org/10.1201/9781315116174-133.

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Kolegain, Komlan, François Léonard, Sandra Chevret, Amarilys Ben Attar, and Gabriel Abba. "Robotic Friction Stir Welding Path Planning with Deflection Compensation Using B-Splines." In ROMANSY 22 – Robot Design, Dynamics and Control, 264–71. Cham: Springer International Publishing, 2018. http://dx.doi.org/10.1007/978-3-319-78963-7_34.

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Regensburg, Anna, Michael Grätzel, René Schürer, Michael Hasieber, and Jean Pierre Bergmann. "Process Force Reduction During Robotic Friction Stir Welding of Aluminum Alloys with Reduced Tool Aspect Ratios." In The Minerals, Metals & Materials Series, 277–85. Cham: Springer International Publishing, 2017. http://dx.doi.org/10.1007/978-3-319-52383-5_27.

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Das, Suman Kalyan, Suresh Gain, and Prasanta Sahoo. "Friction Stir Welding." In Welding Technology, 1–39. Cham: Springer International Publishing, 2021. http://dx.doi.org/10.1007/978-3-030-63986-0_1.

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Fujii, Hidetoshi. "Friction Stir Welding." In Novel Structured Metallic and Inorganic Materials, 177–89. Singapore: Springer Singapore, 2019. http://dx.doi.org/10.1007/978-981-13-7611-5_11.

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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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Mishra, Rajiv Sharan, Partha Sarathi De, and Nilesh Kumar. "Friction Stir Processing." In Friction Stir Welding and Processing, 259–96. Cham: Springer International Publishing, 2014. http://dx.doi.org/10.1007/978-3-319-07043-8_9.

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Vilaça, Pedro, and Wayne Thomas. "Friction Stir Welding Technology." In Structural Connections for Lightweight Metallic Structures, 85–124. Berlin, Heidelberg: Springer Berlin Heidelberg, 2011. http://dx.doi.org/10.1007/8611_2011_56.

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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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Conference papers on the topic "Robotic friction stir welding":

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Voellner, G., M. F. Zaeh, J. Silvanus, and O. Kellenberger. "Robotic Friction Stir Welding." In Aerospace Technology Conference and Exposition. 400 Commonwealth Drive, Warrendale, PA, United States: SAE International, 2007. http://dx.doi.org/10.4271/2007-01-3811.

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Jain, A. "Optimal Workplacement for Robotic Friction Stir Welding Task." In Proceedings of The 3rd IFToMM International Symposium on Robotics and Mechatronics, Chair J. Qin and G. Abba. Singapore: Research Publishing Services, 2013. http://dx.doi.org/10.3850/978-981-07-7744-9_059.

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Mendes, Nuno, Pedro Neto, and Altino Loureiro. "Robotic friction stir welding aided by hybrid force/motion control." In 2014 IEEE Emerging Technology and Factory Automation (ETFA). IEEE, 2014. http://dx.doi.org/10.1109/etfa.2014.7005266.

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Fehrenbacher, Axel, Christopher B. Smith, Neil A. Duffie, Nicola J. Ferrier, Frank E. Pfefferkorn, and Michael R. Zinn. "Combined Temperature and Force Control for Robotic Friction Stir Welding." In ASME 2013 International Manufacturing Science and Engineering Conference collocated with the 41st North American Manufacturing Research Conference. American Society of Mechanical Engineers, 2013. http://dx.doi.org/10.1115/msec2013-1161.

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Abstract:
The objective of this research is to develop a closed-loop control system for robotic friction stir welding (FSW) that simultaneously controls force and temperature in order to maintain weld quality under various process disturbances. FSW is a solid-state joining process enabling welds with excellent metallurgical and mechanical properties, as well as significant energy consumption and cost savings compared to traditional fusion welding processes. During FSW, several process parameter and condition variations (thermal constraints, material properties, geometry, etc.) are present. The FSW process can be sensitive to these variations, which are commonly present in a production environment; hence, there is a significant need to control the process to assure high weld quality. Reliable FSW for a wide range of applications will require closed-loop control of certain process parameters. A linear multi-input-multi-output process model has been developed that captures the dynamic relations between two process inputs (commanded spindle speed and commanded vertical tool position) and two process outputs (interface temperature and axial force). A closed-loop controller was implemented that combines temperature and force control on an industrial robotic FSW system. The performance of the combined control system was demonstrated with successful command tracking and disturbance rejection. Within a certain range, desired axial forces and interface temperatures are achieved by automatically adjusting the spindle speed and the vertical tool position at the same time. The axial force and interface temperature is maintained during both thermal and geometric disturbances and thus weld quality can be maintained for a variety of conditions in which each control strategy applied independently could fail.
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"BLENDING TOOL PATHS FOR G1-CONTINUITY IN ROBOTIC FRICTION STIR WELDING." In 4th International Conference on Informatics in Control, Automation and Robotics. SciTePress - Science and and Technology Publications, 2007. http://dx.doi.org/10.5220/0001624400920097.

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Soron, Mikael, and Ivan Kalaykov. "A Robot Prototype for Friction Stir Welding." In 2006 IEEE Conference on Robotics, Automation and Mechatronics. IEEE, 2006. http://dx.doi.org/10.1109/ramech.2006.252646.

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Dardouri, F., G. Abba, and W. Seemann. "Parallel Robot Structure Optimizations for a Friction Stir Welding Application." In 14th International Conference on Informatics in Control, Automation and Robotics. SCITEPRESS - Science and Technology Publications, 2017. http://dx.doi.org/10.5220/0006434203720381.

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Imani, Yousef, and Michel Guillot. "Axial Force Reduction in Friction Stir Welding of AA6061-T6 at Right Angle." In ASME 2014 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2014. http://dx.doi.org/10.1115/imece2014-39649.

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Abstract:
Invented in 1991, friction stir welding (FSW) is a new solid state joining technique. This process has many advantages over fusion welding techniques including absence of filler material, shielding gas, fumes and intensive light, solid state joining, better microstructure, better strength and fatigue life, and etc. The difficulty with FSW is in the high forces involved especially in axial direction which requires use of robust fixturing and very stiff FSW machines. Reduction of FSW force would simplify implementation of the process on less stiff CNC machines and industrial robots. In this paper axial welding force reduction is investigated by use of tool design and welding parameters in FSW of 3.07 mm thick AA6061-T6 sheets at right angle. Attempt is made to reduce the required axial force while having acceptable ultimate tensile strength (UTS). It is found that shoulder working diameter and shoulder angle are the most important parameters in the axial force determination yet pin angle has minor effect. According to the developed artificial neural network (ANN) model, proper selection of shoulder diameter and angle can lead to approximately 40% force reduction with acceptable UTS. Regions of tool design and welding parameters are found which result in reduced axial force along with acceptable UTS.
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Ahmad, Azman. "Refurbishing damaged surfaces of nickel-aluminum bronze propellers: A robotic approach using gas metal arc welding and friction stir processing." In PROCEEDINGS OF 8TH INTERNATIONAL CONFERENCE ON ADVANCED MATERIALS ENGINEERING & TECHNOLOGY (ICAMET 2020). AIP Publishing, 2021. http://dx.doi.org/10.1063/5.0053484.

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Qingxia, Wang, Ge Zengwen, Wu Chongjun, Ren Fei, and Guo Lijie. "Experimental Investigations of Axial Force Control for Friction Stir Welding Based on Multi-Level Fuzzy Control." In 2019 5th International Conference on Control, Automation and Robotics (ICCAR). IEEE, 2019. http://dx.doi.org/10.1109/iccar.2019.8813466.

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Reports on the topic "Robotic friction stir welding":

1

Miller, Richard. Guidelines for Friction Stir Welding. Fort Belvoir, VA: Defense Technical Information Center, March 2011. http://dx.doi.org/10.21236/ada605039.

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Hovanski, Yuri. Temporarily alloying titanium to facilitate friction stir welding. Office of Scientific and Technical Information (OSTI), May 2009. http://dx.doi.org/10.2172/1004029.

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Sanella, M. Friction Stir Welding of Lightweight Vehicle Structures: Final Report. Office of Scientific and Technical Information (OSTI), August 2008. http://dx.doi.org/10.2172/958678.

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ROCKWELL SCIENTIFIC CO THOUSAND OAKS CA. Corrective Measures to Restore Corrosion Resistance Following Friction Stir Welding. Fort Belvoir, VA: Defense Technical Information Center, January 2004. http://dx.doi.org/10.21236/ada432085.

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Ren, Weiju, and Zhili Feng. Initial Development in Joining of ODS Alloys Using Friction Stir Welding. Office of Scientific and Technical Information (OSTI), August 2007. http://dx.doi.org/10.2172/1093012.

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Dawson, Paul R. Development of Finite Element Forulations for High-Fidelity Polycrystals and Damage Avoidance in Friction Stir Welding. Fort Belvoir, VA: Defense Technical Information Center, July 2010. http://dx.doi.org/10.21236/ada524918.

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Ferrando, William A. The Concept of Electrically Assisted Friction Stir Welding (EAFSW) and Application to the Processing of Various Metals. Fort Belvoir, VA: Defense Technical Information Center, September 2008. http://dx.doi.org/10.21236/ada487182.

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8

Hoelzer, David T., Jeffrey R. Bunn, and Maxim N. Gussev. Complete Status Report Documenting Development of Friction Stir Welding for Joining Thin Wall Tubing of ODS Alloys. Office of Scientific and Technical Information (OSTI), August 2017. http://dx.doi.org/10.2172/1407750.

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Brendlinger, Jennifer. Potential Applications of Friction Stir Welding to the Hydrogen Economy. Hydrogen Regional Infrastructure Program In Pennsylvania, Materials Task. Office of Scientific and Technical Information (OSTI), July 2009. http://dx.doi.org/10.2172/1344074.

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Hoelzer, David T., Caleb P. Massey, Christopher M. Fancher, and Wei Tang. Complete Status Report Documenting the Development of Friction Stir Welding for Producing a Butt Joint in Thin Wall Tubing of ODS Alloys. Office of Scientific and Technical Information (OSTI), September 2018. http://dx.doi.org/10.2172/1492167.

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