Understanding the Fixture Design for friction stir welding research experiments

Friction stir welding (FSW) process was developed in 1991 by The Welding Institute (TWI) to weld nonferrous metals especially Aluminium alloys. Later on the process could extend its viability for other non-ferrous metals like copper and brass and for welding of dissimilar material combinations and composites. The process is adapted and experiments were carried out in a piecemeal manner by numerous researchers, but till the date a thumb rule is not possible to be developed. Most of the researchers have done the research or investigations for variable parameters (e.g. spindle speed, tool feed etc.) and their effect on different properties, but for experimental purpose it is said that a rigid clamping is of utmost importance in the FSW. The present paper will throw some light in the direction of systematic design, considering different requirements for design and fabrication of flexible fixture which will accommodate different thickness and size of substrate, and controlled gap in the abutting region, which ultimately will facilitate the researcher for successful FSW experiment. (C) 2017 Elsevier Ltd. All rights reserved.