Next Article in Journal
Influence of Residual Stress on Fatigue Weak Areas and Simulation Analysis on Fatigue Properties Based on Continuous Performance of FSW Joints
Previous Article in Journal
Mechanical Properties of Tool Steels with High Wear Resistance via Directed Energy Deposition
Previous Article in Special Issue
Effect of the Tool Tilt Angle on the Heat Generation and the Material Flow in Friction Stir Welding
Article Menu
Issue 3 (March) cover image

Export Article

Open AccessArticle
Metals 2019, 9(3), 283; https://doi.org/10.3390/met9030283

Performance of Plunge Depth Control Methods During Friction Stir Welding

1
Joining Research Group, Korea Institute of Industrial Technology, Incheon 21999, Korea
2
School of Mechanical Engineering, Hanyang University, Seoul 04763, Korea
3
Department of Mechanical and Materials Engineering, Portland State University, Portland, OR 97201, USA
*
Author to whom correspondence should be addressed.
Received: 13 February 2019 / Revised: 26 February 2019 / Accepted: 27 February 2019 / Published: 2 March 2019
(This article belongs to the Special Issue Friction Stir Welding and Processing in Alloy Manufacturing)
Full-Text   |   PDF [4144 KB, uploaded 2 March 2019]   |  

Abstract

Friction stir welding is a preferred solid state welding process for Al/Fe joints, and in friction stir lap welding, the plunge depth is the most critical parameter for joint strength. We compared three plunge depth control methods, namely conventional position control, offset position control, and deflection compensation control in the friction stir lap welding of 3 mm-thick Al 5083-O alloy over 1.2 mm-thick DP 590 steel. The desired plunge depth was 0.2 mm into the steel sheet. However, the pin did not reach the steel surface under conventional position control due to deflection of the vertical axis of the welding system. In offset position control, an additional offset of 0.35 mm could achieve the desired plunge depth with considerable accuracy. Nevertheless, a gradual increase of the plunge depth along the longitudinal direction was unavoidable, due to an in-situ decrease of the material yield strengths. In deflection compensation control, the deflection is estimated by the coaxially measured plunging force and the force-deflection relationship, and then corrected by feedback control. Thus, the plunge depth is stabilized along the longitudinal direction and is precisely controlled with a 3.3-μm standard deviation of error during the tool traverse phase. There is also a consistent bias of 32 μm caused by the resolution of the measuring system, and it can be easily calibrated in the feedback control system. View Full-Text
Keywords: Al/Fe dissimilar joining; friction stir welding; plunge depth control; offset position control; deflection compensation control Al/Fe dissimilar joining; friction stir welding; plunge depth control; offset position control; deflection compensation control
Figures

Figure 1

This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
SciFeed

Share & Cite This Article

MDPI and ACS Style

Yoon, J.; Kim, C.; Rhee, S. Performance of Plunge Depth Control Methods During Friction Stir Welding. Metals 2019, 9, 283.

Show more citation formats Show less citations formats

Note that from the first issue of 2016, MDPI journals use article numbers instead of page numbers. See further details here.

Related Articles

Article Metrics

Article Access Statistics

1

Comments

[Return to top]
Metals EISSN 2075-4701 Published by MDPI AG, Basel, Switzerland RSS E-Mail Table of Contents Alert
Back to Top