Physics-based interpretation of tool-workpiece interface temperature signals for detection of defect formation during friction stir welding

The objective of the work is the reduction and eventual avoidance of post welding inspections that are currently needed to ensure defect-free welds. An analytical thermal model of the FSW process along with an analytical disturbance model is developed. This disturbance model relates defect formation to variations in the measured temperature and is based on experimental process identification. A dynamic disturbance observer computes an estimate of the disturbance signal, which is further processed in order to provide information about the presence of defects along the weld. Experiments for one kind of disturbance verify that the observer shows good tracking behavior. © 2015 Society of Manufacturing Engineers (SME).