Fsw tool design for thick weld joints

Abstract

The present invention provides a novel pin design for a friction stir welding (FSW) tool that can penetrate more deeply into workpieces to form a thicker weld joint without overloading the tool. The pin is provided with threads on its surface. Some portions of the threads are in a positive hand (d,, d,); positive threads screw in to draw the pin into workpieces when the pin is rotated. Other portions of the threads are in a negative hand (d,, d,); negative threads screw out to oppose drawing-in of the pin. When the pin is rotated and driven into workpieces under an applied vertical load, the positive threads encourage penetration of the pin into the workpieces while the negative threads enhance shearing of workpiece material into particles. The positive threads thus reduce the amount of vertical load required to drive the pin, and therefore allow the pin to penetrate more deeply into workpieces to form a thicker weld joint without overloading the tool. Preferably, the pin diameter is decreased from its proximal end (d,) to its distal end (d,), either discretely in steps or linearly in a tapering manner. The reducing profile of the pin further eases penetration of the pin into workpieces, and also reduces the amount of transverse welding load required to traverse the pin along the weld interface.