Vision

Three friction stir welds made during a training course in Munich

The Vision of the aiCAM^stir project came-up during a friction stir welding training course in Munich.

Some years ago, Stephan Kallee had worked on a project on making tailor welded blanks by friction stir welding. A new spindle, a new jig, two FSW experts and a new technician were available, who was experienced in operating milling machines but had not received in-depth training on parameter optimisation. Due to an unforeseen business trip, they worked on three different sites: in the lab, in the office and in a hotel. They could only communicate by mobile phone, sharing photos and information on the parameter settings. After a few iterations, optimised parameters could be found.

Some years later, he considered using neuro-networks for optimising FSW parameters. During a training course in Munich, the concept of using artificial intelligence in computer aided manufacturing was discussed in more detail and a project with very promising results was conducted.

In the aiCAM^stir project we want to go one step further. We want to create a cloud, into which FSW operators can upload images and information on parameter settings during feasibility studies, prototyping, production ramp-up and series production, and get feedback about the weld quality and recommendations on optimising the parameters. In the final stage, such a system would be integrated into the FSW machine, and the machine would optimise the parameters itself within boundries set by the operator.

The first welds

The first welds were made by a group of experts and trainees in Munich. The trainees could choose the parameters after discussions with the experts and found visually acceptable parameter settings after a few iterations. The parameter matrix investigated during the course is shown below: