The longitudinal forces generated from the Friction Stir Welding process are substantial. An understanding of these forces is critical to proper tool design. This study describes a technique to measure the longitudinal force distribution on a friction stir weld pin tool. Total longitudinal forces were recorded on a dynamometer while welding 6061 aluminum with non-threaded pins that varied in length and diameter. A model was developed that characterizes pin force as a function of pin length and diameter. Results suggest that force generally increases with pin length, while forces remain relatively constant with pin diameter. Unexpected force variation was found at large pin lengths, which yielded several possible models of the force distribution. All of the modeled force distributions proved to be non-uniform and increase linearly with pin length, which produces a pin force that increases with the square of the pin length.
College and Department
Ira A. Fulton College of Engineering and Technology; Mechanical Engineering
BYU ScholarsArchive Citation
Stahl, Aaron L., "Experimental Measurements of Longitudinal Load Distributions on Friction Stir Weld Pin Tools" (2005). Theses and Dissertations. 662.
friction stir welding, force measurement, force distribution, tool design