Evaluating tool life for robotic refill friction stir spot welding

Refill friction stir spot welding has been shown to be an effective joining method for aluminum alloys. In comparison to resistance spot welding, it uses less energy, improves mechanical properties, and in many cases can be joined with faster cycle times. While an increasing body of information is available documenting process parameters, mechanical properties, surface finish, and cycle times, understanding the cost per spot related to tool costs is still relatively undefined. The current effort focuses on understanding the tool life of refill friction stir spot welding tools in a manufacturing environment, so that a clear indication of tool life can be integrated into future cost models for the process.