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

Measurement ◽  
2018 ◽  
Vol 129 ◽  
pp. 112-118 ◽  
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

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

2015 ◽  
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.

An analytical and experimental investigation considering the effect of material flow velocity on tensile strength of a steel alloy joint produced by friction stir welding process

2020 ◽  
pp. 095440622093631
Author(s):  
Behzad Hadi ◽  
ME Aalami-Aleagha ◽  
Saeed Feli
Keyword(s):  
Friction Stir Welding ◽  
Flow Velocity ◽  
Analytical Method ◽  
Rotational Speed ◽  
Material Flow ◽  
Welding Process ◽  
Linear Speed ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

In this paper, the effects of linear speed, rotational speed, and tool radius of the pin and shoulder are investigated on the material flow velocity in friction stir welds. To obtain the maximum material flow velocity by an analytical method, a suggested relation is introduced for the rotational speed and tool optimum radius. The derived relation is based on the assumption of a velocity field in the stirring region. Besides, the effect of the linear speed on material flow velocity is investigated based on continuity and momentum equations. Finally, by using the experimental method and checking the mechanical properties of the welded parts obtained with different rotational speed, linear speed, and tool dimensions, the proposed analytical model is validated. The results indicate that in the friction stir welding process, the significant component effect on the stirring process is generated through the tool pin radius size. Besides, increasing the material flow velocity in the boundary layer increases the yield and ultimate strength of welds. To achieve the high-quality welds, rotational speed and other tool dimensions must be selected considering the equation extracted from the analytical method. Also, to make the maximum life for the pin and its components in friction stir welding of high melting point metals such as steel alloys, the operation is adjusted at a lower linear speed to prevent the destruction of the tool and improve the quality of the joint.

scholarly journals Modeling and Simulation Based Analysis of the Matter Flow During Friction Stir Welding Process

2021 ◽  
Vol 54 (2) ◽  
pp. 363-369
Author(s):  
Zine El Abidine Harchouche ◽  
Abdelkader Lousdad ◽  
Mothtar Zemri ◽  
Nabila Dellal ◽  
Foudil Khelil
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Rapid Development ◽  
Thermal Power ◽  
Great Part ◽  
Welding Process ◽  
Industrial Applications ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

Friction Stir Welding (FSW) is a recent assembly process which has been developed at the British Welding Institute (TWI) at the beginning of the 90's. This welding process has gone a rapid development and an increasing success. Many remarkable industrial applications achieved mainly in spatial, aeronautical, automobile, railways, marine and naval industries.... The translation and the rotation of the tool during the FSW process generate the flow and plastic deformation of the material which had been often differently interpreted in contradictory manner. In this paper, an analytical model is proposed to describe the flow of matter in the vicinity of the FSW tool pin during the welding process. Analytical solutions are elaborated on the basis of conventional fluid mechanics theory which is used to solve the associated equation to the mentioned problem based on the Laurent's series (called also Laurent's development). The knowledge of the material flow around the tool pin can lead to a better understanding of the metallurgical phenomena which have a significant effect on the mechanical properties of the welded joint and allows a better description of the speed fields which is worth full for the thermal modelisation since the great part of the thermal power is generated by auto-heating energy. The results obtained on the effect of the speeds on the material flow are in good accordance with the experimental results found in the literature. The study highlights and gives a better understanding of the material flow phenomenon during the Friction Stir Welding process.

scholarly journals Effect of Friction Stir Welding Process on Crystallinity and Degradation of Polypropylene

2020 ◽  
Vol 55 (2) ◽  
Author(s):  
Bambang Kusharjanta ◽  
Rudy Soenoko ◽  
Anindito Purnowidodo ◽  
Yudy Surya Irawan
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Type D ◽  
Degradation Temperature ◽  
Degradation Data ◽  
Crystallinity Changes ◽  
Tool Pin

The aim of this study was to investigate the crystallinity changes and degradation of polypropylene due to heat generated by friction stir welding, i.e., heat generated by friction between the rotation tool and the welded materials. The tool pin was rotated at 620 rpm in the welding process. The travelling speed was varied between 7.3 mm/minute and 13 mm/minute. A cylindrical tool pin, 4.5 mm in diameter and 5.7 mm in length, was used in this experiment. The shoulder dimension was 18 mm in diameter and 90 mm in length. A conventional milling machine was used in the friction stir welding process. The crystallinity test was carried out with X-ray diffraction, hardness was observed using a Shore Type-D durometer, and polymer degradation data was obtained by thermogravimetry analysis. The areas compared were base material, weld nugget area, and thermomechanical affected zone. The results showed that there was a change in the percentage of crystallinity in areas that had undergone friction stir welding, and that the change was inversely proportional to the traveling rate of the friction stir welding process. The friction stir welding process was affected by the initial degradation temperature and hardness property of the polypropylene. This result shows that it is possible to choose specific parameters of friction stir welding in order to obtain good weld joint properties.

scholarly journals EFFECT OF TOOL PIN PROFILES OVER SQUARE WAVE TOOL PATH PATTERN ON FRICTION STIR WELDING OF AA6061-CU DISSIMILAR ALLOYS

2021 ◽  
Vol 55 (5) ◽  
Author(s):  
Loganathan Prabhu ◽  
Satish Shanmugam ◽  
Thiagarajan Chandrasekaran
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Movement Pattern ◽  
Step Size ◽  
Square Wave ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Friction Stir Welding Process ◽  
Uniform Dispersion ◽  
Tool Pin

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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