Sensor-Assisted Real-Time Analysis of Hybrid Tool Pin Geometry Effects on Force Generation, Spindle Torque, and Macro-Microstructural Evolution During FSW of 2050-T84 Al-Cu-Li Alloy Plates
Guru Sewak Kesharwani and Sanjeev Kumar
This study investigates real-time process analysis in friction stir welding (FSW) of 6 mm thick 2050-T84 Al-Cu-Li alloy plates using integrated sensors and data acquisition systems. Three distinct hybrid tool pin profiles were evaluated to assess their influence on weld quality, particularly elongation. Real-time sensor feedback was used to monitor key parameters such as force, temperature, and torque, enabling the detection and correction of process deviations. Among the tools tested, the hybrid pin operating at 1400 rpm and a traverse speed of 4 mm/s yielded the highest tensile strength (404.2 MPa), elongation (7.56%), and joint efficiency (76.4%). This setup also recorded the highest total heat input of 1180 KJ/m, including 330 KJ/m at the pin and 25 KJ/m at the tip. Macro- and microstructural analysis revealed fine equiaxed grains in the stir zone and elongated grains in the thermomechanically affected zone. Scanning electron microscopy (SEM) confirmed ductile fracture features. Overall, the integration of real-time monitoring with optimized tool design significantly enhances weld quality and provides valuable insights for refining FSW process parameters.
Keywords: Data acquisition, sensors, real-time analysis, and friction stir welding