Low cost transformation of a conventional milling machine into a simple FSW work station

Many of the typical problems related to fusion welding of aluminium alloys can be avoided by using non conventional joining techniques. One of particular interest is the Friction Stir Welding (FSW) in which the joined material remains at solid state, thus allowing to avoid solidification phenomena such as formation of dendritic structures or liquation cracking. Since FSW is governed by two completely mechanical processes, i.e. mixing and forging, it is possible to join heterogeneous aluminium alloys without filler metal. Using specially designed tools and machines up to 75mm of aluminium can be welded in a single pass. This paper describes a low-cost method of transforming a conventional milling machine into a simple FSW work station. The machine adaptation process includes the implementation of a temperature measurement and a downward and horizontal forces monitoring systems, as well as designing of a tool fixing system and the tool itself. Finally are presented the results obtained using the modified FSW work station along with the cost related considerations.