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| Title: | Automatic gap detection in friction stir butt welding operations |
| Author (s): | Yang, Yu Kalya, Prabhanjana Landers, Robert G. Krishnamurthy, K. |
| Department/Lab Affiliations: | Intelligent Systems Center Mechanical & Aerospace Engineering University Transportation Center Virtual Reality & Rapid Prototyping Lab |
| Keywords: | friction stir welding gaps monitoring |
| Issue Date: | 2008-02 |
| Publisher: | Elsevier |
| Citation: | Yu, Y., P. Kalya, R.G. Landers, and K. Krishnamurthy “Automatic Gap Detection in Friction Stir Butt Welding Operations”, International Journal of Machine Tools and Manufacturer, vol. 48, no. 10, pp. 1161-1169, 2008. |
| Abstract: | Friction stir welding (FSW) is a new solid-state welding technology that has been used successfully in many joining applications. A common problem that arises when welding two sheets is the presence of a gap between the sheets. Gaps may be due to improper fixturing, imprecision in the processes used to manufacture the sheets, etc. When the FSW tool encounters a gap, material can possibly escape from the processing zone and the welded part's effective cross-sectional area around the gap will decrease. Both of these effects can possibly cause an unsuitable weld. This paper develops a monitoring algorithm to detect gaps in friction stir butt welding operations in real time (i.e., during the operation). Experimental studies are conducted to determine how the process parameters (e.g., tool rotation rate and tool traverse speed) and the gap width affect the welding process; particularly, the plunge force (i.e., the force acting vertically down on the part). The proposed monitoring algorithm examines the filtered plunge force in the frequency domain to determine the presence of a gap. Several experimental studies are conducted for 2024 aluminum with a variety of process parameters and the monitoring algorithm is shown to be able to reliably detect the presence of gaps in friction stir butt welding operations for tool traverse speeds below 4.233 mm/s and gap sizes above 0.3048 mm |
| Type: | Article - Journal text |
| In Title: | International Journal of Machine Tools and Manufacture |
| Copyright Notice: | This material is presented to ensure timely dissemination of scholarly and technical work. Copyright and all rights therein are retained by authors or by other copyright holders. All persons copying this information are expected to adhere to the terms and constraints invoked by each author's copyright. In most cases, these works may not be reposted without the explicit permission of the copyright holder. Pre-print: author can archive; Post-print: author can archive; FULL COPYRIGHT INFORMATION: |
| Publisher URL: | |
| Link to this page: |
| title | Automatic gap detection in friction stir butt welding operations |
| contributor.author | Yang, Yu |
| contributor.author | Kalya, Prabhanjana |
| contributor.author | Landers, Robert G. |
| contributor.author | Krishnamurthy, K. |
| contributor.deptlab | Intelligent Systems Center |
| contributor.deptlab | Mechanical & Aerospace Engineering |
| contributor.deptlab | University Transportation Center |
| contributor.deptlab | Virtual Reality & Rapid Prototyping Lab |
| contributor.sponsor | Air Force Research Lab |
| subject | friction stir welding |
| subject | gaps |
| subject | monitoring |
| date.issued | 2008-02 |
| publisher | Elsevier |
| identifier.citation | Yu, Y., P. Kalya, R.G. Landers, and K. Krishnamurthy “Automatic Gap Detection in Friction Stir Butt Welding Operations”, International Journal of Machine Tools and Manufacturer, vol. 48, no. 10, pp. 1161-1169, 2008. |
| identifier.pub.URI | |
| description.abstract | Friction stir welding (FSW) is a new solid-state welding technology that has been used successfully in many joining applications. A common problem that arises when welding two sheets is the presence of a gap between the sheets. Gaps may be due to improper fixturing, imprecision in the processes used to manufacture the sheets, etc. When the FSW tool encounters a gap, material can possibly escape from the processing zone and the welded part's effective cross-sectional area around the gap will decrease. Both of these effects can possibly cause an unsuitable weld. This paper develops a monitoring algorithm to detect gaps in friction stir butt welding operations in real time (i.e., during the operation). Experimental studies are conducted to determine how the process parameters (e.g., tool rotation rate and tool traverse speed) and the gap width affect the welding process; particularly, the plunge force (i.e., the force acting vertically down on the part). The proposed monitoring algorithm examines the filtered plunge force in the frequency domain to determine the presence of a gap. Several experimental studies are conducted for 2024 aluminum with a variety of process parameters and the monitoring algorithm is shown to be able to reliably detect the presence of gaps in friction stir butt welding operations for tool traverse speeds below 4.233 mm/s and gap sizes above 0.3048 mm |
| type | Article - Journal |
| type.DCMIType | text |
| type.status | Postprint |
| rights | This material is presented to ensure timely dissemination of scholarly and technical work. Copyright and all rights therein are retained by authors or by other copyright holders. All persons copying this information are expected to adhere to the terms and constraints invoked by each author's copyright. In most cases, these works may not be reposted without the explicit permission of the copyright holder. |
| rights | Pre-print: author can archive; Post-print: author can archive; |
| rights.URI | |
| relation.isPartOf | International Journal of Machine Tools and Manufacture |
| date.available | 2008-09-23T14:12:53Z |
| identifier.persist.URI |