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.

Probeless Tool Aided Friction Stir Welding as a Fabrication Technique for Tungsten Embedded Mechanical Composite of Copper

2014 ◽  
Author(s):  
Yogita Ahuja ◽  
Raafat Ibrahim ◽  
Anna Paradowska ◽  
Daniel Riley
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Base Metal ◽  
Parametric Study ◽  
Effective Parameter ◽  
Frictional Heat ◽  
Fabrication Technique ◽  
Shear Testing ◽  
Friction Stir ◽  
Parameter Combination

Friction stir welding (FSW) is a relatively new solid state metallurgical joining technique. It flourishes on the simple principle of utilising frictional heat by the stirring motion of a non-consumable rotating tool to create the seam. Feasibility of FSW aided by a newly designed probeless tool was investigated for fabricating copper-tungsten mechanical composite. The most effective parameter combination was determined by conducting a parametric study of the probeless tool aided FSW copper. Strength of the mechanical composite fabricated at this condition was evaluated through punch shear testing. Punch shear testing established that the friction stir welded interface of the copper-tungsten composite was 87% as strong as the base metal (i.e. copper). Advantages of the designed technique have been summarised.

Axial Force Reduction in Friction Stir Welding of AA6061-T6 at Right Angle

2014 ◽  
Author(s):  
Yousef Imani ◽  
Michel Guillot
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Axial Force ◽  
Tool Design ◽  
Industrial Robots ◽  
Welding Parameters ◽  
Minor Effect ◽  
Friction Stir ◽  
Force Reduction ◽  
Solid State Joining

Invented in 1991, friction stir welding (FSW) is a new solid state joining technique. This process has many advantages over fusion welding techniques including absence of filler material, shielding gas, fumes and intensive light, solid state joining, better microstructure, better strength and fatigue life, and etc. The difficulty with FSW is in the high forces involved especially in axial direction which requires use of robust fixturing and very stiff FSW machines. Reduction of FSW force would simplify implementation of the process on less stiff CNC machines and industrial robots. In this paper axial welding force reduction is investigated by use of tool design and welding parameters in FSW of 3.07 mm thick AA6061-T6 sheets at right angle. Attempt is made to reduce the required axial force while having acceptable ultimate tensile strength (UTS). It is found that shoulder working diameter and shoulder angle are the most important parameters in the axial force determination yet pin angle has minor effect. According to the developed artificial neural network (ANN) model, proper selection of shoulder diameter and angle can lead to approximately 40% force reduction with acceptable UTS. Regions of tool design and welding parameters are found which result in reduced axial force along with acceptable UTS.

Fatigue of Friction Stir and GTAW Welded AZ31B Magnesium Alloy

2012 ◽  
Author(s):  
J. A. Ávila ◽  
H. E. Jaramillo ◽  
F. Franco
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Solid State ◽  
Magnesium Alloy ◽  
Mechanical Behavior ◽  
Arc Welding ◽  
Az31b Magnesium Alloy ◽  
Friction Stir ◽  
Gas Tungsten Arc ◽  
Hardness Tests

The mechanical behavior of butt welds made on AZ31B magnesium alloy plates by solid-state friction stir welding (FSW) and gas tungsten arc welding (GTAW) is presented. Fatigue, tensile strength, and hardness tests were performed. Also, fractographic analyses of the weld microstructures were conducted. Tests results show that the fatigue performance of FSW joints was superior to that of conventional welding (GTAW).

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.

Numerical Modeling of Thermal Field Distribution during Friction Stir Welding (FSW) of Dissimilar Materials

2016 ◽  
Vol 254 ◽  
pp. 261-266
Author(s):  
Bogdan Radu ◽  
Cosmin Codrean ◽  
Radu Cojocaru ◽  
Cristian Ciucă
Keyword(s):  
Numerical Modeling ◽  
Friction Stir Welding ◽  
Solid State ◽  
Thermal Field ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Dissimilar Joints ◽  
Element Analysis ◽  
Friction Stir ◽  
The Cost

Friction Stir Welding (FSW) is an innovative solid state welding process, relatively new in industry, which allow welding of two or more materials which have very different properties, particularly thermal properties as fusion temperature, thermal expansion coefficient, specific heat and thermal conduction and have a predisposition to form intermetallic brittle phases, neither one of the components to be weld reach to the melting point. Being a solid state welding process temperature field is very important for the quality of the welded joint, and a lot of researches focused on this topic. This paper presents some results in modeling and estimation of thermal field developed during FSW of dissimilar joints, using Finite Element Analysis. Numerical modeling of thermal field allows engineers to predict, in advance, the evolution of temperature and to estimate the behavior of the welded materials during the welding process. This will reduce significantly the time and number of experiments that have to be carried out, in the process of establishing a good FSW technology, as well as reducing significantly the cost of the tests.

scholarly journals A Cooler Weld

2003 ◽  
Vol 125 (03) ◽  
pp. D10-D16 ◽  
Author(s):  
Matt Hansen
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Arc Welding ◽  
Federal Aviation Administration ◽  
Phase Changes ◽  
Fusion Welding ◽  
Friction Stir ◽  
State Process ◽  
Joining Technology ◽  
The Us

This article provides details of a low-temperature joining technology called friction stir welding. Friction stir welding (FSW) uses a cylindrical, shouldered tool with a profiled pin that is rotated and slowly plunged into the joint line between two pieces of sheet or plate material. According to an engineer, stir welding eliminated 60 percent of the rivets that the plane would have otherwise required. Eclipse Aviation Corp., Albuquerque, NM, is building a separate plant to house its stir welding operations for commercial production, once its plane receives certification by the US Federal Aviation Administration. FSW is a solid-state process, more like forging and extruding than to fusion welding. Since the process is solid state, the joint is not subject to any shrinkage because of phase changes. The process also introduces minimal heat into the weld, so the heat-affected zone is relatively small in comparison to arc welding.

scholarly journals Investigation of microstructural and mechanical properties of AA1050-AZ91D dissimilar friction stir welding

2021 ◽  
Vol 15 (3) ◽  
pp. 8332-8343
Author(s):  
Oyindamola Kayode ◽  
Esther Titilayo Akinlabi
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Solid State ◽  
Chemical Properties ◽  
Traverse Speed ◽  
Friction Stir ◽  
Microhardness Distribution ◽  
Dissimilar Weld ◽  
State Diffusion ◽  
Dissimilar Friction Stir Welding

Joining of aluminium and magnesium alloys frequently pose significant challenges to the extent where joining may seem impossible, due to differences in the physical, metallurgical, and chemical properties of the materials. Friction stir welding is a solid-state welding technique which uses a non-consumable tool to join metals. This study examines the dissimilar friction stir welding of 3 mm thick AA1050 and AZ91D alloy sheets. Successful defect-free joints were achieved at rotational speeds of 400 rpm and 600 rpm, and a constant traverse speed of 50 mm/min. The metallurgical investigations used to characterize the microstructure of the welds are optical microscopy (OM), scanning electron microscope (SEM) and X-ray diffraction (XRD). The microstructures of the samples show distinct morphology attributed to their different rotational speeds. However, Al3Mg2 intermetallics (IMCs) phase was detected in the white bands present in both weld samples. The IMCs were formed through solid-state diffusion. The mechanical properties characterizations includes the microhardness profiles and tensile testing. The variation in the rotational speeds do not have a significant effect on the microhardness distribution of the weld samples. The tensile strength of the dissimilar weld improved substantially with the presence of an interpenetration feature (IPF).

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