Influences of welding parameters on friction stir welding of AA 6063 Al-alloy and copper plates – An experimental study

The influence of friction stir welding (FSW) parameters on thermo-mechanical behaviour of the material during welding is analysed. An aluminium alloy is considered (Al 2024 T351), and different rotating speed and welding speed are applied. Finite element model consists of the plate (Al alloy), backing plate and welding tool, and it is formed and solved in software package Simulia Abaqus. The influence of the welding conditions on material behaviour is taken into account by application of the Johnson-Cook material model. The rotation of the tool affects the results: if increased, it contributes to an increase of friction-generated heat intensity. The other component of the generated heat, the plastic deformation of the material, is negligibly changed. When the welding speed is increased, the intensity of friction-generated heat decreases, while the heat generation due to plastic deforming increases. Combined, these two effects cause small change of the total heat generation. For the same welded joint length, the plate welded by lower speed will be heated more intensively. The changes of the heat generation influence both the temperature field and reaction force, which are also considered.

Download Full-text

Effect of double-sided friction stir welding on the mechanical and microstructural characteristics of AA5754 aluminium alloy

Materials Testing ◽

10.1515/mt-2021-0009 ◽

2021 ◽

Vol 63 (9) ◽

pp. 829-835

Author(s):

Sare Çelik ◽

Fatmagül Tolun

Keyword(s):

Friction Stir Welding ◽

Al Alloys ◽

Fusion Welding ◽

Welding Parameters ◽

Al Alloy ◽

Test Results ◽

Feeding Rates ◽

Microstructural Characteristics ◽

Friction Stir ◽

Tool Tilt Angle

Abstract AA5754Al alloy is widely used in industry. However, as in the case of all Al alloys, the 5xxx series Al alloys cannot be easily joined through fusion welding techniques. To address this problem, in this study, the effect of double-sided friction stir welding at various tool rotational speeds (450, 710, and 900 rpm), feeding rates (40, 50, and 80 mm × min-1), and tool tilt angles (0°, 1°, 2°) on the welding parameters and mechanical and microstructural characteristics of AA5754 Al alloy was determined. Tensile strength tests and microhardness tests were performed to examine the mechanical properties of the welded specimens. The microstructures of the welded zone were examined by obtaining optical microscopy and scanning electron microscopy images. The tensile test results indicated that the specimens exhibited the highest welding performance of 95.17 % at a tool rotational speed, feed rate, and tool tilt angle of 450 rpm, 50 mm × min-1 and 1°, respectively.

Download Full-text

Effects of Heat Dissipation from Friction Stir Welding to Microstructures of Semi-Solid Cast 6063 Al Alloy

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.904.70 ◽

2021 ◽

Vol 904 ◽

pp. 70-75

Author(s):

Chaiyoot Meengam ◽

Kittima Sillapasa ◽

Yotsakorn Pratumwal ◽

Somboon Otarawanna

Keyword(s):

Friction Stir Welding ◽

Heat Dissipation ◽

Maximum Temperature ◽

Al Alloy ◽

Element Analysis ◽

Friction Stir ◽

Tool Shoulder ◽

Measurement Results ◽

6063 Al Alloy ◽

Semi Solid

In this work, temperature distribution in semi-solid cast 6063 aluminum alloy workpieces during friction stir welding (FSW) was determined by finite element analysis (FEA). The FEA results were validated by comparing them with the measurement results from thermocouples. The maximum temperature of 534.2oC was predicted at the workpiece surface contacted with the tool shoulder. The temperature profiles obtained from FEA were used to explain microstructural changes during FSW. It was observed that relatively high temperature made α-Al grains became elongated and Mg2Si intermatalics turned into a rod-like morphology with round edges.

Download Full-text

Comparison of tool wear during friction stir welding of Al alloy and Al-SiC metal matrix composite

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering ◽

10.1177/09544089211005994 ◽

2021 ◽

pp. 095440892110059

Author(s):

Ashish Bist ◽

JS Saini ◽

Vikas Sharma

Keyword(s):

Surface Roughness ◽

Friction Stir Welding ◽

Tool Wear ◽

Rotational Speed ◽

Welding Parameters ◽

Aluminum Matrix Composites ◽

Al Alloy ◽

Friction Stir ◽

Prolonged Contact ◽

Tool Pin

Aluminum matrix composites have received considerable attention due to their high specific strength and specific stiffness, high hardness, and wear resistance along with being light in weight. These composites are preferably joined using friction stir welding process. The major concern in friction stir welding is the wear of the welding tool pin which is the backbone of the process. The wear is due to the prolonged contact between the tool and the harder reinforcements in the composite materials. The present work deals with the study of tool wear and its surface roughness with respect to different selected friction stir welding parameters such as rotational speed, transverse speed, length of weld, and different composition of Aluminum composite. It was found that the total amount of material removed from the tool and the surface roughness of the tool is in direct proportion to the rotational speed of the tool and the length of the weld but inversely proportional to the transverse rate. The increase in wt.% of SiC reinforcement leads to the higher tool wear but reduces the surface roughness of the tool.

Download Full-text

Experimental Study on Effect of Welding Parameters of Friction Stir Welding (FSW) on Aluminium AA5083 T-joint

Information Technology Journal ◽

10.3923/itj.2016.99.107 ◽

2016 ◽

Vol 15 (4) ◽

pp. 99-107 ◽

Cited By ~ 4

Author(s):

M. T.S.M. Sai ◽

D. A. Hamid ◽

A. Ismail ◽

S. N.N. Zaina ◽

M. Awang ◽

...

Keyword(s):

Experimental Study ◽

Friction Stir Welding ◽

Welding Parameters ◽

Friction Stir

Download Full-text

Establishing optimal friction stir welding parameters for AA2219-T87 Al-alloy using comprehensive RSM and GA approach

Engineering Research Express ◽

10.1088/2631-8695/ac41b5 ◽

2021 ◽

Author(s):

Boddu Rajnaveen ◽

Govada Rambabu ◽

Kollabothina Prakash ◽

Kotipalli Srinivasa Rao

Keyword(s):

Friction Stir Welding ◽

Aluminium Alloy ◽

Welding Process ◽

Welding Parameter ◽

Welding Parameters ◽

Al Alloy ◽

Regression Equations ◽

Corrosion Properties ◽

Friction Stir ◽

Aa2219 Alloy

Abstract AA2219-T87 aluminium alloy has been used in aerospace applications because of its high strength, low density and resistance to corrosion. The copper in the alloy improves the hardness and lowers melting point, which makes two sections easily joined with a process called friction stir welding of aluminium alloy. In the present work, heat-treated AA2219 alloy was butt welded by solid-state friction stir welding process. This work aims to develop a suitable combination of welding parameters for producing defect-free weld joints of AA2219 alloy to improve tensile and corrosion properties. The most influencing control parameter for optimising the friction stir welding responses was determined using sophisticated design of experiments (DOE) techniques. Ultimate tensile strength and corrosion resistance are observed as responses in this study. To achieve the desired weld responses, a three-factor, three-level Box-behneken design was used. Analysis of Variance (ANOVA) was carried out to examine the interaction effect and significant welding parameter to set the optimal level of welding conditions. Multi-response regression equations have been developed using response surface methodology (RSM) to estimate the output characteristics of weld. The Genetic algorithm (GA) was used to optimise the predicted mathematical model under given optimization constraints. The results shown that the optimum responses are obtained at input factors rotational speed 300 rpm, welding speed 80 mm/min, and axial force of 10kN.

Download Full-text