Effects of tool pin thread on temperature field and material mixing in friction stir welding of dissimilar Al/Mg alloys

2022 ◽  
Vol 74 ◽  
pp. 112-122
Author(s):  
Tao Jiang ◽  
ChuanSong Wu ◽  
Lei Shi
Keyword(s):  
Temperature Field ◽  
Friction Stir Welding ◽  
Mg Alloys ◽  
Friction Stir ◽  
Tool Pin ◽  
Al Mg Alloys ◽  
Material Mixing

Understanding the effect of tool geometrical aspects on intensity of mixing and void formation in friction stir process

2020 ◽  
pp. 095440622093841
Author(s):  
Vinayak Malik ◽  
Satish V Kailas
Keyword(s):  
Friction Stir Welding ◽  
Shear Strain ◽  
Void Formation ◽  
Parent Material ◽  
Friction Stir ◽  
Element Simulation ◽  
Processed Material ◽  
Geometrical Features ◽  
Tool Pin ◽  
Material Mixing

The reduction of agglomeration of particulate reinforcement in friction stir processing and elimination of joint line remnant in friction stir welding depends on stirring ability of friction stir tool. The magnitude of stirring is indicated by the intensity of material inter-mixing in tool interacted region. Present investigations analyse the influence of geometrical aspects of classical friction stir tool on the intensity of material intermixing, location of high stir regions and void formation during the steady-state phase of friction stir welding. The classical tool was chosen as its geometrical features undergo minimal wear in the harsher processing environment. Investigating material mixing using metallic inserts have their shortcomings due to different flow properties of insert/marker and parent material. Therefore, bi-colour plasticine configuration possessing primary colours was adopted to understand the level of intermixing. The hue attribute of the generated secondary colour was utilised to identify and quantify material mixing. Experimental results revealed that the pin diameter positively influenced mixing and negatively affected void formation. Shoulder size and pin taper angle aided in the closure of void with inferior mixing. The intensity of mixing enhances on selection of tools possessing a shoulder to pin diameter ratio of 2.5. Finite element simulation studies were conducted to understand the reasons for mixing under certain tooling conditions. Since material subjected to stirring is concentrated primarily on a portion of advancing side, components of shear strain, shear strain rates, shear stress and velocity were tracked for this portion of processed material during its interaction with tool pin for one complete rotation.

Effect of pin diameter and different cooling media on friction stir welding of dissimilar Al-Mg alloys

2020 ◽  
Author(s):  
Harshadkumar H. Jadav ◽  
Vishvesh Badheka ◽  
Daulat Kumar Sharma ◽  
Gautam Upadhyay
Keyword(s):  
Friction Stir Welding ◽  
Mg Alloys ◽  
Friction Stir ◽  
Cooling Media ◽  
Al Mg Alloys

A comparative study between weldability of polycarbonate and nylon-6 using different pin geometries in friction stir welding

2021 ◽  
pp. 095440542110407
Author(s):  
Santosh K Sahu ◽  
Debasish Mishra ◽  
Kamal Pal
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Solid State ◽  
Nylon 6 ◽  
Comparative Assessment ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Base Materials ◽  
Tool Pin ◽  
Material Mixing

The solid state friction stir welding (FSW) has been recently the choice for joining of thermoplastics. The present work aims at analyzing the implementation of FSW in joining of different thermoplastics namely, polycarbonate and nylon-6 sheets using varying tool pin profiles, cylindrical, square, and triangular. The novelty of this article is the comparative assessment that has been made on the weldability of these two thermoplastics by determining the mechanical properties of the joint along with real-time acquired force, torque, and temperature signals. Higher axial force with reduced torque has been observed for nylon-6 as compared to polycarbonate. The joint efficiency was found to be maximum (>50%) at tool rotational speed 1800 rpm and welding speed 20 mm/min using square tool pin profile for each of the base materials. Minor undercut defect along with improved material mixing has been seen during the tool stirring process. The study would be helpful for the industries to choose thermoplastics based on their applications.

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

Sign in / Sign up

Export Citation Format

Share Document