Heat Loss Through the Tool in Friction stir welding

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Heat Loss Through the Tool in Friction stir
welding

• Ashley Lavin
• Ken Ross

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How Friction Stir Welding (FSW)Works
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Purpose

• Determine the effect of tool material on the heat
  lost during FSW through the tool

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Materials

• Tools with identical geometries were made from
  the following materials. Shafts are painted black
  to create a constant emissivity for the tool
  surface
• Tungsten k 84.02
• H-13 Tool Steel k 28.6
• Nickel Alloy (ALGxN) k11.8

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Procedure

• Perform a weld using each of the tools at the
  same traverse and rotational speed and record the
  following
• Record temperature of the tool at the top and
  bottom of the shaft using ThermaCam
• Record power input into the weld
• Calculate the fraction of the total power lost to
  heat transfer through the tool using each material

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Setup
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Video of Weld(H-13 Tool)
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Analysis
T1
L
T2

• Nomenclature
• k thermal conductivity W/mK
• L Length (m)
• T temperature (Celsius)
• RPM rotation per minute
• MTorque (Nm)

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Results
Tungsten H-13 NLGxN
Qloss 217.17 W 60.62
W 22.87W Qloss/Qtotal 10.0
3.24 0.85 Where Qloss/Qtotal is percent of
the total heat input into the weld lost though
the tool
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Conclusion

• The ratio of heat lost through the tool
  correlates to the thermal conductivity of the
  tool material

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Questions
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Analysis Macro