Validation of a Newly Developed Robotic System for Friction Stir Welding Process by Joining and Characterizing Joints Of Aluminum Alloy 5052 H34

Abstract

This project deals with the validation of a newly developed system for a welding by friction welding process, which was adapted to an anthropomorphic robot with a capacity of 500 kg and six degrees of freedom. To ensure that the designed system is capable of soldering materials for the FSW process, that is, make sure that it has sufficient stiffness, strength and torque to perform a welding operation, it is necessary to perform a calibration of the same. To do so, it was necessary to find a known material, with already established parameters, and to use an appropriately sized tool. In this way, the alloy 5052 H43 of 3 mm thickness was used, used in the production of ships, boats and automotive structures. For a welding of the finished joints, it was manufactured in AISI H13, with smooth conical pin and shoulder diameter of 18 mm. The rotational speed of the tool was kept constant at 378 rpm, and an advance speed of 7.5 mm / min, with a tool slope of 2 °. It was verified after the tests that the designed welding system proved to be effective in FSW welding applications, presenting sufficient torque and mechanical strength for a union of materials with low melting point. Through the parameters used, as well as the geometry of the tool, it is possible to obtain 5052 H34 aluminum alloy seals welded with: good surface appearance, low burr values, no grooves or voids along the welding line and with total penetration.

Key-words:
Friction stir welding; Welding; Robotization; Friction; Industrial