Preliminary Investigation of the Effect of Temperature Control in Friction Stir Welding

2021 ◽  
pp. 81-89
Author(s):  
Johnathon B. Hunt ◽  
David Pearl ◽  
Yuri Hovanski ◽  
Carter Hamilton
Keyword(s):  
Friction Stir Welding ◽  
Temperature Control ◽  
Preliminary Investigation ◽  
Effect Of Temperature ◽  
Friction Stir

scholarly journals A preliminary investigation on microstructure and mechanical properties of dissimilar Al to Cu friction stir welds prepared using silver interlayer

10.30544/294 ◽  
2018 ◽  
Vol 24 (1) ◽  
pp. 45-57
Author(s):  
Shailesh N. Pandya ◽  
Jyoti Menghani
Keyword(s):  
Friction Stir Welding ◽  
Preliminary Investigation ◽  
Pure Copper ◽  
Xrd Analysis ◽  
Fusion Welding ◽  
Dissimilar Welding ◽  
X Ray Diffraction ◽  
Friction Stir ◽  
Ag Particles ◽  
Particle Form

Due to its solid-state nature, friction stir welding (FSW) process can be considered a better alternative for dissimilar welding metals. However, like fusion welding techniques, in friction stir welding growth of thick layers of brittle intermetallics - Cu9Al4 and CuAl2 is a significant issue. One solution to this problem is the use of the suitable interlayer material. Use of interlayer material modifies the joint microstructure with the replacement of thick, brittle intermetallics by more ductile intermetallics in a thin layer or particle form. The present study is a preliminary investigation about joining of AA6082-O to pure copper joints with and without silver (Ag) wire interlayer. Friction stir welded joints were characterized regarding optical microscopy, X-Ray Diffraction (XRD) analysis, microhardness measurement, tensile testing and Scanning Electron Microscopy (SEM) based fractography. The Al-Cu weld prepared using silver interlayer was stronger than without it. The higher strength of the weld with silver interlayer is attributed to the formation of a composite type of structure with intercalation of more ductile Ag2Al intermetallics along with dispersion of Ag particles in stir zone.

Closed-Loop Temperature Control of Material Plasticisation during Friction Stir Welding

2014 ◽  
Vol 1019 ◽  
pp. 120-125
Author(s):  
D.G. Hattingh ◽  
Theo I. van Niekerk ◽  
Raymond Pothier
Keyword(s):  
Friction Stir Welding ◽  
Temperature Control ◽  
Closed Loop ◽  
Control Strategies ◽  
Industrial Process ◽  
Traverse Speed ◽  
Feedback Signal ◽  
Monitoring And Control ◽  
Friction Stir ◽  
Tool Geometries

This research presents the potential for improved joint integrity of friction stir welding by controlling the plasticisation temperature in the weld nugget. During a typical FSW, temperature fluctuates with position along the length of the weld. Working from a basis that for all material and tool geometries, there is an Optimal Plasticisation Temperature (OPT), this paper provides a strategy for maintaining this optimal weld temperature by adjusting selected weld input parameters ensuring consistent joint quality, irrespective of component geometry or clamp configuration. This proposed methodology can also be used to determine the OPT for different FSW tool geometries and material combinations. Advanced monitoring and control strategies are essential to ensure that FSW can be made a more robust industrial process that can keep pace with the modern demand for more consistent production and reliability of welded structures. The potential lies in the possibility for an operator to now select an OPT point for a specific approved welding program and allow the welding platform to maintain the OPT via closed-loop temperature control which adjusts tool rotation and or tool traverse speed. This paper further reports on the potential of integration of a closed-loop temperature control algorithm for FSW. The system measures the temperature inside the FSW tool using thermocouple sensors (creating the feedback signal). The controller then applies a PID algorithm which in turn drives the spindle speed (and if necessary, tool traverse speed) in order to change the energy input rate to the weld for controlling plasticisation temperature.

Adaptive model-based temperature control in friction stir welding

2017 ◽  
Vol 93 (1-4) ◽  
pp. 1157-1171 ◽  
Author(s):  
A. Bachmann ◽  
J. Gamper ◽  
M. Krutzlinger ◽  
A. Zens ◽  
M. F. Zaeh
Keyword(s):  
Friction Stir Welding ◽  
Temperature Control ◽  
Adaptive Model ◽  
Friction Stir ◽  
Model Based

scholarly journals Thermal Dissipation Effect on Temperature-controlled Friction Stir Welding

2019 ◽  
Vol 24 ◽  
Author(s):  
Ana Magalhães ◽  
Jeroen De Backer ◽  
Gunnar Bolmsjö
Keyword(s):  
Friction Stir Welding ◽  
Temperature Control ◽  
Tensile Tests ◽  
Fast Response ◽  
Lap Joints ◽  
Thermal Dissipation ◽  
Welding Parameter ◽  
Weld Quality ◽  
Welding Temperature ◽  
Friction Stir

Abstract During Friction Stir Welding (FSW) of complex geometries, the thermal dissipation, induced by geometric features or the surrounding environment, may strongly affect the final weld quality. In order to guarantee a consistent weld quality for different conditions, in-process welding parameter adaptation is needed. This paper studies the effect of thermal dissipation, induced by the backing bar thermal conductivity, on the weld temperature and the temperature controller response to it. A new temperature sensor solution, the Tool-Workpiece Thermocouple (TWT) method, was applied to acquire online temperature measurements during welding. An FSW-robot equipped with temperature control, achieved by rotation speed adaptation, was used. AA7075-T6 lap joints were performed with and without temperature control. The cooling rate during welding was register plus macrographs and tensile tests were assessed. The controller demonstrated a fast response promoting the heat input necessary to maintain the set welding temperature. The results demonstrated that temperature control using the TWT method is suitable to achieve higher joint performance and provides a fast setup of optimal parameters for different environments.

Effect of Temperature Field on Formation of Friction Stir Welding Joints of Ti–6Al–4V Titanium Alloy

2017 ◽  
Vol 36 (7) ◽  
pp. 733-739 ◽  
Author(s):  
Yumei Yue ◽  
Quan Wen ◽  
Shude Ji ◽  
Lin Ma ◽  
Zan Lv
Keyword(s):  
Titanium Alloy ◽  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Temperature Gradient ◽  
Rotational Velocity ◽  
Welding Process ◽  
Effect Of Temperature ◽  
Friction Stir ◽  
Simulation And Experiment ◽  
Welding Joints

AbstractIn order to investigate the formation mechanism of tunnel defect produced near the bottom of stir zone (SZ) in friction stir welding joint of Ti–6Al–4V titanium alloy, the temperature distribution during welding process was analyzed by numerical simulation and experiment. Results show that macrostructure morphology of SZ in cross section presents “bowl” shape owing to the characteristic of temperature distribution. Obvious temperature gradient appears along the thickness direction of joint. Decreasing rotational velocity reduces peak temperature and temperature gradient, which is beneficial to eliminate tunnel defect.

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