Production of robust friction stir welds

Since its invention in 1991, friction stir welding (FSWing) has demonstrated the ability to join a wide variety of metals including dissimilar combinations. However, during these two decades of development, while the versatility and benefits of the process have been demonstrated, the selection of process parameters and tooling has been found to be an "art form" based on experience. This experience has been gained through trial and error, often without acquiring the data necessary to understand the process. Consequently, the quality of FSWs has varied, often due to minor but misunderstood changes to the processing parameters or workpiece material. Current development is putting more emphasis on methods to more precisely predict and control the process in an effort to reduce costs and produce repeatable, consistent quality FSWs. To improve FSWing to the level of a robust process, scientific rationale combined with experimental knowledge is needed. This contribution discusses the methodology required to lay the ground work for realizing robust FSWing processes.

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