skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Physics-based process model approach for detecting discontinuity during friction stir welding

Abstract

The goal of this work is to develop a method for detecting the creation of discontinuities during friction stir welding. This in situ weld monitoring method could significantly reduce the need for post-process inspection. A process force model and a discontinuity force model were created based on the state-of-the-art understanding of flow around an friction stir welding (FSW) tool. These models are used to predict the FSW forces and size of discontinuities formed in the weld. Friction stir welds with discontinuities and welds without discontinuities were created, and the differences in force dynamics were observed. In this paper, discontinuities were generated by reducing the tool rotation frequency and increasing the tool traverse speed in order to create "cold" welds. Experimental force data for welds with discontinuities and welds without discontinuities compared favorably with the predicted forces. The model currently overpredicts the discontinuity size.

Authors:
; ; ; ; ; ;
Publication Date:
Research Org.:
Argonne National Lab. (ANL), Argonne, IL (United States)
Sponsoring Org.:
USDOE Office of Science (SC); National Science Foundation (NSF)
OSTI Identifier:
1391644
DOE Contract Number:  
AC02-06CH11357
Resource Type:
Journal Article
Resource Relation:
Journal Name: International Journal of Advanced Manufacturing Technology; Journal Volume: 79; Journal Issue: 1-4
Country of Publication:
United States
Language:
English
Subject:
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS

Citation Formats

Shrivastava, Amber, Pfefferkorn, Frank E., Duffie, Neil A., Ferrier, Nicola J., Smith, Christopher B., Malukhin, Kostya, and Zinn, Michael. Physics-based process model approach for detecting discontinuity during friction stir welding. United States: N. p., 2015. Web. doi:10.1007/s00170-015-6868-x.
Shrivastava, Amber, Pfefferkorn, Frank E., Duffie, Neil A., Ferrier, Nicola J., Smith, Christopher B., Malukhin, Kostya, & Zinn, Michael. Physics-based process model approach for detecting discontinuity during friction stir welding. United States. doi:10.1007/s00170-015-6868-x.
Shrivastava, Amber, Pfefferkorn, Frank E., Duffie, Neil A., Ferrier, Nicola J., Smith, Christopher B., Malukhin, Kostya, and Zinn, Michael. Thu . "Physics-based process model approach for detecting discontinuity during friction stir welding". United States. doi:10.1007/s00170-015-6868-x.
@article{osti_1391644,
title = {Physics-based process model approach for detecting discontinuity during friction stir welding},
author = {Shrivastava, Amber and Pfefferkorn, Frank E. and Duffie, Neil A. and Ferrier, Nicola J. and Smith, Christopher B. and Malukhin, Kostya and Zinn, Michael},
abstractNote = {The goal of this work is to develop a method for detecting the creation of discontinuities during friction stir welding. This in situ weld monitoring method could significantly reduce the need for post-process inspection. A process force model and a discontinuity force model were created based on the state-of-the-art understanding of flow around an friction stir welding (FSW) tool. These models are used to predict the FSW forces and size of discontinuities formed in the weld. Friction stir welds with discontinuities and welds without discontinuities were created, and the differences in force dynamics were observed. In this paper, discontinuities were generated by reducing the tool rotation frequency and increasing the tool traverse speed in order to create "cold" welds. Experimental force data for welds with discontinuities and welds without discontinuities compared favorably with the predicted forces. The model currently overpredicts the discontinuity size.},
doi = {10.1007/s00170-015-6868-x},
journal = {International Journal of Advanced Manufacturing Technology},
number = 1-4,
volume = 79,
place = {United States},
year = {Thu Feb 12 00:00:00 EST 2015},
month = {Thu Feb 12 00:00:00 EST 2015}
}