Effect of reverse dual rotation process on properties of friction stir welding of AA7075 to AISI304

The friction stir lap welding of AISI304 stainless steel to AA7075 aluminium alloy was investigated using the conventional friction stir welding (C-FSW) and the reverse dual rotation friction stir welding (DR-FSW) processes. In order to reduce the heat input, a dual rotation tool with a lower shoulder rotating speed was used. The results showed that both processes provide welds with excellent appearance and free of internal defects. The use of the DR-FSW process with the tool shoulder rotating reversely at low speed results in larger grain refinement in the nugget and less change in the microstructure of the aluminium alloy than using the C-FSW. The use of DR-FSW process at low speed of rotation allows to reduce the amount of intermetallic compounds in the welding interface, but does not prevent their formation. Although DR-FSW welding exhibits tensile strength superior to that achieved with the conventional process (C-FSW), both exhibit brittle behaviour with fracture at the weld interface.

Improving weld formability by a novel dual-rotation bobbin tool friction stir welding

A novel dual-rotation bobbin tool friction stir welding （DBT-FSW） was developed, in which the upper shoulder （US） and lower shoulder （LS） have different rotational speeds. This process was tried to weld 3.2 mm thick alunlinum-lithium alloy sheets. The metallographic analysis and torque measurement were carried out to characterize the weld formabiliW. Experimental results show that compared to conven- tional bobbin tool friction stir welding, the DBT-FSW has an excellent process stability, and can produce the defect-free joints in a wider range of welding parameters. These can be attributed to the significant improvement of material flow caused by the formation of a staggered layer structure and the unbalanced force between the US and LS during the DBT-FSW process.

Orthogonal transformation operation theorem of a spatial universal uniform rotating magnetic field and its application in capsule endoscopy

According to the anti-phase sine current superposition theorem, the orientation, the magnetic flux density, the angular speed and the rotational direction of the spatial universal rotating magnetic field (SURMF) can be controlled within the tri-axial orthogonal square Helmholtz coils (TOSHC). Nevertheless, three coupling direction angles of the normal vector of the SURMF in the Descartes coordinate system cannot be separately controlled, thus the adjustment of the orientation of the SURMF is difficult and the flexibility of the robotic posture control is restricted. For the dimension reduction and the decoupling of control variables, the orthogonal transformation operation theorem of the SURMF is proposed based on two independent rotation angular variables, which employs azimuth and altitude angles as two variables of the three-phase sine current superposition formula derived by the orthogonal rotation inverse transformation. Then the unique control rules of the orientation and the rotational direction of the SURMF are generalized in each spatial quadrant, thus the scanning of the normal vector of the SURMF along the horizontal or vertical direction can be achieved through changing only one variable, which simplifies the control process of the orientation of the SURMF greatly. To validate its feasibility and maneuverability, experiments were conducted in the animal intestine utilizing the innovative dual hemisphere capsule robot (DHCR) with active and passive modes. It was demonstrated that the posture adjustment and the steering rolling locomotion of the DHCR can be realized through single variable control, thus the orthogonal transformation operation theorem makes the control of the orientation of the SURMF convenient and flexible significantly. This breakthrough will lay a foundation for the human-machine interaction control of the SURMF.