A mobile fixture system for friction stir welding application

In an attempt to provide a more flexible means of achieving friction stir welding (FSW) of Aluminum without the use of expensive FSW machine tool, which are not readily available, this study developed a mobile fixture system (MFS) for FSW on Vertical milling Machine Tool (VMMT) and Pillar drilling machine Tool (PDMT). A conceptual design of the fixture system with a moving work table, which provides for transverse feed (movement) of the workpieces during FSW, was generated.  The detailed design of the components of the MFS was done using existing mechanical design formulae. Subsequently, the design was fabricated and evaluated. An ATmega 328P Arduino Uno microcontroller was used to design a control system to automate the MFS worktable movement. Results revealed that the MFS worked smoothly during FSW of AA 1100 materials. The MFS performed well during the FSW of the Aluminum materials on the VMMT as well as the PDMT. The efficiency of its motion accuracy was estimated as 87.2%. Also, the trend of the tensile strength and the hardness value as well as the joint efficiencies of the AA 1100 weldments produced using the developed MFS agreed with existing studies.