Solid-State Welding: Friction and Friction Stir Welding Processes

2020 ◽  
Author(s):  
Esther Titilayo Akinlabi ◽  
Rasheedat Modupe Mahamood
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Friction Stir ◽  
Welding Processes

Solid State Welding Process for Aerospace Components

2015 ◽  
Vol 1119 ◽  
pp. 597-600
Author(s):  
Hyun Ho Jung ◽  
Ye Rim Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo ◽  
Kyung Ju Min ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Structural Integrity ◽  
Welding Process ◽  
Diffusion Welding ◽  
Intimate Contact ◽  
Friction Stir ◽  
Base Materials ◽  
Welding Processes ◽  
And Diffusion

Since solid state welded joint is formed from an intimate contact between two metals at temperatures below the melting point of the base materials, the structural integrity of welding depends on time, temperature, and pressure. This paper provides some of examples of friction stir welding and diffusion welding process for aerospace components. Friction stir welding process of AA2195 was developed in order to study possible application for a large fuel tank. Massive diffusion welding of multiple titanium sheets was performed and successful results were obtained. Diffusion welding of dissimilar metals of copper and stainless steel was necessary to manufacture a scaled combustion chamber. Diffusion welding of copper and steel was performed and it is shown that the optimum condition of diffusion welding is 7MPa at 890°C, for one hour. It is shown that solid state welding processes can be successfully applied to fabricate lightweight aerospace parts.

scholarly journals Joining of dissimilar materials by friction stir welding

2018 ◽  
Vol 224 ◽  
pp. 01118 ◽  
Author(s):  
Zakaria Boumerzoug
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Physical Properties ◽  
Dissimilar Materials ◽  
Total Weight ◽  
Friction Stir ◽  
Pipe Welding ◽  
Race Cars ◽  
Welding Processes ◽  
Solid State Joining

Welding is a process of joining materials into one piece. Welding is used extensively for pipe welding, aerospace, aviation, biomedical implants, fabrication of race cars, choppers, etc. Welding processes include thermal fusion joining processes and solid-state joining processes. Among solid-state joining processes, there is a friction stir welding which is applied to join two workpieces without materials. This technique of welding has great is used to weld dissimilar materials. This type of welding is gaining renewed interest, because the main objective is to reduce the total weight and maintaining essential physical properties. The objective of this paper is to focus on the friction stir welding of dissimilar materials.

A Friction Stir Welding Platform of Thin Plates

2012 ◽  
Vol 628 ◽  
pp. 206-210 ◽  
Author(s):  
Jia Liang Zhang ◽  
Bei Zhi Li ◽  
Xin Chao Zhang ◽  
Qing Xia Wang
Keyword(s):  
Friction Stir Welding ◽  
Virtual Instrument ◽  
Production Efficiency ◽  
Cost Effective ◽  
Field Analysis ◽  
Sensor Data ◽  
Thin Plates ◽  
Increase Production Efficiency ◽  
Friction Stir ◽  
Welding Processes

Friction stir welding processes involve many variables. Engineers and operators often find it difficult to effectively design or control it. The objective of this work is to develop a friction stir welding platform of thin plates to improve welding quality and to increase production efficiency. The study is conducted by using finite element modeling and temperature field analysis technology to obtain optimization parameters, and using virtual instrument, multi-sensor data fusion to monitor the force of the stirring spindle. Experiment results show that the developed platform can reach the requirements of processing quality and is cost-effective.

scholarly journals Design and Fabrication of Friction Stir Welding End-Effector for an ABB IRB1410 Robot

2016 ◽  
Vol 5 (2) ◽  
pp. 98
Author(s):  
Santosh Vanama
Keyword(s):  
Friction Stir Welding ◽  
High Strength ◽  
Fusion Welding ◽  
Fusion Temperature ◽  
End Effector ◽  
Friction Stir ◽  
Aluminum Sheets ◽  
Operation Pressure ◽  
Welding Processes ◽  
Tool Rotation

<p>The paper propose modelling and fabrication of friction stir welding end-effector for ABB IRB1410 robot. A dynamically developing version of pressure welding processes, join material without reaching the fusion temperature called friction stir welding. As friction stir welding occurs in solid state, no solidification structures are created thereby eliminating the brittle and eutectic phase’s common to fusion welding of high strength aluminium alloys. In this paper, Friction stir welding is applied to aluminum sheets of 2 mm thickness. A prototype setup is developed to monitor the evolution of main forces and tool temperature during the operation. Pressure of a gripper plays a major role for tool rotation and developing torque.  Fabrication of the tool has done. Force calculations are done by placing the sensors on the outer surface of gripper. Methods of evaluating weld quality are surveyed as well.</p>

Multiaxial Mechanical Strength of AA-2024-T3 Aluminium Alloy Sheets Joined by Friction Stir Welding Processes

2009 ◽  
Vol 83-86 ◽  
pp. 1243-1250 ◽  
Author(s):  
R.L.L.P. Cerveira ◽  
G. F. Batalha
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Short Review ◽  
Multiaxial Loading ◽  
Angle Variation ◽  
Friction Stir ◽  
Aa 2024 ◽  
Aeronautical Industry ◽  
Welding Processes ◽  
Joining Process

The aim is to analyze a junction produced by a Friction Stir Welding (FSW) joining process under multiaxial loading, employing a modified Arcan test that allows an angle variation of the loading in order to evaluate the failure of the FSW weldment as compared to the base material. A short review of the earlier studies and relevant theories about the FSW processes and fracture modes I and II under multiaxial loading are presented and were experimentally evaluated for an AA2024-T3 aluminum alloy sheets (t = 1.6 mm) processed by FSW. The results obtained can serve as a basis to compare the junctions made using FSW and conventional joint methods such as rivets (very common practice in the aeronautical industry).

Study on Forming Behaviour of Friction Stir Welded Blanks During Single Point Incremental Forming (SPIF) Process

2020 ◽  
Author(s):  
Shalin Marathe ◽  
Harit Raval
Keyword(s):  
Friction Stir Welding ◽  
Incremental Forming ◽  
Single Point ◽  
Base Material ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Cnc Milling ◽  
Forming Process ◽  
Friction Stir ◽  
Welding Processes

Abstract The automobile, transportation and shipbuilding industries are aiming at fuel efficient products. In order to enhance the fuel efficiency, the overall weight of the product should be brought down. This requirement has increased the use of material like aluminium and its alloys. But, it is difficult to weld aluminium using conventional welding processes. This problem can be solved by inventions like friction stir welding (FSW) process. During fabrication of product, FSW joints are subjected to many different processes and forming is one of them. During conventional forming, the formability of the welded blanks is found to be lower than the formability of the parent blank involved in it. One of the major reasons for reduction in formability is the global deformation provided on the blank during forming process. In order to improve the formability of homogeneous blanks, Single Point Incremental Forming (SPIF) is found to be giving excellent results. So, in this work formability of the welded blanks is investigated during the SPIF process. Friction Stir Welding is used to fabricate the welded blanks using AA 6061 T6 as base material. Welded blanks are formed in to truncated cone through SPIF process. CNC milling machine is used as SPIF machine tool to perform the experimental work. In order to avoid direct contact between weld seam and forming tool, a dummy sheet was used between them. As responses forming limit curve (FLC), surface roughness, and thinning are investigated. It was found that use of dummy sheet leads to improve the surface finish of the formed blank. The formability of the blank was found less in comparison to the parent metal involved in it. Uneven distribution of mechanical properties in the welded blanks leads to decrease the formability of the welded blanks.

Establishing the Dependence of Output Parameters Depending on Local Process Conditions for Friction Stir Welding of Pure Copper Plates

2018 ◽  
Vol 1146 ◽  
pp. 32-37 ◽  
Author(s):  
Marius Adrian Constantin ◽  
Ana Boşneag ◽  
Eduard Niţu ◽  
Lia Nicoleta Boţilă
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Speed ◽  
Frictional Heating ◽  
Pure Copper ◽  
Fusion Welding ◽  
Process Conditions ◽  
Friction Stir ◽  
Local Process ◽  
Welding Processes

Welding copper and its alloys is usually difficult to achieve by conventional fusion welding processes because of high thermal diffusivity of the copper, which is at least 10 times higher than most steel alloys, in addition to this, there are the well-known disadvantages of conventional fusion welding represented by necessity of using alloying elements, a shielding gas and a clean surface. To overcome these inconveniences, Friction Stir Welding (FSW), a solid state joining process that relies on frictional heating and plastic deformation, is being explored as a feasible welding process. In order to achieve an increased welding speed and a reduction in tool wear, this process is assisted by another one (TIG) which generates and adds heat to the process. The research includes two experiments for the FSW process and one experiment for tungsten inert gas assisted FSW process. The process parameters that varied were the rotational speed of the tool [rpm] and the welding speed [mm/min] while the compressive force remained constant. The purpose of this paper is to correlate the evolution of temperature, tensile strength, elongation and microscopic aspect with the linear position on the joint (local process parameters) for each experimental case and then make comparisons between them, and to identify and present the set of process parameters that has the best mechanical properties for this material.

Friction Stir Welding of the Aluminum Matrix Composite - A Literature Review

2015 ◽  
Vol 787 ◽  
pp. 669-673
Author(s):  
K. Reddi Prasad ◽  
Arumugam Mahamani
Keyword(s):  
Friction Stir Welding ◽  
Literature Review ◽  
Weight Ratio ◽  
Ex Situ ◽  
Aluminium Matrix ◽  
Matrix Composites ◽  
Aluminium Matrix Composites ◽  
Friction Stir ◽  
Joint Efficiency ◽  
Welding Processes

Aluminium matrix composites have received the attention of numerous researchers, because of its attractive properties like high strength, good thermal conductivity and more strength to weight ratio. Application of the conventional welding processes for aluminium matrix composites, facilitates the formation of undesirable phase at the welded region, which limits the wide spread application. The objective of this paper is to review the literatures belonging to the friction stir welding of the composites and explore the challenges associated to maximize joint efficiency. The major contribution of this paper is to study the issue of welding of ex-situ and in-situ composites, various process parameters, properties of joint and post weld heat treatment process to improve the joint efficiency. This literature review provides some research gaps in the friction stir welding of composites.

On the solid-state-bonding mechanism in friction stir welding

2020 ◽  
Vol 37 ◽  
pp. 100727
Author(s):  
Xue Wang ◽  
Yanfei Gao ◽  
Martin McDonnell ◽  
Zhili Feng
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Bonding Mechanism ◽  
Friction Stir ◽  
Solid State Bonding

Characterization o Solid-State Vortices Associated with the Friction-Stir Welding of Copper to Aluminum

1998 ◽  
Vol 4 (S2) ◽  
pp. 530-531
Author(s):  
R. D. Flores ◽  
L. E. Murr ◽  
E. A. Trillo
Keyword(s):  
Plastic Deformation ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Weld Zone ◽  
Thick Plates ◽  
6061 Aluminum Alloy ◽  
Friction Stir ◽  
The Past ◽  
Joining Process

Although friction-stir welding has been developing as a viable industrial joining process over the past decade, only little attention has been given to the elucidation of associated microstructures. We have recently produced welds of copper to 6061 aluminum alloy using the technique illustrated in Fig. 1. In this process, a steel tool rod (0.6 cm diameter) or head-pin (HP) traverses the seam of 0.64 cm thick plates of copper butted against 6061-T6 aluminum at a rate (T in Fig. 1) of 1 mm/s; and rotating at a speed (R in Fig. 1) of 650 rpm (Fig. 1). A rather remarkable welding of these two materials results at temperatures measured to be around 400°C for 6061-T6 aluminum welded to itself. Consequently, the metals are stirred into one another by extreme plastic deformation which universally seems to involve dynamic recrystallization in the actual weld zone. There is no melting.

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