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Science and Technology of Welding and Joining Volume 24, 2019 - Issue 2
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Research Articles

Effect of friction stir welding tool design on welding thermal efficiency

Hongjun LiFaculty of Mechanical Engineering and Automation, Xiasha Higher Education Zone, Zhejiang Sci-Tech University, Hangzhou, People’s Republic of ChinaCorrespondence[email protected]
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,
Jian GaoFaculty of Mechanical Engineering and Automation, Xiasha Higher Education Zone, Zhejiang Sci-Tech University, Hangzhou, People’s Republic of ChinaView further author information
,
Qinchuan LiFaculty of Mechanical Engineering and Automation, Xiasha Higher Education Zone, Zhejiang Sci-Tech University, Hangzhou, People’s Republic of ChinaView further author information
,
Alexander GallowayDepartment of Mechanical & Aerospace Engineering, University of Strathclyde, Glasgow, UKView further author information
&
Athanasios ToumpisDepartment of Mechanical & Aerospace Engineering, University of Strathclyde, Glasgow, UKView further author information
Pages 156-162 | Received 07 May 2018, Accepted 27 Jun 2018, Published online: 22 Jul 2018
 
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ABSTRACT

Enhancing the heat transfer to the material being welded, instead of the tool, will improve the welding thermal efficiency. Friction stir welding of 5 mm thick 6061-T6 aluminium alloy plates was carried out with the newly produced tools. It was found that the thermal efficiency increased by 4.2% using a tool with all the new design features (i.e. hollow, fluted and thermally insulated) compared to the conventional tool for aluminium welding. To assess the benefits of the new tool design on steel FSW, a finite element numerical simulation study was undertaken. In this case, the simulation results yielded a welding thermal efficiency increase of 10–15% using a thermally coated tool, thereby offering potential productivity gains.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

This research was supported by the National Natural Science Foundation of China under Grant No. 51605444 and No. 51475431.

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