![]() Some attempts are made to overcome this issue. However, FSW equipment costs and royalties limit the use of this technique in current industry. It is a green, versatile technology capable of making high quality welds. In the past decades, it has increasingly attracted the interest of researchers and industry owing to its prominent advantages over fusion welding techniques. It is identified that one can achieve a quality lap joint at traverse speeds as high as 1400 mm/min and downward axial forces as low as 3.2 kN by a low-cost RAFSW technique.įriction stir welding (FSW) is a newly emerged solid-state joining process. The results indicate that a quality weld can be obtained at low downward axial forces during welding by proper selection of tool design and process parameters. The Taguchi method is used to design the experiments and artificial neural network (ANN) modeling is applied to predict the plunging force and the strength of the joints. Moreover, the effect of tool rotational speed, traverse speed, plunge depth and lap joint configuration is evaluated. ![]() The studied tool design parameters are shoulder diameter, shoulder groove depth, pin length, pin angle, pin base diameter and pin lead. The welds are made by a low-cost friction stir welding technique at right angle (RAFSW). In this paper, the effect of tool design and process parameters on the generated downward axial force and strength of AA6061-T6 lap joints is studied. FSW lap joint is an interesting alternative for rivets, fusion welds and bonding particularly in the transportation industry. In recent decades, friction stir welding (FSW) has attracted extensive attention of academic and industrial sectors as the most considerable development in metal joining processes.
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