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<p>This study explores real-time force and torque signals for weld quality analysis in dissimilar Al/Cu friction stir welding. Straight hexagonal and straight cylindrical threaded tool geometries were used in this study, with varying traverse speeds (mm/s). Discrete wavelet transform decomposes the raw signals to reveal features linked to weld quality. The optimal mother wavelet function and corresponding decomposition level were chosen based on "maximum energy-to-entropy" ratio. Straight hexagonal tool exhibited less signal fluctuation compared to straight cylindrical tool. Detail signals are linked with bead surface texture, material state of uniformity, and instability during welding. In contrast, approximate signals signify deformation and material flow. Macrostructural observation reveals inadequate material mixing, resulting in a void in stir zone at 1.2 mm/s for straight cylindrical threaded tool. At 1.8 mm/s, both tools demonstrated effective material mixing in stir zone. During tensile strength analysis, straight cylindrical threaded tool showed a significant drop in tensile strength at a lower speed (1.2 mm/s), while both tools achieved their highest strength at the optimal speed (1.8 mm/s), with straight hexagonal tool exhibiting the best (93.4 MPa). Discrete wavelet transform analysis of friction stir welding signals has revealed significant observations in which poor weld quality shows defects in macrostructure.</p>

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Analysis of Weld Quality in Dissimilar Friction Stir Welding of Aluminium and Copper Using Characterization of Force and Torque Signals

  • 期刊论文

  • 发表日期：

    2025年5月27日

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  • Abhishek Mandal,
  • Abhijit Banik,
  • Arpan Kumar Mondal,
  • John Deb Barma,
  • Gautam Majumdar

摘要

This study explores real-time force and torque signals for weld quality analysis in dissimilar Al/Cu friction stir welding. Straight hexagonal and straight cylindrical threaded tool geometries were used in this study, with varying traverse speeds (mm/s). Discrete wavelet transform decomposes the raw signals to reveal features linked to weld quality. The optimal mother wavelet function and corresponding decomposition level were chosen based on "maximum energy-to-entropy" ratio. Straight hexagonal tool exhibited less signal fluctuation compared to straight cylindrical tool. Detail signals are linked with bead surface texture, material state of uniformity, and instability during welding. In contrast, approximate signals signify deformation and material flow. Macrostructural observation reveals inadequate material mixing, resulting in a void in stir zone at 1.2 mm/s for straight cylindrical threaded tool. At 1.8 mm/s, both tools demonstrated effective material mixing in stir zone. During tensile strength analysis, straight cylindrical threaded tool showed a significant drop in tensile strength at a lower speed (1.2 mm/s), while both tools achieved their highest strength at the optimal speed (1.8 mm/s), with straight hexagonal tool exhibiting the best (93.4 MPa). Discrete wavelet transform analysis of friction stir welding signals has revealed significant observations in which poor weld quality shows defects in macrostructure.