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Friction Stir Welding and Processing X pp 149–160Cite as

Intermittent Flow of Material and Force-Based Defect Detection During Friction Stir Welding of Aluminum Alloys

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Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Abstract

The cost limitations of post-weld inspection have driven the need for in situ process monitoring of subsurface defects. Subsurface defects are believed to be formed due to a breakdown in the intermittent flow of material around the friction stir tool once per revolution. This work examines the intermittent flow of material and its relation to defect formation. In addition, advances have been made in a force-based defect detection model that links changes in process forces to the formation and size of defects. A range of aluminum alloys has been examined, showing that softer aluminum alloys produce less distinct changes in process forces during defect formation and harder aluminum alloys produce more distinct changes when using the same tool geometry.

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Acknowledgements

The authors gratefully acknowledge financial support of this work by the Department of Mechanical Engineering at the University of Wisconsin-Madison, the Machine Tool Technology Research Foundation, and the U.S. National Science Foundation through grants CMMI-1332738 and CMMI-1826104.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Wisconsin-Madison, 1513 University Ave, Madison, WI, USA

    Daniel J. Franke, Michael R. Zinn & Frank E. Pfefferkorn

Authors
  1. Daniel J. Franke
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  2. Michael R. Zinn
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  3. Frank E. Pfefferkorn
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Corresponding author

Correspondence to Frank E. Pfefferkorn .

Editor information

Editors and Affiliations

  1. Brigham Young University, Provo, UT, USA

    Yuri Hovanski

  2. University of North Texas, Denton, TX, USA

    Rajiv Mishra

  3. Tohoku University, Sendai, Japan

    Yutaka Sato

  4. Pacific Northwest National Laboratory, Richland, WA, USA

    Piyush Upadhyay

  5. San Jose State University, San Jose, CA, USA

    David Yan

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© 2019 The Minerals, Metals & Materials Society

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Franke, D.J., Zinn, M.R., Pfefferkorn, F.E. (2019). Intermittent Flow of Material and Force-Based Defect Detection During Friction Stir Welding of Aluminum Alloys. In: Hovanski, Y., Mishra, R., Sato, Y., Upadhyay, P., Yan, D. (eds) Friction Stir Welding and Processing X. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-05752-7_14

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