In-situ Process Monitoring in Friction Stir Welding

When friction stir welding, you have to keep an eye on the process forces and heat development. They constantly change with material and welding speed. If you don't control it properly, you get stresses in the component that can lead to cracks or distortion. The microstructure also suffers if the temperature is not right – the material becomes brittle or soft. Monitor the machine via sensors and react immediately when values exceed limits. You'll find the right setting through trial welds. Make sure the heat goes in and out evenly, then the microstructure becomes homogeneous and the part holds.