Force generation during friction stir welding of AA2024-T3

Force measurement in friction stir welding (FSW) provides a significant insight into the process in terms of machine and tool limitations and design. In the present research the tool forces were investigated experimentally using a rotating component dynamometer and through the development of a finite element model. The model correlated well with experimental temperatures and tool forces and was capable of predicting tool forces for different welding parameters, predicting regions were tool failure is likely to occur and identifying tool pin designs which can process the workpiece more efficiently.