| Abstract Scope |
Friction stir processing (FSP) performance is governed by tool geometry and process parameters that influence material flow, tool loading, heat generation, and process stability. This study evaluates the effects of tool pin profile, rotational speed, and travel speed on online force–torque responses during FSP of pure aluminium-based composites. Taper-threaded, cylindrical-threaded, and square pins will be tested at rotational speeds of 2100, 2450, and 2800 rpm and travel speeds of 20, 40, and 60 mm/min. Axial force, tool tilt angle, and plunge depth will remain constant at 11 kN, 2.5°, and 0.2 mm, respectively. A full-factorial design comprising 27 parameter combinations will be employed. Force and torque signals will be recorded during plunging and steady travel. Peak values, mean responses, fluctuations, and signal stability will be compared to identify profile- and parameter-dependent behaviour. The findings will support improved process monitoring, tool selection, parameter optimisation, and early detection of unstable FSP conditions. |