FSW of AA2024: effects of tool wear on energy consumption

This study shows that the progressive adhesion of weld material to the tool in friction stir welding AA 2024-T3, up to tool saturation, brings about a decrease in power consumption until a plateau is reached. The cause of this behavior is the hindering of the stirring action of the tool due to the material accumulated on it. The built-up material changes the nature of the tool/material interaction and then the friction condition at their interface. The direct consequence is a decrease in the shearing strain and therefore in the heat generated by friction. Bits of this adhering material break off from the tool at intervals. Macro and micro detachments are identified. Micro-detachments happen continuously at small periodic intervals and produce vibrations. The amplitude of these vibrations increases in all their characteristic spectral components up to tool saturation. Macro-detachments generate oscillations in power consumption and leave galling on the weld bead.