scholarly journals Simulation of Friction Stir Spot Welding of Copper and Aluminium During Plunging Phase

2021 ◽  
Vol 2129 (1) ◽  
pp. 012002
Author(s):  
N N S M Shobri ◽  
S R Pedapati ◽  
M Awang
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
Regression Line ◽  
Friction Stir Spot Welding ◽  
Peak Temperature ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Explicit Analysis ◽  
Residual Plots

Abstract Simulation is limited and remains briefly addressed in the literature of friction stir spot welding (FSSW) process in joining dissimilar copper and aluminium. Thus, this study simulated the FSSW process of copper and aluminium to investigate the peak temperature during the plunging phase produced by all possible combinations of levels for tool rotational speed, plunge rate, and plunge depth according to the full factorial design. The modeling was established by Coupled Eulerian-Lagrangian (CEL) model and ‘dynamic, temperature-displacement, explicit’ analysis. The highest peak temperature of 994.4 oC was produced by 2400 rpm rotational speed, 100 mm/min plunge rate, and 1.6 mm plunge depth. The combination was suggested to be the optimum welding parameters in joining copper to aluminium as sufficient heat input was essential to soften the area around the welding tool and adequately plasticize the material. Three sets of confirmation tests presented consistent responses with a mean peak temperature of 994.4 °C, which validated that the response produced by the suggested optimum welding parameters was reliable. The statistical result reported that the variability in the factors could explain 84.12% of the variability in the response. However, only the rotational speed and plunge depth were statistically significant. The residual plots showed that the regression line model was valid.

Effect of Welding Parameters on Temperature Distribution During Friction Stir Spot Welding of Commercial Pure Copper Lap Joint

2018 ◽  
Author(s):  
Ahmed Mahgoub ◽  
Abdelaziz Bazoune ◽  
Fadi Al-Badour ◽  
Necar Merah ◽  
Abdelrahman Shuaib
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Pure Copper ◽  
Friction Stir Spot Welding ◽  
Temperature History ◽  
Welding Parameters ◽  
Deformation Model ◽  
Friction Stir ◽  
Good Agreement

In this paper, a Coupled Eulerian Lagrangian (CEL) finite element model (FEM) was developed to simulate the friction stir spot welding (FSSW) of commercial pure copper. Through simulations results, the paper presents and discusses the effect of FSSW process parameters; namely rotational speed, plunging rate and dwell time, on the developed temperatures and their distribution within the workpiece as well as material flow and deformation. Model validation showed a good agreement between predicted temperature history and the experiment one, with a maximum error of 6%. Furthermore, the predicted formation of flash was also found in good agreement with the experiment with an error of only 7%. Simulation results predicted peak temperature and plastic strain among all studied welding conditions were 920 K and 3.5 respectively at 1200 rpm rotational speed, 20 mm/min plunging rate and 4 seconds dwell time, which is approximately 70% of the melting point of pure copper.

Effect of Welding Conditions on Sheets’ Interface Properties in Friction Stir Spot Welding of Copper

2019 ◽  
Author(s):  
Ahmed Mahgoub ◽  
Neçar Merah ◽  
Abdelaziz Bazoune
Keyword(s):  
Surface Morphology ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Tensile Failure ◽  
Welding Parameters ◽  
Welding Condition ◽  
Friction Stir ◽  
Joint Fracture

Abstract Friction Stir Spot Welding (FSSW) is a solid-state joining technique widely applied to high conductive metals. In this paper, the effects of FSSW parameters, namely, rotational speed (N), plunging rate (V) and dwell time (DT) on the joint fracture mode and fractured surface morphology were investigated using scanning electron microscopy (SEM). The effect of the abovementioned welding parameters on the microhardness profile along the sheets’ interface was also investigated to gain insight into the strength of the joint and the width of the bonding ligament. Two conditions were considered for each parameter 1200 rpm and 900 rpm for N, 60 mm/min and 20 mm/min for V, 4 and 2 seconds for DT. The welding condition 1200 rpm rotational speed, 20 mm/min plunging rate and 2 seconds dwell time showed a wider bonding ligament, relatively higher elongation, higher tensile failure load, and greater microhardness on the sheets’ interface. Dimple surface morphology (DSM) with regular dimples along the stir zone was also observed at the abovementioned set of process parameters.

scholarly journals Pinless friction stir spot welding of aluminium alloy with copper interlayer

2020 ◽  
Vol 10 (1) ◽  
pp. 804-813
Author(s):  
Balsam H. Abed ◽  
Omar S. Salih ◽  
Khalid M. Sowoud
Keyword(s):  
Diffusion Process ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Tensile Shear ◽  
Plunge Depth ◽  
Friction Stir ◽  
Copper Interlayer ◽  
Cu Interlayer

AbstractSpot welding joints of Al-Mg-Si alloy (AA6061-T6) were produced with and without the addition of copper interlayer using pinless friction stir spot welding (P-FSSW). To investigate the effects of welding parameters on the metallurgical and mechanical properties of the weldment, various tool plunge depth and dwell time were used. Optical microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy (EDS) have been used for microstructural characterisation.Meanwhile, the mechanical characterisation of the welded joints was evaluated by tensile-shear test. The experimental results showed that a larger bonding area and sound joint were achieved with the addition of Cu interlayer due to the improvement in thermal distribution. Also, an alloying reaction took place between the aluminium substrate and Cu interlayer during P-FSSW, forming intermetallic compounds layer in the interface through the diffusion process. The increasing of dwell time and plunge depth to some extent were beneficial to the formation of the joint and diffusion process, and thus increasing the tensile-shear load of the joints. The observed fracture mode of the joint was either completely shear off in the interface or complete nugget pullout.

scholarly journals Refill Friction Stir Spot Welding of Dissimilar 6061/7075 Aluminum Alloy

2019 ◽  
Vol 38 (2019) ◽  
pp. 69-75 ◽  
Author(s):  
Zhenlei Liu ◽  
Kang Yang ◽  
Dejun Yan
Keyword(s):  
Aluminum Alloy ◽  
Spot Welding ◽  
Joint Strength ◽  
Shear Failure ◽  
Failure Load ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Lap Shear

AbstractRefill friction stir spot welding (RFSSW) was used to join 6061-T6 and 7075-T6 aluminum alloys in this work. Different sheet configurations and welding parameters were used to optimize joint strength. The effect of sleeve plunge depth on the microstructure and mechanical properties of the joints were investigated. The results showed that no defects were obtained when 6061-T6 aluminum alloy was placed as the upper sheet. The lap shear failure load of the joint using 6061-T6 aluminum alloy as the upper sheet was higher than that using 7075-T6 as the upper sheet. The maximum failure load of 12,892 N was attained when using the sleeve plunge depth of 3.6 mm. The joint failed at the upward flowing 7075 near the hook.

scholarly journals A Weighting Grade-Based Optimization Method for Determining Refill Friction Stir Spot Welding Process Parameters

2019 ◽  
Vol 28 (10) ◽  
pp. 6471-6482
Author(s):  
Rafał Kluz ◽  
Andrzej Kubit ◽  
Tomasz Trzepiecinski ◽  
Koen Faes ◽  
Wojciech Bochnowski
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Spot Welding ◽  
Load Capacity ◽  
Base Material ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir

Abstract The welding process used in fabricating thin-walled structures by refill friction stir spot welding (RFSSW) should be characterized by a high strength of welds and high process repeatability which is demonstrated by a small dispersion of the load capacity of the joints. The present work is designed to optimize RFSSW process parameters for 7075-T6 Alclad aluminum alloy sheets used to fabricate aircraft structures. The optimization was performed by scalarization of the objective function using the weighting grades method. The study considers the effect of process parameters, i.e., tool plunge depth, duration of welding, tool rotational speed, on the tensile/shear strength of the joints, and dispersion of the load capacity. It was found that it was possible to choose the optimal welding parameters taking into account maximization of the load capacity and minimization of the dispersion of the joint strength via a best compromise between the tool rotational speed ensuring adequate plasticization of the base material and the duration of welding ensuring that a fine-grained joint microstructure is obtained.

Effects of High Speed Tool Rotation in Micro Friction Stir Spot Welding of Aluminum A1100

2014 ◽  
Vol 493 ◽  
pp. 739-742 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
Suwarsono ◽  
Gandjar Kiswanto ◽  
Winarto
Keyword(s):  
Shear Strength ◽  
Spot Welding ◽  
High Speed ◽  
Tool Material ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Processes ◽  
Tool Rotation

Technology of Friction Stir Welding (FSW) is a relatively new technique for joining metal. In some cases on Aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and less distortion. The purpose of this study is to analyze the parameters effect of high speed tool rotation onmicro Friction Stir Spot Welding(μFSSW) to theshear strengthof welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. The spindle speed was fixed at 30000 rpm. Tool shoulder diameter was 3 mm, and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of pin diameter (1.5 mm, 2.0 mm, and 2.5 mm), a variable ofplunge speed(2 mm/min, 4 mm/min, 6 mm/min), and the variable ofdwell time(2 seconds, 4 seconds, 6 seconds). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was theshear strength.Response Surface Methods(RSM) was used to analyze μFSSW parameters with theshear strengthof welds. From the result of experiment and analysis, it is shown that the important welding parameters in high speed μFSSW process are pin diameter and plunge speed.

Relation between Friction Stir Spot Welding Parameters and Mechanical Properties of High Density Polyethylene/Glass Spheres Polymer Composites

2016 ◽  
Vol 860 ◽  
pp. 49-52 ◽  
Author(s):  
Munir Tasdemir ◽  
Mustafa Kemal Bilici ◽  
Mehmet Kurt
Keyword(s):  
Mechanical Properties ◽  
Polymer Composites ◽  
High Density Polyethylene ◽  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
High Density ◽  
Welding Parameters ◽  
Friction Stir ◽  
Glass Spheres ◽  
Welding Properties

In the present study, we attempt to use powder of glass spheres filler and reinforce material in HDPE to produce composite structure and then evaluate its mechanical properties to study the effect of welding parameters and filler content on mechanical properties of HDPE. The effect of welding parameters (tool rotational speed, the plunge depth and the dwell time) on friction stir spot welding properties of high density polyethylene/glass spheres (hollow) polymer composites sheets was studied.

Friction Stir Spot Welding of AZ31B Magnesium Alloy

2017 ◽  
Vol 867 ◽  
pp. 105-111
Author(s):  
S. Ramesh Babu ◽  
M. Nithin ◽  
S. Pavithran ◽  
B Parameshwaran
Keyword(s):  
Shear Strength ◽  
Magnesium Alloy ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Resistance Welding ◽  
Hardness Distribution ◽  
Tool Rotational Speed ◽  
Friction Stir

The Electrical Resistance Welding (ERW) of Magnesium and Aluminium is more difficult than steel because the welding machines must provide high currents and exact pressures in order to provide the heat necessary to melt the magnesium for proper fusion at the interface in order to produce a sound weld. Further, resistance welding of magnesium requires a backup plate made of steel to conduct the heat to the workpiece material. To overcome this problem, Friction Stir Spot Welding (FSSW) has been developed. In this study, the hardness distribution and the tensile shear strength of FSSW welds in the AZ31B Magnesium alloy has been investigated and it has been found that tool rotational speed and dwell time plays a major role in determining the weld strength. From the experimental study, a tool rotational speed of 1100 rpm and dwell time of 20 s produced good shear strength of 2824 N and the corresponding grain size was 4.54 μm. This result is very well supported by microstructural examinations and hardness distribution studies.

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