Design and Development of Robust Fixture to Perform Friction Stir Welding/Processing on Conventional Vertical Milling Machine

2021 ◽  
pp. 83-94
Author(s):  
Jainesh Sarvaiya ◽  
Dinesh Singh
Keyword(s):  
Friction Stir Welding ◽  
Milling Machine ◽  
Design And Development ◽  
Friction Stir ◽  
Vertical Milling ◽  
Vertical Milling Machine

scholarly journals Influence of Tool Pin Profile and Tool Rotating Speed on Mechanical Properties of Al6082 Alloy

2019 ◽  
Vol 8 (12) ◽  
pp. 3342-3345
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Automatic Process ◽  
Work Piece ◽  
Milling Machine ◽  
Friction Stir ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Tool Pin

Friction stir welding is a solid state welding which uses non consumable welding tool. It is an automatic process which generally performs on the vertical milling machine. In this type of welding, the relative motion between the tools and work piece creates heat which uses the region of work piece to be welded get softened and to joint the two work pieces. Friction stir welding process is more reliable for the materials which are generally non heat treatable. In this present investigation it will observe that how the rotational speeds of the tool and different shapes of the tool pins effects the mechanical properties of the aluminium alloy 6082. For this purpose three tools with different profiles, i.e triangular, cylindrical and square was designed and fabricated. At three different rotational speeds of 560 rpm, 900 rpm, 1800 rpm work pieces are joined using vertical milling machine. Specimens are prepared and tested for mechanical properties, tensile, impact, and hardness tests are performed and to detect the defects and voids x-ray test performed on the weld joints. And it was observed that highest tensile strength was presented when the square pin tool used at 560 rpm. The rotational speed increased mechanical properties are reducing significantly.

Reconfiguration of a Milling Machine to Achieve Friction Stir Welds

2012 ◽  
Vol 232 ◽  
pp. 86-91 ◽  
Author(s):  
Akinlabi Esther Titilayo ◽  
Madyira Daniel Makundwaneyi ◽  
Akinlabi Stephen Akinwale
Keyword(s):  
Control System ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Friction Stir Processing ◽  
Joint Strength ◽  
Milling Machine ◽  
Friction Stir ◽  
Backing Plate ◽  
Vertical Milling ◽  
Vertical Milling Machine

This paper reports on the reconfiguration of a milling machine to produce friction stir welds of aluminium and copper and friction stir processing of 6086 aluminium alloy. Friction stir welding tools were designed and manufactured from tool steel. The tools were inserted into the chuck of the milling machine. A backing plate was also specially designed and manufacturedfrom mild steel to protect the milling machine table and was placed on the bed with the use of T-nuts. The plates were secured firmly on the backing plate with the use of specially designed clamping fixtures. The varied welding speeds and the rotational speeds were achieved using the control system on the vertical milling machine. The reconfigured milling machine was successfully employed to produce friction stir processing of aluminium and friction stir welds of aluminium and copper. An optimum joint strength of 74% was achieved.

scholarly journals A Research on Friction Stir Welding using M42 Tool on Aisi 1018 Steel Plates

2019 ◽  
Vol 8 (12S) ◽  
pp. 362-366
Keyword(s):  
Friction Stir Welding ◽  
High Speed ◽  
High Speed Steel ◽  
Steel Plates ◽  
Milling Machine ◽  
Friction Stir ◽  
High Melting Temperature ◽  
Ferrous Material ◽  
Vertical Milling ◽  
Vertical Milling Machine

Friction Stir Welding was mainly suitable for aluminum alloys due to low softening temperatures. It is challenging to join the high melting temperature metals due to the lack of tool materials. The main focus of this work is to study the feasibility of joining the similar or dissimilar ferrous material. The molybdenum based high speed steel acts a rotating non consumable tool to weld the two ferrous plates. The friction stir welding was achieved using vertical milling machine. Welding samples were examined by destructive and nondestructive test. The welds were produced by 3 mm plate over a range of spindle speed from 500 to 1000 rpm. The results of FSW, stir zone of hardness varies from 139 to 145 HV executed on AISI 1018 plate steel.

Friction Stir Forming for Mechanical Interlocking of Ultra-Thin Stainless Steel Strands and Aluminum Alloys

2018 ◽  
Vol 382 ◽  
pp. 114-119 ◽  
Author(s):  
Hamed Mofidi Tabatabaei ◽  
Tadashi Nishihara
Keyword(s):  
Stainless Steel ◽  
Aluminum Alloys ◽  
Tensile Tests ◽  
Al Alloys ◽  
Milling Machine ◽  
Mechanical Interlocking ◽  
Friction Stir ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Novel Method

In this study, a novel method of mechanical interlocking of super-thin stainless steel strands with different aluminum alloys was conducted by using friction stir forming (FSF). The potential for the development of a multi-functional composite material was studied experimentally. It was concluded that FSF can successfully interlock stainless steel strands and different Al alloys and presents the possibility of improving the mechanical properties of the alloy. Trials of FSF were carried out on a modified vertical milling machine. The results are discussed in terms of microstructure observations, hardness distributions and tensile tests.

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

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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