Optimization of transversal flow stress and strain and weld seam microstructure analysis in butt-HDPE friction stir welded plates

2020 ◽  
Vol 21 (5) ◽  
pp. 501
Author(s):  
Khaled Hamrouni ◽  
Mohamed-Ali Rezgui ◽  
Ali Trabelsi ◽  
Zoltan Kiss ◽  
Rachid Nasri
Keyword(s):  
Flow Stress ◽  
Failure Modes ◽  
Rotation Speed ◽  
Base Material ◽  
Microscopic Analysis ◽  
Structural Defects ◽  
Stress And Strain ◽  
Friction Stir ◽  
Welded Seam ◽  
Transversal Flow

The paper aims to optimize the characteristic performances of friction stir welding of high-density polyethylene in order to predict failure modes in weld nugget and interfacial zones. Three replicates of a face central composite design are employed to estimate the effects of parameters process, on the transversal flow stress and strain of the seam and to understand root causes, which may lead to structural defects such as the onset of cracks and the seam-base metal rupture. The study findings disclose that maximum responses are obtained when the tool rotation speed is set middle and both the feed rate and the plunged surface are set high. The transversal flow stress of the welded seam is found highly sensitive to the plunged surfaces and at a lesser degree to the rotation speed, whereas, the transversal flow strain of the welded seam is mostly sensitive to the rotation speed and at a lesser degree to the plunged surfaces. For the microscopic analysis, it is shown that at low rotation speed, there exist four structural layers in the transition zone between the seam and the base material giving rise to the formation of a continuous line of cracks that can initiate structure failure.

Influence of Friction Stir Processing Parameters on Anisotropic Behavior Property of 5086-O Aluminum Alloy

2011 ◽  
Vol 702-703 ◽  
pp. 348-351
Author(s):  
Shivanna Pradeep ◽  
Sumit Kumar Sharma ◽  
Vivek Pancholi
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Processing ◽  
Rotation Speed ◽  
Base Material ◽  
Processing Parameters ◽  
Mechanical Anisotropy ◽  
Al Alloy ◽  
Anisotropic Behavior ◽  
Planar Anisotropy ◽  
Friction Stir

In the present work, 5086 Al alloy is subjected to single and multi pass friction stir processing (FSP) to modify microstructure and mechanical anisotropy. The processing is carried out at constant rotation speed of 1025 rpm and different traverse speeds of 30 mm/min and 50 mm/min with and without cooling. Mechanical anisotropy is evaluated in terms of normal and planar anisotropy by performing tensile test in 0, 45 and 90o direction to processing direction. Material processed using multi pass FSP at 30 mm/min is showing lower planar anisotropy as compared to base material. The mechanical anisotropy property is correlated with the development of micro texture.

Microstructure and Mechanical Properties of Cu-Cr-Zr Alloy by Friction Stir Welding

2012 ◽  
Vol 602-604 ◽  
pp. 608-611
Author(s):  
Di Qiu He ◽  
Rui Lin Lai ◽  
Shao Hua Xu ◽  
Kun Yu Yang ◽  
Shao Yong Ye ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Base Material ◽  
Traverse Speed ◽  
Nugget Zone ◽  
Alloy Plate ◽  
Friction Stir ◽  
Microstructure And Mechanical Properties ◽  
Zr Alloy

In this study, Cu-Cr-Zr alloy joints are successfully fabricated by friction stir welding (FSW). Defect-free weld are produced on 12mm thick Cu-Cr-Zr alloy plate useing a non-consumable tool with a specially designed and shoulder with a constant rotation speed and a fixed traverse speed. The effect of friction stir welding (FSW) on the microstructure and mechanical properties of Cu-Cr-Zr alloy joints are investigated in details: The joints showed the presence of various zones such as nugget zone (NZ) and thermo-mechanically affected zone (TMAZ) and base metal (BM), the microhardness and the tensile strength of welded joints are lower than that of the base material.

scholarly journals Fatigue Modeling Containing Hardening Particles and Grain Orientation for Aluminum Alloy FSW Joints

Materials ◽  
2019 ◽  
Vol 12 (12) ◽  
pp. 2024 ◽  
Author(s):  
Guoqin Sun ◽  
Yicheng Guo ◽  
Xiuquan Han ◽  
Deguang Shang ◽  
Shujun Chen
Keyword(s):  
Aluminum Alloy ◽  
Grain Orientation ◽  
Base Material ◽  
Correlation Method ◽  
Stress Transfer ◽  
Macroscopic Model ◽  
Fatigue Properties ◽  
Isotropic Hardening ◽  
Stress And Strain ◽  
Friction Stir

The macro-mesoscopic joint fatigue model containing hardening particles and crystal characteristics is established to study the effect of the hardening particles and the grain orientation on fatigue properties of an aluminum alloy friction stir welding (FSW) joint. The macroscopic model is composed of the weld nugget zone, thermo-mechanically affected zone, heat-affected zone, and base material, according to the metallurgical morphology and hardness distribution of the joint. Cyclic stress and strain data are used to determine the material properties. The fatigue parameters used in the calculation of cyclic stresses and strains are obtained with the four-point correlation method. The mesoscopic models of different zones are inserted into the joint macroscopic model as submodules. The models containing the information of hardening particles and grain orientation are established with crystal plasticity theory for the grains and isotropic hardening rule for the hardening particles. The effects of hardening particles and grain orientation on the stress and strain responses are discussed. The simulation results show that high-angle misorientation of adjacent grains hinders the stress transfer. The particle cluster or cracked particles intensify the stress and strain concentrations.

Precipitates formation and its impact in friction stir welded and post-heat-treated Inconel 718 alloy

2011 ◽  
Vol 1363 ◽  
Author(s):  
Kuk Hyun Song ◽  
Han Sol Kim ◽  
Won Yong Kim
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Grain Size ◽  
Inconel 718 ◽  
Rotation Speed ◽  
Base Material ◽  
Post Heat Treatment ◽  
Inconel 718 Alloy ◽  
Friction Stir ◽  
Heat Treated

ABSTRACTIn order to investigate the formation of precipitates such as MC carbides and intermetallic compounds in the friction stir welded and post-heat-treated Inconel 718 alloy, this work was carried out. Furthermore, the microstructural and mechanical properties of welds and post-heat-treated material were evaluated to identify the effect on precipitates formed during post-heat-treatment. Friction stir welding (FSW) was performed at a rotation speed of 200 rpm and welding speed of 150 mm/min; heat treatment was performed after welding at 720 °C for 8 hours in vacuum. As a result, the grain size due to FSW was notably refined from 5–20 μm in the base material to 1–3 μm in the stir zone; this was accompanied by dynamic recrystallization, which resulted in enhancements in the mechanical properties as compared to the base material. In particular, applying heat treatment after FSW led to improvements in the mechanical properties of the welds—the microhardness and tensile strength increased by more than 50% and 40% in fraction, respectively, as compared to FSW alone.

Mechanical Characterization of Friction Stir Channels under Internal Pressure and In-Plane Bending

2011 ◽  
Vol 488-489 ◽  
pp. 105-108 ◽  
Author(s):  
Catarina Vidal ◽  
Virgínia Infante ◽  
Pedro Vilaça
Keyword(s):  
Internal Pressure ◽  
Bending Strength ◽  
Rotation Speed ◽  
Base Material ◽  
Bending Tests ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Pressure Tests ◽  
Plane Bending ◽  
Tool Rotation

Friction Stir Channelling (FSC) is a simple and innovative technique of manufacturing integral and continuous channels (also referred as conformal channels) in monolithic plates in a single step. This paper is focused on the mechanical behaviour of integral and continuous FS channels produced in a monolithic plate of the aluminium alloy AA7178‑T6 with 13mm of thickness, typically used in structural aircraft applications. Internal pressure tests were conducted on specimens with a longitudinal friction stir channel. In-plane bending tests were carried out in specimens with longitudinal and transversal channels; different conditions were analysed for each FSC parameters set. Results were analysed and compared concerning the FS channels microstructure and base material mechanical properties. Bending tests results show that tool rotation speed has more influence in the FSC specimens bending strength than tool travel speed and internal pressure tests show that increase tool rotation speed increases the minimum pressure that leaking points arise.

The Effect of Tool Rotation Speed on Hardness, Tensile Strength, and Microstructure of Dissimilar Friction Stir Welding of Dissimilar AA5083 and AA6061-T6 Alloys

2021 ◽  
Vol 892 ◽  
pp. 159-168
Author(s):  
Arif Wahyudianto ◽  
Mochammad Noer Ilman ◽  
Priyo Tri Iswanto ◽  
Kusmono ◽  
Akhyar Akhyar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Base Material ◽  
Metallographic Analysis ◽  
Friction Stir ◽  
Dissimilar Alloys ◽  
Dissimilar Friction Stir Welding ◽  
Solid State Joining ◽  
Tool Rotation

The welding between two different grades of aluminum alloy, specifically AA5083 and AA6061-T6, is very difficult to obtain optimal results when using conventional welding methods such as TIG/MIG welding. Therefore, a solid-state joining technique is highly recommended to overcome these problems, one of which is friction stir welding (FSW). The effect of rotation speed on microstructure, microhardness, and tensile properties of dissimilar Friction Stir welded AA5083 and AA6061-T6 aluminum alloys were investigated. Three different rotation speeds (910, 1500, and 2280 rpm) were used to weld the dissimilar alloys. The metallographic analysis of joints showed the presence of various zones such as BM (base material), HAZ (heat affected zone), TMAZ (thermo-mechanically affected zone), and NZ (nugget zone) were observed and analyzed by mean of optical and scanning electron microscope. The results showed that increasing the rotation speed from 900 to 2280 rpm made grain coarsening in NZ and the mass distribution of the material is more evenly distributed, as well as increased hardness and tensile strength of the joint. The highest values in microhardness in NZ and tensile strength at the join were founded at the speed of 2280 rpm and 1500 rpm which was similar to 2280 rpm, respectively.

Experimental Application of Friction Stir Welding (FSW) on Thermo Plastic Medium Density Polyethylene Blanks

2010 ◽  
Author(s):  
S. Saeedy ◽  
M. K. Besharati Givi
Keyword(s):  
Friction Stir Welding ◽  
Tilt Angle ◽  
Rotation Speed ◽  
Weld Zone ◽  
Base Material ◽  
Material Strength ◽  
Medium Density ◽  
Welding Condition ◽  
Friction Stir ◽  
Tool Tilt Angle

The feasibility of friction stir welding has been studied on medium density polyethylene blanks. The design and analysis of experiments have been performed with Taguchi method. The mechanical properties of the joints have been analyzed based on two parameters of rotation speed and tool tilt angle. The optimum welding condition has been determined. It has been demonstrated that rotation speed and tool tilt angle have key roles in the seam elongation and strength respectively. By applying this method of welding on polyethylene blanks 70% of the base material strength is achieved. SEM micrographs show microstructural changes of the weld zone which result in the reduction of the seam weld strength and elongation.

Microstructural and Mechanical Characterization of Friction Stir Processed 5086 Aluminum Alloy

2012 ◽  
Vol 710 ◽  
pp. 253-257 ◽  
Author(s):  
Shivanna Pradeep ◽  
Sumit Kumar Sharma ◽  
Vivek Pancholi
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Mechanical Characterization ◽  
Rotation Speed ◽  
Bulk Material ◽  
Base Material ◽  
Superplastic Forming ◽  
Traverse Speed ◽  
Friction Stir

In the present investigation friction stir processing (FSP) is carried out by single and multipass FSP on a 5086 aluminum alloy to modify microstructure and mechanical properties. The processing is carried out at constant rotation speed of 1025 rpm and at a traverse speed of 30 mm/min. Inhomogeneous microstructural distribution was observed across the processed zone. EBSD analysis has been done to evaluate the microstructure. Overlapping passes is showing same grain size as in single pass FSPed material. Material processed using multi pass FSP at 30 mm/min is showing higher mechanical strength as compared to base material. The bulk material produced due to multipass seems to be good for superplastic forming applications.

An appraisal of characteristic mechanical properties and microstructure of friction stir welding for Aluminium 6061 alloy – Silicon Carbide (SiCp) metal matrix composite

2019 ◽  
Vol 13 (4) ◽  
pp. 5804-5817
Author(s):  
Ibrahim Sabry
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Welded Joint ◽  
Rotation Speed ◽  
Fusion Welding ◽  
Friction Stir ◽  
Al 6061

It is expected that the demand for Metal Matrix Composite (MMCs) will increase in these applications in the aerospace and automotive industries sectors, strengthened AMC has different advantages over monolithic aluminium alloy as it has characteristics between matrix metal and reinforcement particles.  However, adequate joining technique, which is important for structural materials, has not been established for (MMCs) yet. Conventional fusion welding is difficult because of the irregular redistribution or reinforcement particles.  Also, the reaction between reinforcement particles and aluminium matrix as weld defects such as porosity in the fusion zone make fusion welding more difficult. The aim of this work was to show friction stir welding (FSW) feasibility for entering Al 6061/5 to Al 6061/18 wt. % SiCp composites has been produced by using stir casting technique. SiCp is added as reinforcement in to Aluminium alloy (Al 6061) for preparing metal matrix composite. This method is less expensive and very effective. Different rotational speeds,1000 and 1800 rpm and traverse speed 10 mm \ min was examined. Specimen composite plates having thick 10 mm were FS welded successfully. A high-speed steel (HSS) cylindrical instrument with conical pin form was used for FSW. The outcome revealed that the ultimate tensile strength of the welded joint (Al 6061/18 wt. %) was 195 MPa at rotation speed 1800 rpm, the outcome revealed that the ultimate tensile strength of the welded joint (Al 6061/18 wt.%) was 165 MPa at rotation speed 1000 rpm, that was very near to the composite matrix as-cast strength. The research of microstructure showed the reason for increased joint strength and microhardness. The microstructural study showed the reason (4 %) for higher joint strength and microhardness.  due to Significant   of SiCp close to the boundary of the dynamically recrystallized and thermo mechanically affected zone (TMAZ) was observed through rotation speed 1800 rpm. The friction stir welded ultimate tensile strength Decreases as the volume fraction increases of SiCp (18 wt.%).

scholarly journals Analysis of Different Complex Multilayer PACVD Coatings on Nanostructured WC-Co Cemented Carbide

Coatings ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 823
Author(s):  
Danko Ćorić ◽  
Mateja Šnajdar Musa ◽  
Matija Sakoman ◽  
Željko Alar
Keyword(s):  
Mechanical Properties ◽  
Surface Layer ◽  
Base Material ◽  
Single Layer ◽  
Production Costs ◽  
Structural Defects ◽  
Cemented Carbides ◽  
Material System ◽  
Tin Coating ◽  
Ticn Coating

The development of cemented carbides nowadays is aimed at the application and sintering of ultrafine and nano-sized powders for the production of a variety of components where excellent mechanical properties and high wear resistance are required for use in high temperature and corrosive environment conditions. The most efficient way of increasing the tribological properties along with achieving high corrosion resistance is coating. Using surface processes (modification and/or coating), it is possible to form a surface layer/base material system with properties that can meet modern expectations with acceptable production costs. Three coating systems were developed on WC cemented carbides substrate with the addition of 10 wt.% Co using the plasma-assisted chemical vapor deposition (PACVD) method: single-layer TiN coating, harder multilayer gradient TiCN coating composed of TiN and TiCN layers, and the hardest multilayer TiBN coating composed of TiN and TiB2. Physical and mechanical properties of coated and uncoated samples were investigated by means of quantitative depth profile (QDP) analysis, nanoindentation, surface layer characterization (XRD analysis), and coating adhesion evaluation using the scratch test. The results confirm the possibility of obtaining nanostructured cemented carbides of homogeneous structure without structural defects such as eta phase or unbound carbon providing increase in hardness and fracture toughness. The lowest adhesion was detected for the single-layer TiN coating, while coatings with a complex architecture (TiCN, TiBN) showed improved adhesion.

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