Dimensional analysis and a potential classification algorithm for prediction of wear in friction stir welding of metal matrix composites

The objective of this study is to develop a dimensionless parameter which can be used to estimate the amount of volumetric wear, a friction stir welding tool will experience in joining a metal matrix composite. Metal matrix composites are strong, lightweight materials consisting of a metal matrix (often an aluminum alloy) reinforced with ceramic particles or fibers. This study derives a dimensionless number based on three major process variables in friction stir welding: rotation speed, traverse speed, and length of weld. This number is correlated with wear data collected from experiments in which a steel friction stir welding tool was used to join Al 359/SiC/20p. The use of the dimensionless number as a classifier for tool condition is also evaluated.