scholarly journals Material flow in Friction Stir Welding

2008 ◽  
Vol 14 (S3) ◽  
pp. 87-90 ◽  
Author(s):  
C. Leitão ◽  
R.M. Leal ◽  
D.M. Rodrigues ◽  
P. Vilaça ◽  
A. Loureiro
Keyword(s):  
Plastic Deformation ◽  
Friction Stir Welding ◽  
Automotive Industry ◽  
Aluminium Alloys ◽  
Material Flow ◽  
Dissimilar Materials ◽  
Tool Geometry ◽  
X Ray ◽  
Friction Stir ◽  
Solid State Joining

Friction stir welding (FSW) is a solid-state joining technique initially developed for aluminium alloys. The heat generated by a rotating tool softens the material in the vicinity of the tool. The material undergoes intense plastic deformation following quite complex paths around the tool, depending on the tool geometry, process parameters and material to be welded. The comprehension of the material flow is essential to prevent voids and other internal defects which may form during welding. Several techniques have been used for tracking material flow during FSW such as metallography, the use of a marker material as a tracer or the flow visualization by FSW of dissimilar materials or even the X-ray and computer tomography. Some of these techniques are useless in the analysis of welds in homogenous materials or welds between materials of the same group. The aim of this investigation is tracking the material flow in FSW between 1mm thick sheets in aluminium alloys AA 5182-H111 and AA 6016-T4, currently used in automotive industry.

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.

Material flow and void defect formation in friction stir welding of aluminium alloys

2018 ◽  
Vol 23 (8) ◽  
pp. 677-686 ◽  
Author(s):  
X. H. Zeng ◽  
P. Xue ◽  
D. Wang ◽  
D. R. Ni ◽  
B. L. Xiao ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Material Flow ◽  
Defect Formation ◽  
Void Defect ◽  
Friction Stir

Friction stir welding of T-joints in dissimilar materials: Influence of tool geometry and materials properties

2019 ◽  
Vol 6 (10) ◽  
pp. 106528 ◽  
Author(s):  
Neves Manuel ◽  
Claúdio Silva ◽  
José Moreira Domingos da Costa ◽  
Altino Loureiro
Keyword(s):  
Friction Stir Welding ◽  
Dissimilar Materials ◽  
Tool Geometry ◽  
T Joints ◽  
Materials Properties ◽  
Friction Stir

scholarly journals Effect of Deformation Resistance of Steel on Material Flow in Friction Stir Welding – In-situ Observation by X-ray Radiography –

2016 ◽  
Vol 102 (2) ◽  
pp. 74-79 ◽  
Author(s):  
Yoshiaki Morisada ◽  
Zhe Lei ◽  
Hidetoshi Fujii ◽  
Muneo Matsushita ◽  
Rinsei Ikeda
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Deformation Resistance ◽  
X Ray ◽  
Friction Stir

Numerical Study of the Tool Rake Angle Effect on the Material Flow in Friction Stir Welding Process

2007 ◽  
Author(s):  
Hosein Atharifar ◽  
Radovan Kovacevic
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Numerical Study ◽  
Welding Process ◽  
Rake Angle ◽  
Heat Transfer Analysis ◽  
Tool Geometry ◽  
Friction Stir ◽  
Tool Pin ◽  
Welding Processes

Minimizing consumed energy in friction stir welding (FSW) is one of the prominent considerations in the process development. Modifications of the FSW tool geometry might be categorized as the initial attempt to achieve a minimum FSW effort. Advanced tool pin and shoulder features as well as a low-conductive backing plate, high-conductive FSW tools equipped with cooling fins, and single or multi-step welding processes are all carried out to achieve a flawless weld with reduced welding effort. The outcomes of these attempts are considerable, primarily when the tool pin traditional designs are replaced with threaded, Trifiute or Trivex geometries. Nevertheless, the problem remains as to how an inclined tool affects the material flow characteristics and the loads applied to the tool. It is experimentally proven that a positive rake angle facilitates the traverse motion of the FSW tool; however, few computational evidences were provided. In this study, numerical material flow and heat transfer analysis are carried out for the presumed tool rake angle ranging from −4° to 4°. Afterwards, the effects of the tool rake angle to the dynamic pressure distribution, strain-rates, and velocity profiles are numerically computed. Furthermore, coefficients of drag, lift, and side force and moment applied to the tool from the visco-plastic material region are computed for each of the tool rake angles. Eventually, this paper confirms that the rake angle dramatically affects the magnitude of the loads applied to the FSW tool, and the developed advanced numerical model might be used to find optimum tool rake angle for other aluminum alloys.

A Weld that Lasts for 100,000 Years: Friction Stir Welding of Copper Canisters

2003 ◽  
Vol 807 ◽  
Author(s):  
Lars Cederqvist
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Aluminium Alloys ◽  
Development Program ◽  
Production Level ◽  
Friction Stir ◽  
Solid State Joining ◽  
Joining Process ◽  
New Machine

ABSTRACTFriction Stir Welding (FSW) is a novel solid-state joining process where the work pieces are joined together using a rotating non-consumable tool. The process has mainly been used for joining aluminium alloys, and has not yet been used in production for any other metal. However, the results from the development program confirm that FSW can consistently seal 50mm thick copper canisters without creating defects. A new machine is now installed at SKB's Canister Laboratory to further automate the process to production level.

New Joining Techniques for the Production of the Electrical Components in the Automotive Industry

2018 ◽  
Vol 1146 ◽  
pp. 98-105 ◽  
Author(s):  
Radu Cojocaru ◽  
Cristian Ciucă ◽  
Lia Nicoleta Boţilă ◽  
Victor Verbiţchi ◽  
Ion Aurel Perianu
Keyword(s):  
Friction Stir Welding ◽  
Production Process ◽  
Automotive Industry ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Butt Welding ◽  
Friction Stir ◽  
Preliminary Results ◽  
Friction Stir Welding Process ◽  
Electrical Components

In the paper are presented some preliminary results regarding the possibilities of using of the friction stir welding process (FSW) and FSW assisted with TIG (FSW – TIG) welding for joining of the electrical components in the automotive industry. Couples of dissimilar materials approached in experiments were Aluminium EN AW 1200 and Copper Cu99, with thicknesses in conformity with real cases in the production process. The results obtained for butt welding an overlap welding of different thicknesses of materials (aluminium thickness s1 = 2mm and copper thickness s2 = 5mm) are presented. There are some general conclusions regarding the possibilities of joining the two materials under the specified conditions.

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