A review of tool wear prediction during friction stir welding of aluminium matrix composite

Friction stir welding is the preferred joining method for aluminium matrix composites. It is a solid-state process which prevents the formation of the intermetallic precipitates responsible for degradation of mechanical properties in fusion welds of these composites. The major concern in friction stir welding is the wear of the welding tool pin. The wear is due to the prolonged contact between the tool and the harder reinforcements in the composite materials. This paper provides an overview of the effects of different parameters of friction stir welding on the tool wear. It was found that the total amount of material removed from the tool is in direct proportion to the rotational speed of the tool and the length of the weld but inversely proportional to the transverse rate. The results even demonstrate that the tool geometry also has significant influence on the wear resistance of the tool. The tool even converts itself into a self-optimized shape to minimize its wear.