Heat Loss Through the Tool in Friction stir welding Ashley Lavin Ken Ross

How Friction Stir Welding (FSW) Works Pin Downward force maintains pressure Rotating tool creates friction and applies pressure Direction of tool translation

Purpose Determine the effect of tool material on the heat lost during FSW through the tool

Materials Tools with identical geometries were made from the following materials. Shafts are painted black to create a constant emissivity for the tool surface Tungsten k = H-13 Tool Steel k= 28.6 Nickel Alloy (ALGxN)k=11.8

Procedure Perform a weld using each of the tools at the same traverse and rotational speed and record the following Record temperature of the tool at the top and bottom of the shaft using ThermaCam Record power input into the weld Calculate the fraction of the total power lost to heat transfer through the tool using each material

Setup Tool ThermaCam Workpiece

Video of Weld(H-13 Tool)

Analysis T1T1 T2T2 L Nomenclature k= thermal conductivity W/mK L= Length (m) T= temperature (Celsius) RPM= rotation per minute M=Torque (Nm)

Results Q loss = W W22.87W Q loss /Q total 10.0% 3.24%0.85% Where Q loss /Q total is percent of the total heat input into the weld lost though the tool Tungsten H-13 NLGxN

Conclusion The ratio of heat lost through the tool correlates to the thermal conductivity of the tool material

Questions

Analysis Macro