The Effect of Process Parameters and Tool Geometry on Thermal Field Development and Weld Formation in Friction Stir Welding of the Alloys AZ31 and AZ61

Experimental and numerical investigations have been performed in order to study the effect of welding parameters on properties of FSW-ed AZ31 magnesium alloy sheets. The results, presented in terms of tensile strength and numerical field variables distributions, allow to understand the behaviour of such material when FSW-ed using different rotational and welding speeds for a given tool geometry.

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TAGUCHI OPTIMIZATION OF PROCESS PARAMETERS IN FRICTION STIR WELDING OF THE AA7010–SiC–Al2O3 HYBRID COMPOSITE

High Temperature Material Processes An International Quarterly of High-Technology Plasma Processes ◽

10.1615/hightempmatproc.2016017921 ◽

2016 ◽

Vol 20 (3) ◽

pp. 185-196

Author(s):

Ponnusamy Gopi Krishnan ◽

K. Siva

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Hybrid Composite ◽

Taguchi Optimization ◽

Friction Stir ◽

Optimization Of Process Parameters

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Influence of Tool Geometry and Process Parameters on the Properties of Friction Stir Spot Welded Multiple (AA 5754 H111) Aluminium Sheets

Materials ◽

10.3390/ma14051157 ◽

2021 ◽

Vol 14 (5) ◽

pp. 1157

Author(s):

Danka Labus Zlatanovic ◽

Sebastian Balos ◽

Jean Pierre Bergmann ◽

Stefan Rasche ◽

Milan Pecanac ◽

...

Keyword(s):

Mechanical Properties ◽

Process Parameters ◽

Spot Welding ◽

Minimum Energy ◽

Tool Geometry ◽

Friction Stir ◽

Minimum Energy Consumption ◽

Punch Test ◽

Wide Range ◽

Lap Welding

Friction stir spot welding is an emerging spot-welding technology that offers opportunities for joining a wide range of materials with minimum energy consumption. To increase productivity, the present work addresses production challenges and aims to find solutions for the lap-welding of multiple ultrathin sheets with maximum productivity. Two convex tools with different edge radii were used to weld four ultrathin sheets of AA5754-H111 alloy each with 0.3 mm thickness. To understand the influence of tool geometries and process parameters, coefficient of friction (CoF), microstructure and mechanical properties obtained with the Vickers microhardness test and the small punch test were analysed. A scanning acoustic microscope was used to assess weld quality. It was found that the increase of tool radius from 15 to 22.5 mm reduced the dwell time by a factor of three. Samples welded with a specific tool were seen to have no delamination and improved mechanical properties due to longer stirring time. The rotational speed was found to be the most influential parameter in governing the weld shape, CoF, microstructure, microhardness and weld efficiency. Low rotational speeds caused a 14.4% and 12.8% improvement in joint efficiency compared to high rotational speeds for both tools used in this investigation.

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Procedure to find out the optimal ranges of process parameters for friction stir welding

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/1464420721993145 ◽

2021 ◽

pp. 146442072199314

Author(s):

Shubham Verma ◽

Joy Prakash Misra ◽

Meenu Gupta

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Tilt Angle ◽

Welding Speed ◽

Rotational Speed ◽

Optical Microscope ◽

Graphical Analysis ◽

Friction Stir ◽

Steepest Ascent ◽

Vertical Milling Machine

The present study deals with the application of sequential procedure (i.e. steepest ascent) to obtain the optimum values of process parameters for conducting friction stir welding (FSW) experiments. A vertical milling machine is modified by fabricating fixture and tool ( H13 material) for performing FSW operation to join AA7039 plates. The steepest ascent technique is employed to design the experiments at different rotational speed, welding speed, and tilt angle. The ultimate tensile strength is considered as a performance characteristic for deciding the optimal levels. The mechanical and metallurgical characteristics of the joints are studied by executing tensile and microhardness tests. It is concluded from the graphical analysis of the steepest ascent technique that the optimal maximum and minimum values are 1812–1325 r/min for rotational speed, 43–26 mm/min for welding speed, and 2°–1.3° for tilt angle, respectively. Besides, optical microscope and scanning electron microscope are utilized for microstructural and fractographic analyses for a better understanding of the process.

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Influence of Tool Geometry and Contact Condition on Friction Stir Welding of Al-Cu Laminated Composites

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.856.16 ◽

2013 ◽

Vol 856 ◽

pp. 16-21

Author(s):

R. Beygi ◽

Mohsen Kazeminezhad ◽

A.H. Kokabi ◽

S. Mohammad Javad Alvani ◽

D. Verdera ◽

...

Keyword(s):

Friction Stir Welding ◽

Material Flow ◽

Laminated Composites ◽

Flow Behavior ◽

Tool Geometry ◽

Contact Conditions ◽

Friction Stir ◽

Tool Geometries ◽

Welding Procedure ◽

Sem Analyses

In this study friction stir welding of Al-Cu laminated composites were carried out by two different tool geometries. Welding procedure was carried out from both sides of Al and Cu. Analyzing cross section of welds showed that different contact conditions between shoulder and material, offers different material flow behavior which is dependent on the tool geometry. SEM analyses showed that mixing of materials in nugget region is more pronounced in the advancing side. Also XRD results indicated that welding from Cu side, leads to intermetallic formation in mixed regions.

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