Abstract
Friction stir welding (FSW) is relatively an advanced solid-state joining process in which no consumable materials are used. It is an energy-efficient and environment-friendly process. However, one of the limitations of the FSW process is that a pin hole remains at the end of the joint and some offset distance needs to be provided at the start of the joint. The present work focuses on different approaches in finding an appropriate starting position and to eliminate the end hole type of defect in FSW process. It is based on several distinct experimental trials. These trial runs consist of numbers of different cases of start and end locations. The main aim of these case studies is to achieve maximum joint length and minimum material wastage while joining two 6-mm-thick aluminum plates by FSW process. All the process parameters like rotational speed, welding speed, plunging depth, tool geometry, and dwell time were kept constant during the trial runs. From the experimental results, it was found that by restricting edge deformation by means of an abutting plate at an appropriate position, full starting length can be utilized as a proper joint. Also by providing a runoff material of an appropriate size, the end hole can be transferred to the runoff plate and joint length will get maximized.
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Parida, B., Pal, S. An investigation to find an appropriate starting position and elimination of pin hole defect in FSW for maximizing the joint length. Int J Adv Manuf Technol 87, 2889–2900 (2016). https://doi.org/10.1007/s00170-016-8555-y
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DOI: https://doi.org/10.1007/s00170-016-8555-y