PNNL

Abstract

Maintaining consistent tool depth relative to the part surface is a critical requirement for many Friction stir processing (FSP) applications. Force control is often used with the goal of obtaining a constant weld depth. When force control is used, if weld temperature decreases, flow stress increases and the tool is pushed up. If weld temperature increases, flow stress decreases and the tool dives. These variations in tool depth and weld temperature cause various types of weld defects. Robust temperature control for FSP maintains a commanded temperature through control of the spindle axis only. Robust temperature control and force control are completely decoupled in control logic and machine motion. This results in stable temperature, force and tool depth despite the presence of geometric and thermal disturbances. Performance of this control method is presented for various weld paths and alloy systems.