Friction Stir Welding is a developing technology used in various Industrial applications due to the energy efficiency, environment friendliness and versatility. In this, we proposed modeling and fabrication of friction welding end-effector for ABB IRB1410 robot. We have a design in Solid Works and design analysis in ANSYS. Force calculations are done by placing the sensors on the outer surface of a gripper. Methods of evaluating weld quality are surveyed as well. The Friction welding is applied to aluminum sheets of 2 mm thickness. A prototype setup is developed to monitor the developed a main forces and tool temperature during the operation. The pressure of a gripper plays a significant role in tool rotation and developing torque. Fabrication work is done. The application of friction welding is used for the joining of the two dissimilar materials. It is used in industrial application with the perfect welding of work piece.
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