PVD Coatings on Friction Stir Welding Tools

该项目将研究使用新型高能物理气相沉积（PVD）工艺HiPIMS（高功率脉冲磁控溅射）制造涂层FSW工具的可行性。搅拌摩擦焊（FSW）是一种创新的连接工艺，它使用一种旋转的、非消耗性的工具，沿着两个工件的界面穿越。与传统的熔焊工艺相比，该工艺通常提供更高的焊接质量、强度和耐久性，同时降低能耗和环境影响。然而，FSW工具是一个非常苛刻的环境-高温（bb0 - 700°C），高磨损和暴露在新暴露的金属表面的反应效应-这限制了其商业应用于低熔点合金，主要是铝。通过HiPIMS涂层的应用，我们希望能够实现“高温”材料的焊接，例如高价值行业（例如航空航天和运输）的钢和钛。

This project will investigate the feasibility of creating coated FSW tools using a novel high energy physical vapour deposition (PVD) process – HiPIMS (High Power Impulse Magnetron Sputtering). Friction Stir Welding (FSW) is an innovative joining process, which uses a rotating, non-consumable tool, which is traversed along the interface of two work-pieces. The process typically provides enhanced weld quality, strength and durability together with reduced energy consumption and environmental impact when compared to conventional fusion welding processes. However, FSW tooling is an extremely demanding environment – high temperature (>700°C), high abrasion and exposure to the reactive effects of freshly exposed metal surfaces – this has limited its commercial application to low melting point alloys, principally aluminium. Through the application of HiPIMS coating, we hope to enable the welding of ‘high-temperature’ materials, such as steel and titanium for high-value industries (e.g. Aerospace & Transport).