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Dual-rotation Stir Welding - Preliminary trials (April 2004)

   
Published on the Internet April 8 2004

E R Watts, D G Staines, W M Thomas, and E D Nicholas

A dual-rotation FSW variant is being investigated at TWI, whereby, the probe and shoulder rotate separately. The dual-rotation friction stir welding variant provides for a differential in speed and/or direction between the independently rotating probe and the rotating surrounding shoulder as shown in fig 1.

Fig.1. Principle of dual-rotation friction stir welding in the same direction
Fig.1. Principle of dual-rotation friction stir welding in the same direction

 

The apparatus used for this investigation is shown sequentially in fig 2a & b.

Fig.2a) White marks on shoulder and probe almost in line
Fig.2a) White marks on shoulder and probe almost in line
Fig.2b) White marks on shoulder and probe moving apart
Fig.2b) White marks on shoulder and probe moving apart

Fig.2. Dual-rotation apparatus complete with white marks on the shoulder and probe to indicate relative rotational movement

 

The apparatus can enable a range of different rotational speeds to be pre-selected or varied automatically by in-process control to suit the desired welding conditions.

In conventional rotary FSW, the relative velocity of the tool increases from zero at the probe centre to maximum velocity at the outer diameter of the shoulder. The dual-rotation technique can significantly modify the velocity gradient between the probe centre and the shoulder diameter. This technique provides a differential in rotation speed and the option for rotation in opposite directions. For example the shoulder rotational speed can be varied from approximately 30% less than the probe rotational speed while rotating in the same direction or about 25% less than the probe rotational speed when the shoulder is rotated in the opposite direction.

This dual-rotation technique effectively allows for a high probe rotational speed with out a corresponding increase in shoulder peripheral velocity. This technique can provide for a more idealised rotational speed for both probe and shoulder.

Dependent on the material and process conditions used, over heating or melting along the 'near shoulder side' weld surface of certain friction stir welds can occur. Melting can lead to fusion related defects along the 'near shoulder side' weld surface. The dual-rotation technique can be used to reduce the shoulder rotational speed as appropriate and help reduce any tendency towards over heating or melting.

A double sided butt weld using non-optimised conditions was made to demonstrate that dual-rotation stir welding is practicable for certain applications. Figure 3 shows the macrostructural features provided by dual-rotation stir welding using a Flared-triflute TM type probe.

Fig.3. Macrosection of a dual-rotation stir double sided butt weld in 16 mm thick 5083-H111 aluminium alloy, at a welding speed of 3 mm/sec (180mm/min), using 584 revs for the probe and 219 revs for the shoulder. Double-sided weld passes were made in the opposite direction, with the first pass shown on top.
Fig.3. Macrosection of a dual-rotation stir double sided butt weld in 16 mm thick 5083-H111 aluminium alloy, at a welding speed of 3 mm/sec (180mm/min), using 584 revs for the probe and 219 revs for the shoulder. Double-sided weld passes were made in the opposite direction, with the first pass shown on top.

 

Guide bend testing demonstrated freedom from gross defects as shown in figure 4.

Fig 4. Guided side bend test, carried out on a double sided butt weld, in 16 mm thick 5083-H111 aluminium alloy achieved 180°.
Fig 4. Guided side bend test, carried out on a double sided butt weld, in 16 mm thick 5083-H111 aluminium alloy achieved 180°.

 

Figure 5 shows the appearance of the weld surface that is formed beneath the tool shoulder after dual-rotation stir welding.

Fig.5. Surface appearance of dual-rotation stir weld made in 16 mm thick 5083-H111 aluminium alloy at a welding speed of 3 mm/sec (180 mm/min), using 584 revs for the probe and 219 revs for the shoulder.
Fig.5. Surface appearance of dual-rotation stir weld made in 16 mm thick 5083-H111 aluminium alloy at a welding speed of 3 mm/sec (180 mm/min), using 584 revs for the probe and 219 revs for the shoulder.

 

Although further investigation needs to be carried out, the dual-rotation technique may prove to have the following potential advantages over conventional FSW.

  • It may provide more idealised process conditions to suit dissimilar clad plate. Whereby the shoulder rotational speed is selected to suit the clad material and the probe rotational speed is selected to suit the substrate material.
  • It should enable a reduction in the reactive torque necessary to clamp plates together when opposed rotation is used. This may also be useful for robotic applications. (In this regard it would provide a similar benefit to Com-stir TM ).
  • It is capable of minimising any tendency towards over heating or melting associated with the 'shoulder near side' weld surface.
  • It is speculated that the facility to reduce the shoulder rotational speed may help minimise preferential corrosion particularly associated with some friction stir welded 7000 series materials.
  • It is believed that it could benefit material processing and subsequent plate bending where outer surface condition is particularly important.

 

Discussion and concluding remarks

The initial investigation of dual rotation stir welding has demonstrated the feasibility of the technique for butt welding 16 mm thick 5083-H111 condition aluminium alloy but further, work is required to fully characterise the performance and acceptability of the dual stir technique. Work will continue at TWI to investigate the use of dual-rotation on spot, butt, and lap welds. In addition trials will be undertaken to achieve improvements in traverse rate, and investigate tool tilt angle.

Further work will also be undertaken to study the use of the contra-rotation variant see fig 6.

Fig.6. Principle of contra-dual-rotation friction stir welding
Fig.6. Principle of contra-dual-rotation friction stir welding
 

The results from the dual-rotation show promise, but much more work will be required to develop and perfect the technique.

Acknowledgements are made for the support and contributions provided by C S Wiesner, I M Norris, P J Oakley, R E Dolby (retired) Roger Lilly (retired).

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