The investigation of BFSW vibration signal in unsuccessful weld and tool failure by fast fourer transfrom

Wailyn, Nathanael Nawan (2024) The investigation of BFSW vibration signal in unsuccessful weld and tool failure by fast fourer transfrom. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Bobbin friction stir welding is an advanced form of solid-state welding, derived from conventional friction stir welding. It incorporates a modified tool configuration comprising an upper and lower shoulder connected by a penetrating pin, eliminating the need for a backing plate commonly used in traditional friction stir welding. During bobbin friction stir welding, the tool's two shoulders rotate in synchronization, spinning along the upper and lower surfaces of the workpiece in the same direction and at the same speed. This synchronized rotation ensures a uniform distribution of frictional heat throughout the welding process, positively affecting the weld material by enhancing its plastic deformation characteristics and eliminating common defects associated with conventional friction stir welding. In this study, the variation of tool rotational speeds and tool travel speeds is explored as a means to study the generated vibration in the weld material during the welding process. The resulting vibration has subsequent effects on weld quality and mechanical characteristics. Vibrational data is collected using accelerometers, while the heat generated during welding is also measured. The primary objective of this research is to investigate the impact of vibration on the weld material, providing valuable insights into the behaviour and performance of bobbin friction-stir-welding.

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