Friction stir welding (FSW) has developed into a reliable and increasing used industrial joining technology. Various tool configurations can be used for FSW, each of which has advantages and challenges. State-of-the-art FSW employs various tool configurations, including the conventional, the stationary shoulder, and the dual-rotational configuration which is characterized by separate control of shoulder and probe. In this study, an innovative method to combine various tool configurations was developed by a novel FSW spindle stack construction. With an additional servomotor, existing FSW systems can be extended by separate control of shoulder and probe so that varying rotational speeds and rotational directions can be set. This allows enhanced possibilities (a) to adjust frictional heat generation and (b) to apply several tool configurations. The main advantages of this enhanced type of FSW are demonstrated in three ways: increased weld penetration depth, reduction of undesirable machine vibrations, and the combination of varying tool configurations such as stationary shoulder and conventional FSW. The investigations were carried out with 2-mm EN AA 5754 H22 sheets and performed on a robotized FSW setup.

搅拌摩擦焊 (FSW) 已发展成为一种可靠且越来越多使用的工业连接技术。各种工具配置可用于 FSW，每种配置都有优势和挑战。最先进的 FSW 采用各种工具配置，包括传统的、固定的肩部和双旋转配置，其特点是肩部和探头的独立控制。在这项研究中，通过新型 FSW 主轴堆栈结构开发了一种结合各种刀具配置的创新方法。使用额外的伺服电机，现有的 FSW 系统可以通过肩部和探头的单独控制来扩展，以便可以设置不同的旋转速度和旋转方向。这允许增强的可能性 (a) 调整摩擦生热和 (b) 应用多种工具配置。这种增强型 FSW 的主要优势体现在三个方面：增加焊缝熔深、减少不希望的机器振动，以及不同工具配置（例如固定台肩和传统 FSW）的组合。研究使用 2 毫米 EN AA 5754 H22 板材进行，并在机器人 FSW 装置上进行。