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Considerations for Tungsten Carbide as Tooling in RFSSW
Ruth Belnap1, Taylor Smith1, Arnold Wright2
1Ira A Fulton College of Engineering, Department of Manufacturing Engineering, Brigham Young University, 265 CTB, Provo, UT 84602, USA.
Materials (Basel, Switzerland)
|August 10, 2024
Summary
Tungsten carbide (WC-Co) tools show promise for refill friction stir spot welding of 2029 aluminum, lasting nearly 3000 welds. Cleanliness and thermal management are critical for sustained tool life.
Area of Science:
- Manufacturing Engineering
- Materials Science
Background:
- Tool wear significantly impacts manufacturing performance in high-volume refill friction stir spot welding (RFSSW).
- Developing durable tooling is essential for efficient RFSSW processes, particularly for advanced materials like 2029 aluminum.
Purpose of the Study:
- To evaluate tungsten carbide with a cobalt binder (WC-Co) as a tool material for RFSSW of 2029 aluminum.
- To identify critical factors influencing the sustained lifetime of WC-Co tools in this application.
Main Methods:
- Investigated the performance and wear characteristics of WC-Co tools during RFSSW of 2029 aluminum.
- Analyzed the influence of process parameters, specifically cleanliness and thermal management, on tool longevity.
Main Results:
- WC-Co toolsets achieved a lifespan of approximately 2998 welds, comparable to conventional steel tooling.
- Tool cleanliness and effective thermal management were identified as crucial factors for sustained performance.
- The H13 clamp exhibited the most significant wear when using WC-Co shoulders and probes.
Conclusions:
- WC-Co is a viable tool material for RFSSW of 2029 aluminum, offering comparable lifespan to steel.
- Optimizing cleanliness and thermal management is key to maximizing WC-Co tool life.
- Further research may focus on mitigating wear in clamping components.
