Improving the joint strength of the friction stir spot welding of carbon steel and copper using the design of experiments method

2018 ◽  
Vol 14 (5) ◽  
pp. 908-922 ◽  
Author(s):  
Isam Tareq Abdullah ◽  
Sabah Khammass Hussein
Keyword(s):  
Carbon Steel ◽  
Design Of Experiments ◽  
Spot Welding ◽  
Shear Force ◽  
Pure Copper ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Content Type ◽  
Rotating Speed ◽  
Friction Stir

PurposeThe purpose of this paper is to optimize the welding parameters: rotating speed and plunging depth of carbon steel and pure copper joints using friction stir spot welding (FSSW) with the aid of the design of experiments (DOE) method.Design/methodology/approachCarbon steel and pure copper sheets were welded using the FSSW technique with a cylindrical tool and without a probe. The welding parameters were: rotating speed: 1,120, 1,400 and 1,800 RPM and plunging depth: 0.2 and 0.4 mm. The welding process was carried out both with and without pre-heating. The welded specimens were analyzed using a shear tensile test. A microstructural investigation at the optimum conditions was carried out. The results were analyzed and optimized using the statistical software Minitab and following the DOE method.FindingsPre-heating the sample and increasing the rotating speed and plunging depth increased the tensile shear force of the joint. The plunging depth has the biggest effect on the joint efficiency compared with the rotating speed. The optimum shear force (4,560 N) was found at 1,800 RPM, 0.4 mm plunge depth and with pre-heating. The welding parameters were modified so that the samples were welded at 1,800 RPM and at plunging depths of 0.45–1 mm in 0.05 mm steps. The optimized shear force was 5,400 N. The fractured samples exhibited two types of failure mode: interfacial and nugget pull-out.Originality/valueFor the first time, pure copper and carbon steel sheets were welded using FSSW and a tool without a probe with ideal joint efficiency (95 percent).

Influence of Heating Friction Stir Spot Welding Process Parameters on Steel Aluminum Forming Quality

2018 ◽  
Vol 917 ◽  
pp. 246-251
Author(s):  
Kai Xu ◽  
Shu Quan Zhang
Keyword(s):  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Joint Line ◽  
Welding Parameters ◽  
Forming Quality ◽  
Rotating Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Pressure

A lap welding experiment of DP590 steel and 6061 aluminum plate is carried out by using Heating Friction Stir Spot Welding (HFSSW) to study the influence of welding parameters on the forming quality. The results show that a lap joint with better forming can be obtained for the dissimilar metal of steel and aluminum. Under the condition that the rotating speed of the stirring tool is 1000r/min, the penetration depth, 0.2mm, the dwell time, 90s, the welding pressure, 0.2Mp, and the flow rate of cooling air, 20L/min, the forming quality of the surface of the joint line is good & bright, and the exit hole is also smaller. The mechanism of heat production is revealed in the following: the main heat is produced by the friction between the stirring tool shoulder and the welded part & between the probe and the welded part as well as by the latent heat resulted from the plastic deformation of the material in joint line during welding.

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.

Experimental Investigation on Refill Friction Stir Spot Welding Process of Aluminum Alloys

2013 ◽  
Vol 345 ◽  
pp. 243-246 ◽  
Author(s):  
Hong Gang Yang ◽  
Hai Jun Yang
Keyword(s):  
Aluminum Alloys ◽  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Welding Time ◽  
Welding Quality ◽  
Tensile Shear ◽  
Rotating Speed ◽  
Friction Stir

With the growing demand for lightweight reduction and environment protection, lightweight materials like aluminum and magnesium alloys have been widely applied in the automotive and aerospace industry. Being a solid state welding process, refill friction stir spot welding (RFSSW) is suitable for spot joining lightweight metals. In the present paper, the mechanical properties and microstructure of the RFSSW joints of 6061-T6 aluminum alloys were investigated. The influence of welding parameters, such as plunge depth, rotating speed and welding time, on tensile-shear strength was conducted through experiments. It is found that the tensile-shear strength is increased with the increase of plunge depth, rotating speed and welding time. And welding time is found to be an important key factor which affects welding quality. Research results can provide guidance for welding parameters optimization and welding quality promotion of RFSSW process of aluminum alloys.

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.

scholarly journals Effect of Different Friction Stir Spot Welding Techniques on the Mechanical Properties and Microstructure of Aluminum AA2024-T3

2019 ◽  
Vol 22 (2) ◽  
pp. 117-123
Author(s):  
Akeel Z. Mahdi ◽  
Samir A. Amin ◽  
Sadeq H. Bakhy
Keyword(s):  
Spot Welding ◽  
Shear Force ◽  
Mechanical Tests ◽  
Friction Stir Spot Welding ◽  
Tensile Shear ◽  
Shear Tests ◽  
Friction Stir ◽  
Comparison Results ◽  
Microstructure Examination ◽  
Tool Pin

This paper presents a comparison of using different techniques for stir spot welding of Aluminum 2024-T3, which are refill friction stir spot welding (RFSSW), edited (RFSSW-pin) and conventional friction stir spot welding (FSSW), depending on the obtained tensile shear strength property. Specimens were prepared from AA2024-T3 sheet for chemical analysis and mechanical tests. Workpieces were stir spot welded utilizing the above mentioned techniques at four rotational speeds (2000, 2500, 3000 and 4000 rpm) using tool pin diameters (5 and 7 mm) for conducting the tensile shear tests. The microhardness along the cross section of the welded specimens was conducted at the best conditions as well as the microstructure examination. The comparison results revealed that at the rotational speeds (2000 and 4000 rpm) in both cases of tool pin (5 and 7 mm), the ultimate tensile shear force was slightly higher than that for other speeds. However, the ultimate tensile shear force was found higher at 3000 rpm speed with a tool pin 7 mm. The microhardness results manifested a W-shape at the best conditions. Finally, the microstructure examination depicted the morphology of the main zones of the weld joint.

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