scholarly journals A novel double-side welding approach for friction stir welding of polypropylene plate

2021 ◽  
Author(s):  
Rahul Kanti Nath ◽  
Vinayak Jha ◽  
Pabitra Maji ◽  
John Deb Barma
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Polymer Materials ◽  
High Demand ◽  
Cross Sectional ◽  
Friction Stir ◽  
Novel Approach ◽  
Single Side ◽  
Cost Efficient ◽  
Welding Technique

AbstractIn almost every industry, polymer materials are in high demand in recent years due to their lightweight and easy formability. However, eco-friendly, cost-efficient and defect-free joining of polymers is a major concern. In this article, a novel approach is taken for friction stir welding of polypropylene by implementing a double-side welding technique. The effect of tool rotational speed on construction and properties of the welded joints are studied. The torque and forces exerted on the tool during double-side welding are compared with single-side welding. Cross-sectional morphology examination using optical and scanning electron microscope reveals defect-free sound welding by double-side weld with uniform material flow. The molecular bonds of the welded specimens are examined by FTIR analysis. The double-side welding technique yields superior joints in terms of tensile strength and flexural strength than the joints obtained by single-side welding.

scholarly journals Temperature based validation of the analytical model for the estimation of the amount of heat generated during friction stir welding

2012 ◽  
Vol 16 (suppl. 2) ◽  
pp. 337-350 ◽  
Author(s):  
Dragan Milcic ◽  
Miroslav Mijajlovic ◽  
Nenad Pavlovic ◽  
Mica Vukic ◽  
Dragan Mancic
Keyword(s):  
Friction Stir Welding ◽  
Analytical Model ◽  
Material Flow ◽  
Mechanical Energy ◽  
Relative Difference ◽  
Parent Material ◽  
Contact Conditions ◽  
Friction Stir ◽  
Influence Of Temperature On ◽  
Welding Technique

Friction stir welding is a solid-state welding technique that utilizes thermomechanical influence of the rotating welding tool on parent material resulting in a monolith joint - weld. On the contact of welding tool and parent material, significant stirring and deformation of parent material appears, and during this process, mechanical energy is partially transformed into heat. Generated heat affects the temperature of the welding tool and parent material, thus the proposed analytical model for the estimation of the amount of generated heat can be verified by temperature: analytically determined heat is used for numerical estimation of the temperature of parent material and this temperature is compared to the experimentally determined temperature. Numerical solution is estimated using the finite difference method - explicit scheme with adaptive grid, considering influence of temperature on material's conductivity, contact conditions between welding tool and parent material, material flow around welding tool, etc. The analytical model shows that 60-100% of mechanical power given to the welding tool is transformed into heat, while the comparison of results shows the maximal relative difference between the analytical and experimental temperature of about 10%.

scholarly journals A Modified Friction Stir Welding Process Based on Vortex Material Flow

2020 ◽  
Vol 33 (1) ◽  
Author(s):  
Xiaochao Liu ◽  
Yunqian Zhen ◽  
Zhikang Shen ◽  
Haiyan Chen ◽  
Wenya Li ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Tool Wear ◽  
Material Flow ◽  
Pure Aluminum ◽  
Welding Process ◽  
Friction Stir ◽  
New Process ◽  
Identical Material ◽  
Micro Structures ◽  
Welding Technique

AbstractFriction stir welding is a promising solid-state welding technique. However, the issue of tool wear and break restricts its wider industrial application. To avoid the tool wear and break occurring in conventional friction stir welding (FSW), a new modification of the FSW process using a tool made by the identical material as the workpiece has been developed and conducted on pure aluminum. We named this process as Vortex-FSW (VFSW) because it depends on a vortex material flow to realize the welding and joining. The weld macro- and micro-structures are like that in conventional FSW. However, the tool exit-hole in conventional FSW is replaced by a lug boss. The mechanical properties are also equivalent to that in conventional FSW. The principle of this new process is introduced in this paper.

Effect of Porosity Content on the Weldability of Powder Metal Parts Produced by Friction Stir Welding

2007 ◽  
Vol 534-536 ◽  
pp. 789-792 ◽  
Author(s):  
Adem Kurt ◽  
Ilyas Uygur ◽  
Hakan Ates
Keyword(s):  
Friction Stir Welding ◽  
Powder Metal ◽  
Aluminum Powders ◽  
Friction Stir ◽  
Metal Parts ◽  
Constant Friction ◽  
Sintered Powder ◽  
Hardness Values ◽  
Welding Technique ◽  
Traveling Speed

Friction stir welding technique (FSW) has many advantages in terms of tool design, rotational speed and traveling speed, and can be adjusted in a precise manner. It enables heat input into the system to be controlled. In this study, Aluminum powders were compacted at 350,400 and 450 MPa pressure and sintered at 450 oC temperature for 30 minutes in Ar atmosphere. Sintered powder metal parts were joined to each other by FSW at the speed of 1800 rpm and traveling welding speed 200 mm/min under a constant friction force. The results show that the amount of porosity affects the weldability of powder metallurgy (P/M) parts. Furthermore, the porosity and microstructural evolution of the Aluminum also affected the hardness values of the tested materials.

Thermo-Mechanical Modelling of Friction Stir Welding Process

2013 ◽  
Vol 774-776 ◽  
pp. 1155-1159 ◽  
Author(s):  
Xiao Cong He
Keyword(s):  
Finite Element Analysis ◽  
Friction Stir Welding ◽  
Mechanical Behaviour ◽  
Material Flow ◽  
Welding Process ◽  
Element Analysis ◽  
Friction Stir ◽  
Mechanical Modelling ◽  
Major Factors ◽  
Realistic Prediction

Friction stir welding (FSW) is a solid-state welding process where no gross melting of the material being welded takes place. Numerical modelling of the FSW process can provide realistic prediction of the thermo-mechanical behaviour of the process. Latest literature relating to finite element analysis (FEA) of thermo-mechanical behaviour of FSW process is reviewed in this paper. The recent development in thermo-mechanical modelling of FSW process is described with particular reference to two major factors that influence the performance of FSW joints: material flow and temperature distribution. The main thermo-mechanical modelling used in FSW process are discussed and illustrated with brief case studies from the literature.

Grain Structure Formation Ahead of Tool during Friction Stir Welding of AZ31 Magnesium Alloy

2010 ◽  
Vol 160 ◽  
pp. 313-318 ◽  
Author(s):  
Uceu Suhuddin ◽  
Sergey Mironov ◽  
H. Takahashi ◽  
Yutaka S. Sato ◽  
Hiroyuki Kokawa ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Structure Formation ◽  
Material Flow ◽  
Boundary Migration ◽  
Deformation Mode ◽  
Grain Structure ◽  
Az31 Magnesium Alloy ◽  
Structure Evolution ◽  
Friction Stir

The “stop-action” technique was employed to study grain structure evolution during friction-stir welding of AZ31 magnesium alloy. The grain structure formation was found to be mainly governed by the combination of the continuous and discontinuous recrystallization but also involved geometric effect of strain and local grain boundary migration. Orientation measurements showed that the deformation mode was very close to the simple shear associated with the rotating pin and material flow arose mainly from basal slip.

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

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.

Numerical Simulation of Plunge Force During the Plunge Phase of Friction Stir Welding and Ultrasonic Assisted FSW

2008 ◽  
Author(s):  
Kwanghyun Park ◽  
Bongsuk Kim ◽  
Jun Ni
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
High Frequency ◽  
Hybrid Welding ◽  
Ultrasonic Vibrations ◽  
Welding Quality ◽  
Friction Stir ◽  
Ultrasonic Assisted ◽  
Welding Force ◽  
Welding Technique

Ultrasonic assisted friction stir welding (UaFSW) is an hybrid welding technique, where high frequency vibration is superimposed on the movement of a rotating tool. The benefit of using ultrasonic vibration in the FSW process refers to the reduction in the welding force and to the better welding quality. The UaFSW system is being developed and its mechanism needs to be understood using both the experiments and the numerical simulations. In this paper, FE simulations of FSW and UaFSW using ABAQUS/Explicit were carried out to examine plunge forces during the plunge phase of FSW and UaFSW, respectively. First, the simulations of the conventional FSW process were validated. Then, simulation of UaFSW process was performed by imposing sinusoidal horizontal ultrasonic vibrations on the tool.

Prediction of Surface Profile in Friction Stir Welding Using Coupled Eulerian and Lagrangian Method

2020 ◽  
Author(s):  
Debtanay Das ◽  
Swarup Bag ◽  
Sukhomay Pal ◽  
M. Ruhul Amin
Keyword(s):  
Friction Stir Welding ◽  
Surface Morphology ◽  
Process Parameters ◽  
Chip Formation ◽  
Material Flow ◽  
Defect Formation ◽  
Current Model ◽  
Surface Profile ◽  
Green Technology ◽  
Friction Stir

Abstract Friction stir welding (FSW) is widely accepted by industry because of multiple advantages such as low-temperature process, green technology, and capable of producing good quality weld joints. Extensive research has been conducted to understand the physical process and material flow during FSW. The published works mainly discussed the effects of various process parameters on temperature distribution and microstructure formation. There are few works on the prediction of defect formation from a physics-based model. However, these models ignore chip formation or surface morphology and material loss during the FSW process. In the present work, a fully coupled 3D thermo-mechanical model is developed to predict the chip formation and surface morphology during welding. The effects of various process parameters on surface morphology are also studied using the current model. Coupled Eulerian-Lagrangian (CEL) technique is used to model the FSW process using a commercial software ABAQUS. The model is validated by comparing the results in published literature. The current model is capable of predicting the material flow out of the workpiece and thus enables the visualization of the chip formation. The developed model can extensively be used to predict the surface quality of the friction stir welded joints.

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