In a groundbreaking development for the welding industry, researchers have unveiled a novel method to measure welding forces and torque in refill friction stir spot welding (RFSSW) of pure copper, potentially revolutionizing the manufacturing of electrical connectors and thin-sheet heat exchangers. This advancement, led by Xiaole Ge from the National Technical University «Kharkiv Polytechnic Institute» in Ukraine, promises to optimize welding processes, enhance equipment design, and improve weld quality, with significant implications for the energy sector.
The study, published in the ‘Archives of Metallurgy and Materials’ (translated from Ukrainian as ‘Arkhiv Metallurhii ta Materialiv’), introduces an octagonal ring dynamometer (ORD) designed to precisely measure the forces and torque exerted during the RFSSW process. This innovation is a game-changer for understanding material deformation and flow mechanisms, as well as tool wear.
“By accurately measuring these forces, we can fine-tune the welding parameters to achieve superior weld quality,” Ge explained. The research demonstrates that the primary welding force during RFSSW is the axial force, which can be more than ten times greater than the lateral force. The study also identifies critical stages in the welding process where forces and torque increase significantly, such as the clamping, plunging, and refilling phases.
The findings reveal that axial force is most influenced by plunge depth, torque by rotational speed, and lateral force by the combined effects of plunge depth and rotational speed. These insights are crucial for optimizing process parameters and enhancing the efficiency of the RFSSW process.
The practical implications of this research are vast, particularly for industries requiring high-quality copper welds. “This work provides a foundation for future research into enhancing the efficiency and reducing the energy consumption of the RFSSW process,” Ge noted. The ability to predict welding forces and torque with high accuracy can lead to significant cost savings and improved product reliability.
For the energy sector, this research could translate into more robust and efficient electrical connectors and heat exchangers, which are vital components in various energy systems. By improving the welding process, manufacturers can produce components that are more durable and perform better under high-stress conditions.
The study’s findings are not only academically significant but also hold substantial commercial potential. As industries strive for greater efficiency and sustainability, the ability to optimize welding processes becomes increasingly important. This research paves the way for advancements in manufacturing technologies, ultimately benefiting a wide range of applications in the energy sector and beyond.
In summary, Xiaole Ge’s innovative approach to measuring welding forces and torque in RFSSW of pure copper marks a significant step forward in the field of welding technology. The insights gained from this research have the potential to transform industrial practices, leading to higher quality products and more efficient manufacturing processes. As the energy sector continues to evolve, these advancements will play a crucial role in meeting the demands for reliable and high-performance components.