Assessment of the energetic efficiency of friction stir welding/processing

This paper scrutinizes and goes beyond previously published results on the analysis of the energy flow during friction stir welding/processing (FSW/P). An in-depth scientific method was used to assess the individual energetic contribution arising from the main components within the FSW/P system. This investigation was performed during FSW/P of AA7075 with different tool rotations and travel speeds. The main contributors to energy losses during the FSW/P process include the FSW/P tool, anvil, unprocessed base material, and the surrounding environment. It was found that only about 25 % of the total energy is effectively used to perform the welding/processing, while the remaining energy dissipates through heat into the tooling and clamping system. Additionally, around 6 % of the energy is lost towards the base material, forming the heat-affected zone (HAZ). These results suggest that proper selection of the anvil material offers a promising opportunity to enhance effective energy efficiency, considering that approximately 60 % of the total energy input is lost through this component. Addressing this substantial energy loss becomes essential for achieving a more energetically sustainable industrial application of the FSW/P process.

Description

Funding Information: PLI would like to acknowledge Fundação para a Ciência e a Tecnologia (FCT-MCTES) for its financial support via the PhD scholarship FCT-SFRH/BD/146885/2019 . TGS, JPO and FF acknowledge Project 24534 - “INFANTE - Microssatélite para Vigilância Marítima, Observação da Terra e IoT no contexto de constelações”, supported by Operational Program for Competitiveness and Internationalization (COMPETE 2020) and Lisbon Regional Operational Programme (Lisboa 2020), under the PORTUGAL 2020 Partnership Agreement, through the European Regional Development Fund (ERDF). PLI, JPO and TGS acknowledge Fundação para a Ciência e a Tecnologia (FCT - MCTES) for its financial support via the project UIDB/00667/2020 and UIDP/00667/2020 (UNIDEMI). JPO acknowledges the funding of CENIMAT/i3N by national funds through the FCT -Fundação para a Ciência e a Tecnologia, I.P., within the scope of Multiannual Financing of R&D Units, reference UIDB/50025/2020-2023 . Publisher Copyright: © 2023 The Authors

Keywords

Aluminium, Efficiency, Energy, Friction stir Processing (FSP), Friction Stir Welding (FSW)

DOI

10.1016/j.jmapro.2023.08.044

Citation

Inácio , P L , Ferreira , F B , Vilaça , P , Oliveira , J P & Santos , T G 2023 , ' Assessment of the energetic efficiency of friction stir welding/processing ' , Journal of Manufacturing Processes , vol. 103 , pp. 298-308 . https://doi.org/10.1016/j.jmapro.2023.08.044

Permanent link to this item

https://urn.fi/URN:NBN:fi:aalto-202309135870

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[article-cris] Insinööritieteiden korkeakoulu / ENG

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