Simulation of a New Solid State Joining Process Using Single-Shoulder Two-Pin Tool

In friction stir welding (FSW) process, heat is generated by friction between the tool and the workpiece. The conventional tool design employs a cylindrical shoulder with a single profiled pin. A new process has been designed that uses two-pin tool under the same shoulder to increase shear deformation within workpiece that can enhance local heating where joining occurs. The design employs two closely spaced pins rotating in the same direction within the workpiece under a separately controlled shoulder. The process is distinctly different from the Twin-stir™ variant of FSW in which each pin performs an independent function and non-interacting. Prior to gathering considerable experimental data with new equipment, a fully coupled themomechanical three-dimensional finite element model has been developed to compare the existing single-pin technology with new technology of friction driven stitch welding process. The computational results for the two-pin tool show considerable shearing along the joining interface, enhanced local heating, and a reduced reaction force on the pins, which are described in this paper. The results of this study indicate that the two-pin tool design with a separate shoulder, with the same direction of pin rotation, can be a superior design in comparison to the conventional single-pin FSW tool and could minimize damage to tool material.