scholarly journals A Cooler Weld

2003 ◽  
Vol 125 (03) ◽  
pp. D10-D16 ◽  
Author(s):  
Matt Hansen
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Arc Welding ◽  
Federal Aviation Administration ◽  
Phase Changes ◽  
Fusion Welding ◽  
Friction Stir ◽  
State Process ◽  
Joining Technology ◽  
The Us

This article provides details of a low-temperature joining technology called friction stir welding. Friction stir welding (FSW) uses a cylindrical, shouldered tool with a profiled pin that is rotated and slowly plunged into the joint line between two pieces of sheet or plate material. According to an engineer, stir welding eliminated 60 percent of the rivets that the plane would have otherwise required. Eclipse Aviation Corp., Albuquerque, NM, is building a separate plant to house its stir welding operations for commercial production, once its plane receives certification by the US Federal Aviation Administration. FSW is a solid-state process, more like forging and extruding than to fusion welding. Since the process is solid state, the joint is not subject to any shrinkage because of phase changes. The process also introduces minimal heat into the weld, so the heat-affected zone is relatively small in comparison to arc welding.

Fatigue of Friction Stir and GTAW Welded AZ31B Magnesium Alloy

2012 ◽  
Author(s):  
J. A. Ávila ◽  
H. E. Jaramillo ◽  
F. Franco
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Solid State ◽  
Magnesium Alloy ◽  
Mechanical Behavior ◽  
Arc Welding ◽  
Az31b Magnesium Alloy ◽  
Friction Stir ◽  
Gas Tungsten Arc ◽  
Hardness Tests

The mechanical behavior of butt welds made on AZ31B magnesium alloy plates by solid-state friction stir welding (FSW) and gas tungsten arc welding (GTAW) is presented. Fatigue, tensile strength, and hardness tests were performed. Also, fractographic analyses of the weld microstructures were conducted. Tests results show that the fatigue performance of FSW joints was superior to that of conventional welding (GTAW).

scholarly journals Shoulderless Friction Stir Welding: a low-force solid state keyhole joining technique for deep welding of labile structures

2021 ◽  
Author(s):  
Max Hossfeld
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Contact Area ◽  
Industrial Application ◽  
Heat Input ◽  
Friction Stir ◽  
Joining Technology ◽  
Low Distortion ◽  
Opening Up ◽  
Limited Process

AbstractThis paper reports on the possibility of performing Friction Stir Welding (FSW) without the usual immanent shoulder to enable FS processing to deep welding of narrow and labile structures and applications where backing is not possible. Requirements and prerequisites, advantages and limitations for Shoulderless Friction Stir Welding (SLFSW) are discussed and an industrial application of the joining technology is presented. For leaving the shoulder out, its central functions in FSW have to be transferred to the pin. The resulting tool design of SLFSW is comparably small and slim and so reduces contact area and effective lever and in turn forces and heat input during processing. SLFSW allows welding paths almost at the edge of components and enables a complete and gap-free joining while a deformation of overhanging structures can be avoided. Compared to standard FSW processes, force reductions of about 80–85 % and power reductions of about 75–80 % were found in this study for a 6.5 mm deep weld opening up additional potential for integration with other spindle processes like milling. The locally very limited process impact of SLFSW resulted in comparably low distortion with a part precision reached of +/− 0.05 mm.

An overview of R&D work in friction stir welding at SMU

10.30544/381 ◽  
2006 ◽  
Vol 12 (4) ◽  
pp. 275-295 ◽  
Author(s):  
V. SOUNDARARAJAN ◽  
M. VALANT ◽  
R. KOVACEVIC
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Arc Welding ◽  
Production Costs ◽  
Friction Stir ◽  
Dissimilar Metal ◽  
Joining Technology ◽  
Joint Properties ◽  
Dissimilar Alloys ◽  
And Performance

Friction stir welding (FSW) is an innovative solid-state material joining method invented by The Welding Institute (TWI) in 1991 and has been one of the most significant joining technology developments in the last two decades. It has evolved into a process focused on joining arc weldable (5xxx and 6xxx) and unweldable (2xxx and 7xxx) aluminum alloys to a point where it can be implemented by the aerospace and automotive industries for their joining needs.Research towards the further extension of the process to join dissimilar metal combinations like Fe-Al and Al-Cu is currently underway. A few of the important advantages of FSW over conventional joining techniques include improved joint properties and performance, low-deformation of the workpieces, a significant reduction in production costs and the freeing of skilled labor for use in other tasks. Compared to the conventional arc-welding of aluminum alloys, FSW produces a smaller heat affected zone, and it also allows the successful joining of aluminum alloys, steel, titanium, and dissimilar alloys with a stronger joint.

PENGARUH KECEPATAN TOOL PADA DISSIMILAR METAL ALUMINIUM 1100 DAN 5052 TERHADAP KUALITAS HASIL PENGELASAN DENGAN METODE LAS GESEK PUNTIR (FRICTION STIR WELDING)

2020 ◽  
Vol 6 (2) ◽  
pp. 29-35
Author(s):  
Irza Sukamana
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Liquid State ◽  
Fusion Welding ◽  
Friction Stir ◽  
Dissimilar Metal ◽  
Spiral Form ◽  
Metal Aluminium

Pengelasan merupakan proses penggabungan dua atau lebih logam dasar yang disatukan di permukaan kontaknya dengan atau tanpa zat penambah maupun pengisi.Pengelasan terbagi menjadi dua kategori utama yaitu Liquid-State Weldingdan Solid-State Welding. Friction Stir Weldingmerupakan salah satu contoh pengelasan Solid-State Welding (Non-Fusion Welding).   Aluminium adalah logam yang paling banyak terdapat di kerak bumi, dan unsur ketiga terbanyak setelah oksigen dan silikon. Aluminium adalah suatu unsur kimia yang terletak pada golongan 13 periode 3 dengan lambang Al dengan nomor atom 13. Aluminium terbuat dari 66% bauksit dan 33% tanah liat. Aluminium merupakan salah satu material yang sering digunakan sebagai bahan baku sambungan untuk pengelasan Friction Stir Welding.   Friction Stir Welding (FSW) atau Las Gesek Puntir adalah proses pengelasan gesek yang memuntir tool dengan memanfaatkan energi panas dan penekanan tanpa zat penambah maupun pengisi hingga terjadi perubahan fasa pada logam dasar. Parameter proses pengelasan yang dilakukan pada penelitian ini adalah laju translasi tool yaitu, 16 mm/menit dan 22 mm/menit dengan putaran tool 2000 rpm menggunakan jenis indentor changing spiral form. Adapun pengujian yang dilakukan yaitu, pengujian tarik, pengujian kekerasan dan pengujian komposisi kimia.   Hasil dari penelitian ini adalah ditemukan bahwa laju translasi tool, perlakuan panas dan kecepatan pengelasan sangat mempengaruhi sifat – sifat mekanik aluminium seri 1xxx dan seri 5xxx yang telas dilas. Laju translasi 22 mm/menit akan meningkatkan nilai kekerasan dan kekuatan tarik yang lebih baik dibandingkan dengan laju translasi 16 mm/menit, namun tidak terlalu berdampak signifikan terhadap unsur-unsur kimiai di dalamnya.

Microstructure and Corrosion Behavior of Cast A356 and Wrought AA6061 Aluminium Alloy Welds

2010 ◽  
Vol 117 ◽  
pp. 37-42
Author(s):  
K.Ratna Kumar ◽  
G. Madhusudhan Reddy ◽  
K. Srinivasa Rao
Keyword(s):  
Corrosion Resistance ◽  
Electron Beam ◽  
Friction Stir Welding ◽  
Arc Welding ◽  
Electron Beam Welding ◽  
Gas Tungsten Arc Welding ◽  
Fusion Welding ◽  
Friction Stir ◽  
Gas Tungsten Arc ◽  
Gas Tungsten

In this work, it was intended to improve the corrosion resistance of welds of A356 and AA6061 by adopting mainly a special welding techniques, viz., pulsed current gas tungsten arc welding (PCGTAW), electron beam welding (EBW) and friction stir welding (FSW). It was found that the corrosion resistance of A356 and AA6061 welds could be improved by PCGTAW technique rather than continuous current gas tungsten arc welding (CCGTAW). It can be further improved by using electron beam welding. Improved corrosion resistance in A356 welds could be obtained by selecting T6 temper rather than as cast condition. In the case of AA6061, improved corrosion resistance was achieved by selecting T4 temper rather than T6 temper. As for as the welding techniques, friction stir welding (FSW) is useful than fusion welding techniques like CCGTAW,PCGTAW and EBW for improving the corrosion resistance of both the welds.

scholarly journals Numerical Simulation of Heat Transfer Behavior of Dissimilar AA5052-AA6061 Plates in Fiction Stir Welding: An Experimental Validation

2019 ◽  
Vol 69 (1) ◽  
pp. 131-142 ◽  
Author(s):  
M. M. Vishwanath ◽  
N. Lakshamanaswamy ◽  
G. K. Ramesh
Keyword(s):  
Heat Transfer ◽  
Experimental Data ◽  
Friction Stir Welding ◽  
Solid State ◽  
Fusion Welding ◽  
Experimental Investigations ◽  
Unique Type ◽  
Friction Stir ◽  
Heat Transfer Behavior ◽  
Transfer Behavior

AbstractFiction Stir welding (FSW) a unique type of metal joining process in solid state, where the heat generation takes place due to the friction action between the rotating tool and the work piece. It is generally used to join all series of Aluminum alloys with good strength and other metallic alloys finds difficult to weld through regular fusion welding techniques. The metal joining takes place in the solid state as the metal to be welded reaches about 80% to 90% of its melting temperature. The joining of metals in friction stir welding does not require any filler metals all classes of Aluminium alloys can be joined and in some desirable cases dissimilar metal compositions and Aluminiun metals composites can be joined satisfactorily. Joining of dissimilar metals has become a trend in the industries like aerospace, automotive chemical etc. as the helps in reducing the cost incurred by eliminating the costly materials. In the present study an experimental investigations are made to study the heat transfer behavior by determining the temperature distribution in AA5052-AA6061 plates during the Friction Stir welding. A three dimensional transient analysis is made by using ANSYS finite element analysis software. Thermocouples are placed at the suitable locations and the same point the temperature readings were taken from the simulation results. The experimental data is compared with the numerically simulated results. The numerical simulations results obtained are in better agreement with the experimental data obtained.

Process monitoring of friction stir welding via the frequency of the spindle motor current

2016 ◽  
Vol 232 (4) ◽  
pp. 720-730 ◽  
Author(s):  
William R Longhurst ◽  
Isaac C Wilbur ◽  
Brandon E Osborne ◽  
Bryan W Gaither
Keyword(s):  
Friction Stir Welding ◽  
Frequency Spectrum ◽  
Process Monitoring ◽  
Weld Seam ◽  
Spindle Motor ◽  
Fusion Welding ◽  
Friction Stir ◽  
State Process ◽  
Spindle Motor Current ◽  
Insight Into

Friction stir welding is a solid-state process that is gaining preference for the joining of metals with low melting points. Despite the clear advantages of friction stir welding over traditional fusion welding, voids within the weld seam arise when improper conditions are present. The work presented in this article examines the development of an automated process monitoring system for friction stir welding. The system indirectly monitors the welding torque through the supplied current to the spindle motor. To measure the current, a clamp-on current meter was used. Our results have shown that using a simple and inexpensive clamp-on current meter provides good insight into the welding torque. Examination focused on the frequency spectrum of the current. A Fourier transform decomposed the signal into various frequencies present. The results consistently showed that when no void was present, there was a component of the current’s frequency at 14 Hz. However, when the tool encountered a void, the frequency spectrum changed. The component at 14 Hz went away while content in the range of 1–4 Hz increased.

scholarly journals HARDNESS AND TENSILE BEHAVIOR OF FRICTION STIR WELDED ALUMINUM AA6351 ALLOY

2014 ◽  
Vol 44 (1) ◽  
pp. 23-26
Author(s):  
G. Gopala Krishna ◽  
P. Ram Reddy ◽  
M. Manzoor Hussain
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Rolling Direction ◽  
Welding Process ◽  
Fusion Welding ◽  
Frictional Heat ◽  
Work Piece ◽  
Friction Stir ◽  
Superior Mechanical Properties ◽  
Transverse Weld

Friction Stir Welding (FSW) is a solid state welding process gaining more applications in various industries due to better quality of the joint as it has no effect on parent metal. In FSW process a non consumable rotating welding tool is used to generate frictional heat between tool and abutting surface of work piece and plastic dissipation of energy to accomplish the weld. Being a solid state joining process, friction stir welding process offers various advantages like low distortion, absence of melt related defects, high joint strength etc. as compared to other conventional fusion welding techniques.Experiments were conducted on 6 mm thickness Aluminum AA6351-T4, commercially available plates. The seplates are joined by FSW along the rolling direction (longitudinal weld orientation) and across the rolling direction (transverse weld orientation). The hardness and tensile strength results of the weldments are presented. Results show superior mechanical properties for the joints with plates along the rolling direction as compared with the joints obtained by across the rolling direction.DOI: http://dx.doi.org/10.3329/jme.v44i1.19494

scholarly journals Numerical Simulation of Heat Transfer Behavior of Dissimilar AA5052-AA6061 Plates in Fiction Stir Welding: An Experimental Validation

2019 ◽  
Vol 69 (4) ◽  
pp. 159-170
Author(s):  
M. M. Vishwanath ◽  
N. Lakshamanaswamy ◽  
G. K. Ramesh
Keyword(s):  
Heat Transfer ◽  
Experimental Data ◽  
Friction Stir Welding ◽  
Solid State ◽  
Fusion Welding ◽  
Experimental Investigations ◽  
Unique Type ◽  
Friction Stir ◽  
Heat Transfer Behavior ◽  
Transfer Behavior

AbstractFiction Stir welding (FSW) a unique type of metal joining process in solid state, where the heat generation takes place due to the friction action between the rotating tool and the work piece. It is generally used to join all series of Aluminum alloys with good strength and other metallic alloys finds difficult to weld through regular fusion welding techniques. The metal joining takes place in the solid state as the metal to be welded reaches about 80% to 90% of its melting temperature. The joining of metals in friction stir welding does not require any filler metals all classes of Aluminium alloys can be joined and in some desirable cases dissimilar metal compositions and Aluminiun metals composites can be joined satisfactorily. Joining of dissimilar metals has become a trend in the industries like aerospace, automotive chemical etc. as the helps in reducing the cost incurred by eliminating the costly materials. In the present study an experimental investigations are made to study the heat transfer behavior by determining the temperature distribution in AA5052-AA6061 plates during the Friction Stir welding. A three dimensional transient analysis is made by using ANSYS finite element analysis software. Thermocouples are placed at the suitable locations and the same point the temperature readings were taken from the simulation results. The experimental data is compared with the numerically simulated results. The numerical simulations results obtained are in better agreement with the experimental data obtained.

Researching on hybrid friction stir welding between two differential materials as steel and aluminium

2020 ◽  
Vol 3 (SI1) ◽  
pp. First
Author(s):  
Truong Minh Nhat ◽  
Truong Quoc Thanh ◽  
Tran Trong Quyet ◽  
Luu Phuong Minh
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Welding Process ◽  
Welding Parameters ◽  
Thermal Imager ◽  
Friction Stir ◽  
Hybrid Techniques ◽  
State Process

Friction stir welding exploits its solid-state process behavior to join aluminum to steel, which differs in thermal and mechanical properties, and where a combination of these metallic alloys by fusion welding prompts a deleterious reaction as a result of the melting and resolidification phases. Recently, hybrid techniques have been employed in FSW for several materials and alloys, particularly for steel–steel joining. These methods are generally aimed to pre-heat the steel plate materials. This study presents conducted heat simulations and experimental jointing flat-plate of aluminum alloy 6061 and SUS 304. Temperature is simulated by the COMSOL software in three states: (1) Preheat the Friction Stir Welding (FSW) by TIG welding, (2) Thermal contact resistance between aluminum and steel, and (3) The welding process using stirring friction is simulated. The simulations intended to predict the temperature, which is used for the preheating and welding process to ensuring the required solid-state welding. The temperature is also determined and checked by a thermal imager comparing with simulation results. Besides, the results of tensile strength are carried out. The Box - Behnken method is used to identify the relationship between the welding parameters (rotation, speed, and offset), temperature, and tensile strength. The maximum tensile strength is 77% compared to the strength of the aluminum alloy. The optimal set of parameters for the process is n = 676 rpm, v = 46 mm / min and x = 0.6 mm. The optimizing welding parameters to achieving a good quality of the welding process are described. SEM images to determine some properties of welding materials. This is also the basis for initial research to identify some defects in the welding of two different materials (IMC thickness and interconnected pores) and the cause of these defects.

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