Reducing fixturing requirements for friction stir welding with PCD tools

To enable ultra high-speed friction stir lap welding a high-speed spindle capable of operating continuously at 10,000 RPM was used in conjunction with a polycrystalline diamond (PCD) tool. While traditional FSW equipment has not been designed to facilitate these higher rotational velocities, operating at these high spindle speeds changes the overall welding environment with notable improvements. These include the following: reduction in clamping requirements for weld setups, reduced distortion from heat, reduced heat affected zone both in size and magnitude, increased tool life resulting from reduced process forces, improved surface finish, reduction in weld flash, as well as other distinguishable improvements. While the improved throughput makes evaluating ultra high-speed friction stir lap welding a high priority for future designs, the secondary benefits have the potential to realize an even greater financial benefit for high volume production parts.