1.What is the main role tool tilt angle.
2.I have some query regarding the friction stir welding . Spindle torque as we know has an impact on power input to the weldment. What actually mean by X-Torque.As per my knowledge X directional force may be attributed by the tool pin at a large extent(Please correct me if I am wrong).Is X-torque has some relation with tool pin.What is actually the physical meaning of X torque in context to FSW.
Although it does not seem at first glance, FSW is a complex welding process, which depends on many variables (parameters).
Choosing appropriate tools configuration (including pin profile, tool tilt angle and tool shoulder etc.) will get a proper quality of the weld. Thus, tool profile helps in mixing of material and heating of material to the optimum welding temperature (this temperature may be monitored by infrared thermography - see the link bellow).
On the other hand, in order to be able to perform a proper welded joint, we have to introduce energy in the work pieces (this energy is produced by rotational torque and the normal downforce applied via welding tool to the surfaces). This energy is transformed into heat and transferred to the welded components (given a certain coefficient of loss in welding tool and in air). Thus, X-torque and F force are parameters used to control the input energy.
For each welding material (similar or dissimilar) optimum welding parameters should be establish (For this purpose factorial experiments could be used).
http://www.intechopen.com/books/infrared-thermography/applications-of-thermography-in-materials-science-and-engineering
Hi Abhijit,
You have to remember that FSW works like a forming process. The correct tilt angle is crucial in ensuring that the stirred softened material is pressed downwards into place as the tool moves ahead. Typically tilt angles vary from 2 to 4 degrees depending on the material being joined. Tools with a very small shoulder can also work with a zero degree tilt - There may be some flash generated however in this process.
I personally haven't heard of X-Torque, but torque in generally is obviously crucial for the spindle of choice in order to do FSW. In general, for FSW the min. torque of a spindle should be at least 50Nm in order not to damage spindle bearing and spindle life. This is required to stir the material by the pin and for stronger alloys (e.g. 2XXX & 7XXX series Al alloy), the torque has to be higher.
Hope this helps.
Regards,
Samir
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