Prediction of weld zone shape with effect of tool pin profile in friction stir welding process

In this present work friction stir welding of Al6061-annealed pure copper dissimilar metals with square wave pattern tool pin movementwas investigated. The aim of this experiment is to identify the significance square wave tool movement on friction stir welding process along with three different tool pin profiles. Different tool pin profiles of square, round and hexaspiral shapes were selected and their significant outcomes were unveiled. Friction stir welding process parameters of 1500 and 2000rpm & tool pin movement step size of 1.0mm and 2.0mm & weaving rate of 100mm/min and 150mm/min were selected. The advantages of tool movement pattern and tool pin profile shape wereexamined by mechanical testing, microstructure analysis. The mechanical results were showed that process parameter of 1500 rpm, 1.0mm step size, weldingrate of 150mm/min and square tool pin profile combination gives better mechanical properties. Micro structural results unveiled achievement of better grain refinement and uniform dispersion of micro constituents by implementation of square wave tool pin movement pattern along with square tool pin profile.The EDAX report confirms that the weld nugget contains both aluminum and copper as equal percentage, which indicates fine mixing of two parent metals.

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Proposing a new relation for selecting tool pin length in friction stir welding process

Measurement ◽

10.1016/j.measurement.2018.07.015 ◽

2018 ◽

Vol 129 ◽

pp. 112-118 ◽

Cited By ~ 5

Author(s):

Noor Zaman Khan ◽

Arshad Noor Siddiquee ◽

Zahid A. Khan

Keyword(s):

Friction Stir Welding ◽

Welding Process ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Tool Pin

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Effect of Tool pin Profile and Axial Force on Tensile Behavior in Friction Stir Welding of Dissimilar Aluminum Alloys

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.415-417.1140 ◽

2011 ◽

Vol 415-417 ◽

pp. 1140-1146 ◽

Cited By ~ 1

Author(s):

R. Palanivel ◽

P. Koshy Mathews ◽

M. Balakrishnan ◽

I. Dinaharan ◽

N. Murugan

Keyword(s):

Tensile Strength ◽

Friction Stir Welding ◽

Axial Force ◽

Aluminium Alloys ◽

Welding Process ◽

Fusion Welding ◽

Friction Stir ◽

Tool Pin Profile ◽

Dissimilar Aluminum Alloys ◽

Tool Pin

Aluminium alloys generally has low weldability by traditional fusion welding process. The development of the Friction Stir Welding (FSW) has provided an alternative improved way of producing aluminium joints, in a faster and reliable manner. FSW process has several advantages, in particular the possibility to weld dissimilar aluminium alloys. This study focuses on the behavior of tensile strength of dissimilar joints of AA6351-T6 alloy to AA5083-H111 alloy produced by friction stir welding was analysed. Five different tool pin profile such as Straight Square (SS), Tapered Square (TS), Straight Hexagon (SH), Straight Octagon (SO) and Tapered Octagon (TO) with three different axial force (1tonne, 1.5tonne, 2 tonne) have been used to weld the joints. The effect of pin profiles and axial force on tensile properties and material flow behaviour of the joint was analyzed and it was found that the straight square pin profile with 1.5 tonne produced better tensile strength then other tool pin profile and axial force.

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The Preliminary Exploration of Micro-Friction Stir Welding Process and Material Flow of Copper and Brass Ultra-Thin Sheets

Materials ◽

10.3390/ma13102401 ◽

2020 ◽

Vol 13 (10) ◽

pp. 2401

Author(s):

Changqing Zhang ◽

Zhuo Qin ◽

Chen Rong ◽

Wenchen Shi ◽

Shuwen Wang

Keyword(s):

Friction Stir Welding ◽

Flow Behavior ◽

Pure Copper ◽

Weld Zone ◽

Metal Flow ◽

Welding Process ◽

Process Conditions ◽

Friction Stir ◽

Plastic Metal ◽

Tool Pin

In the friction stir welding (FSW) of ultra-thin dissimilar metal sheets, different physical material properties, the reduction of plastic metal in the weld zone, and insufficient plastic metal flow lead to poor weld seam shapes and joint qualities. Therefore, it is necessary to study the flow behavior during the FSW of ultrathin sheets. In this study, micro friction stir welding (μFSW) was conducted and analyzed for the butt welding of 0.6-mm-thick ultrathin brass (H62-H) and pure copper (T2-Y) sheets. By analyzing the electric signals of the temperature and force during the welding process, testing the mechanical properties, and analyzing the metallography of the joint, the influences of the process parameters on the metal flow behavior during μFSW were studied. In the proper process conditions, the material preferentially migrated and concentric vortex flow occurred in the vicinity of the shoulder and tool pin action areas. The copper was pushed from the retreating side (RS) to the advancing side (AS) of the weld, allowing it to flow more fully. A mixture of both materials formed at the bottom of the weld nugget, and less migration occurred in the heat-affected zone of the AS at this time. The highest tensile strength can reach 194 MPa, accounting for 82.6% of the copper. The presence of brittle phases Cu5Zn8, AgZn3 and AgZn caused the hardness to fluctuate slightly.

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Microstructural Characterization and Mechanical Properties in Friction Stir Welding of AA6061 and AA6101 Aluminum Alloys

Advanced Engineering Forum ◽

10.4028/www.scientific.net/aef.40.1 ◽

2021 ◽

Vol 40 ◽

pp. 1-11

Author(s):

Gagandeep Singh ◽

Khushdeep Goyal ◽

Baljinder Ram ◽

Bal Krishan

Keyword(s):

Friction Stir Welding ◽

Base Material ◽

Welding Process ◽

Microstructural Characterization ◽

Friction Stir ◽

Tool Pin Profile ◽

Fine Grain ◽

Metal Plates ◽

Frictional Forces ◽

Tool Pin

In this research paper, two different metal plates of aluminum alloy viz. AA6061 and AA6101 were welded with friction stir welding process. Round tool and square tool pin profiles were used to weld the alloys. Weld microstructures, hardness, and tensile properties were evaluated in as-welded condition. The tensile strength of the joints fabricated with round tool pin profile were lower than the square tool pin profile because of the pulsating effect, in square tool pin profile this effect was produced along with the higher frictional forces. The micro-hardness of friction stir zone was higher than the base material due to active recrystallization occurrence which resulted in fine grain size in case of weld joint with round pin profile. Microstructure indicated uniformly distribution of materials with minimum heat affected zone and dense welded zone without any defects.

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A Study of the Effect of Tool Pin Profiles on Tensile Strength of Welded Joints Produced Using Friction Stir Welding Process

Materials and Manufacturing Processes ◽

10.1080/10426914.2010.532527 ◽

2011 ◽

Vol 26 (9) ◽

pp. 1111-1116 ◽

Cited By ~ 47

Author(s):

C. N. Suresha ◽

B. M. Rajaprakash ◽

Sarala Upadhya

Keyword(s):

Tensile Strength ◽

Friction Stir Welding ◽

Welded Joints ◽

Welding Process ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Tool Pin

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Multi Response Optimization of Submerged Friction Stir Welding Process Parameters Using TOPSIS Approach

Volume 2B: Advanced Manufacturing ◽

10.1115/imece2015-50353 ◽

2015 ◽

Cited By ~ 1

Author(s):

Senthil Kumar Velukkudi Santhanam ◽

Lokesh Rathinaraj ◽

Rathinasuriyan Chandran ◽

Shankar Ramaiyan

Keyword(s):

Friction Stir Welding ◽

Process Parameters ◽

Welding Process ◽

Fusion Welding ◽

Friction Stir ◽

Friction Stir Welding Process ◽

Response Characteristics ◽

Response Optimization ◽

Topsis Approach ◽

Tool Pin

Friction stir welding (FSW) is a solid-state welding process which is used to join high-strength aircraft aluminum alloys and other metallic alloys which are difficult to weld by conventional fusion welding. In this paper, AA6063-O alloy of 6mm thickness was taken and friction stir welded under the water in order to improve the joint properties. The process parameters considered as rotational speed, welding speed and tool pin profiles (cylindrical, threaded and tapered) are optimized with multi response characteristics including hardness, tensile strength and % elongation. In order to solve a multi response optimization problem, the traditional Taguchi approach is insufficient. To overcome this constraint, a multi criteria decision making approach, namely, techniques for order preference by similarity to ideal solution (TOPSIS) is applied in the present study [13]. The optimal result indicates that the multi response characteristics of the AA6063-O during the submerged friction stir welding process can be enhanced through the TOPSIS approach. The Analysis of Variance (ANOVA) was carried out to investigate the significant parameter for the submerged friction stir welding process. The mechanical properties of the submerged FSW are compared with normal FSW joints.

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