An insight into the electrical energy demand of friction stir welding processes: the role of process parameters, material and machine tool architecture

The manufacturing sector accounts for a high share of global electrical energy consumption and CO 2 emissions, and therefore, the environmental impact of production processes is being more and more investigated. An analysis of power and energy consumption in friction stir welding processes can contribute to the characterization of the process from a new point of view and also provide useful information about the environmental impact of the process. An in-depth analysis of electrical energy demand of friction stir welding is here proposed. Different machine tool architectures, including an industrial dedicated machine, have been used to weld aluminum and steel sheets under different process conditions. The influence of tool rotation and feed rate was investigated. A power study, with breakdown analysis, was carried out to identify the contribution of the main sub-units and to determine the total demand. Different setups have been analyzed in order to identify the conditions resulting in the highest energy and mechanical efficiency. Potential control strategies for energy consumption reduction of FSW process are proposed.