A Generalized Method for In-Process Defect Detection in Friction Stir Welding

A Generalized Method for In-Process Defect Detection in Friction Stir Welding

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Friction stir welding (FSW) is an advantageous solid-state joining process Indole 3 Carbinol that is suitable for many materials in multiple industries.In an industrial setting, manufacturers are actively seeking faster welding speeds to increase throughput.Increasing welding speed limits the size of defect-free parameter windows, which may increase the frequency of defects.The push for faster welding speeds emphasizes the need for economical non-destructive evaluation (NDE) for FSW, like any other type of welding.

This work introduces a generalized defect detection method that recognizes the stochastic nature of the FSW process, and that can be generally applied to FSW of a material across a dynamic range of process parameters and welding conditions.When applied to aluminum friction stir-welded blanks Socks at speeds ranging from 1500 to 3000 mm/min with varying ranges of tool tilts, the methodology proved 100% effective at positive detection when defects were present with zero scrap rate.Furthermore, additional development demonstrated the proposed stochastic approach can be used to detect the spatial location of a defect within a weld with 94% detection accuracy and a 4.2% scrap rate.