Al Alloy Tailor welded Blanks Fabrication via Friction Stir Welding: Effect of Shoulder Size

2021 ◽  
pp. 1-9
Author(s):  
Tanveer Majeed ◽  
Nooruddin Ansari ◽  
Yashwant Mehta ◽  
Arshad Noor Siddiquee
Keyword(s):  
Friction Stir Welding ◽  
Butt Joint ◽  
Al Alloy ◽  
Second Phase ◽  
Thick Plates ◽  
Void Defect ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tailor Welded Blanks ◽  
Thermomechanical Behaviour

Abstract Material flow and heat generation by tool shoulder during Friction Stir Welding (FSW) significantly alters the microstructural and thermomechanical behaviour of joints. The effect of shoulder size on mechanical properties of joints has not yet been reported in the FSW of Tailor Welded Blanks (TWBs). This article reports the effect of shoulder size on joint quality in FSW of TWBs between 6.35 mm thick plates of AA2024-T3 and 2.5 mm thick plates of AA7475-T7 alloys in butt joint configuration fabricated under shoulder sizes: 18 mm, 20 mm, and 22 mm. Microstructural evaluation of FSWed joints reveals a significant increase in grain size with shoulder diameter sizes. The X-ray EDS elemental maps reveal the presence of fine second phase particles stir zone. The progressive elimination of void defect with the increase in shoulder size was observed. The tensile testing reveals the highest strength of joints fabricated under shoulder size of 18 mm. Fractographic analyses of broken tensile specimens showed the mixed mode of failure in all the weld specimens.

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

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.

Effect of Tool Rotation Speed and Feed Rate on Friction Stir Welding of 1100 Aluminum Alloy to Carbon Steel

2012 ◽  
Vol 445 ◽  
pp. 741-746 ◽  
Author(s):  
M. Habibnia ◽  
M. Shakeri ◽  
S. Nourouzi ◽  
Namdar Karimi
Keyword(s):  
Friction Stir Welding ◽  
Carbon Steel ◽  
Feed Rate ◽  
Rotation Speed ◽  
Butt Joint ◽  
Al Alloy ◽  
Dissimilar Metals ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

To achieve a defect-free butt joint of dissimilar metals by friction stir welding procedure, there are some major parameters, such as tool material and geometry, tool rotational speed, feed rate and tilt angel. This research is focused on dissimilar metals welding, namely 1100 Al alloy and 1045 carbon steel. In this paper, the effect of tool rotation speed and feed rate are experimentally investigated on surface appearance, microstructure and micro hardness of the friction stir welded plates. Optimum values of tool rotation speed and feed rate have been achieved experimentally by the quality of the butt joint.

scholarly journals Influence of material velocity on heat generation during linear welding stage of friction stir welding

2016 ◽  
Vol 20 (5) ◽  
pp. 1693-1701
Author(s):  
Alin Murariu ◽  
Darko Veljic ◽  
Dragana Barjaktarevic ◽  
Marko Rakin ◽  
Nenad Radovic ◽  
...  
Keyword(s):  
Plastic Deformation ◽  
Friction Stir Welding ◽  
Heat Generation ◽  
Welding Process ◽  
Slip Rate ◽  
Frictional Heat ◽  
Al Alloy ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Pin

The heat generated during friction stir welding (FSW) process depends on plastic deformation of the material and friction between the tool and the material. In this work, heat generation is analysed with respect to the material velocity around the tool in Al alloy Al2024-T351 plate. The slip rate of the tool relative to the workpiece material is related to the frictional heat generated. The material velocity, on the other hand, is related to the heat generated by plastic deformation. During the welding process, the slippage is the most pronounced on the front part of the tool shoulder. Also, it is higher on the retreating side than on the advancing side. Slip rate in the zone around the tool pin has very low values, almost negligible. In this zone, the heat generation from friction is very low, because the material is in paste-like state and subjected to intensive plastic deformation. The material flow velocity around the pin is higher in the zone around the root of the pin. In the radial direction, this quantity increases from the pin to the periphery of the tool shoulder.

Friction stir welding of butt joints of 1420T1 and 1163T alloys sheets

2020 ◽  
pp. 446-453
Author(s):  
V.A. Berezina ◽  
V.V. Ovchinnikov ◽  
E.V. Luk’yanenko
Keyword(s):  
Friction Stir Welding ◽  
Ultimate Strength ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Butt Joint ◽  
Maximum Temperature ◽  
Butt Joints ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Rotation

The results of the butt joint formation of 5 mm thickness sheets from 1420T1 and 1163T aluminium alloys in different combination are presented. It is established that the ultimate strength of the joints depends on the location of the welded alloys relative to the direction of the tool rotation during friction stir welding. It is shown that depending on the location of 1420T1 and 1163T alloys on the side of the run in or out of the tool, the maximum temperature at the edge of the tool shoulder is 385 or 410 °C, in the weld core the metal is heated to 490 °C. The stir zone (the weld metal) consists of two zones corresponding to welded alloys without stir with each other. Ultimate strength to welded joint 1420T1 and 1163T alloys is 0.65...0.73 of ultimate strength to the 1420T1 alloy

Effect of Tool Material and Offset on Friction Stir Welding of Al Alloy to Carbon Steel

2012 ◽  
Vol 445 ◽  
pp. 747-752 ◽  
Author(s):  
Namdar Karimi ◽  
S. Nourouzi ◽  
M. Shakeri ◽  
M. Habibnia ◽  
A. Dehghani
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Carbon Steel ◽  
Feed Rate ◽  
Tool Material ◽  
Butt Joint ◽  
Al Alloy ◽  
Friction Stir ◽  
Tool Offset ◽  
Dissimilar Friction Stir Welding

In this research, effect of tool material and tool offset on tool erosion and metallurgical and mechanical properties of dissimilar friction stir welding of Al alloy to carbon steel are investigated. As the tool erosion is one of the important parameters on the defect-free friction stir welding, especially in butt joint of Al alloy to steel. In present work, different tool material and offset are used in friction stir welding at Al alloy to carbon steel with a constant tool speed and feed rate named as 710 rpm and 28 mm/min respectively. The result of experimental observation is shown better performance by tungsten carbide (WC) tool material with 1 mm offset on Al alloy area.

scholarly journals Enhancement of the Al/Mg Dissimilar Friction Stir Welding Joint Strength with the Assistance of Ultrasonic Vibration

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1113
Author(s):  
Yinghao Bai ◽  
Hao Su ◽  
Chuansong Wu
Keyword(s):  
Friction Stir Welding ◽  
Ultrasonic Vibration ◽  
Joint Strength ◽  
Butt Joint ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Dissimilar Alloys ◽  
Dissimilar Friction Stir Welding ◽  
Fracture Appearance

The assistance of ultrasonic vibration during the friction stir welding (FSW) process has been verified as an effective approach for the improvement of joint strength. In the present study, experimentation on Al/Mg dissimilar alloys in butt joint configuration is implemented by employing FSW with and without the assistance of ultrasonic vibration. An optimized tool shoulder diameter of 12 mm is utilized, and the ultrasonic vibration is applied perpendicularly onto the tool along the welding direction, which is named UVaFSW. The results of joint appearance and macrostructure, characteristics of the intermetallic compounds (IMCs), as well as joint strength and fracture appearance are compared between Al/Mg FSW joints with and without ultrasonic vibration. It is demonstrated that the material intermixing between Al and Mg alloys is substantially strengthened in the UVaFSW joint compared with that in the FSW joint. Additionally, the ultrasonic vibration can be beneficial for the reduction of IMC thickness, as well as the formation of intermittently distributed IMC phases at the Al–Mg bonding interface. Consequently, the mechanical properties of Al/Mg FSW joints are significantly improved with the assistance of ultrasonic vibration. The maximum ultimate tensile strength is 206 MPa at tool rotation speed of 800 rpm and welding speed of 50 mm/min for the Al/Mg UVaFSW joint.

scholarly journals Effect of Stirring Pin Rotation Speed on Microstructure and Mechanical Properties of 2A14-T4 Alloy T-Joints Produced by Stationary Shoulder Friction Stir Welding

Materials ◽  
2021 ◽  
Vol 14 (8) ◽  
pp. 1938
Author(s):  
Haifeng Yang ◽  
Hongyun Zhao ◽  
Xinxin Xu ◽  
Li Zhou ◽  
Huihui Zhao ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Weld Nugget ◽  
Al Alloy ◽  
Nugget Zone ◽  
T Joints ◽  
Friction Stir ◽  
Stationary Shoulder ◽  
Microstructure And Mechanical Properties

In this study, 2A14-T4 Al-alloy T-joints were prepared via stationary shoulder friction stir welding (SSFSW) technology where the stirring pin’s rotation speed was set as different values. In combination with the numerical simulation results, the macro-forming, microstructure, and mechanical properties of the joints under different welding conditions were analyzed. The results show that the thermal cycle curves in the SSFSW process are featured by a steep climb and slow decreasing variation trends. As the stirring pin’s rotation speed increased, the grooves on the weld surface became more obvious. The base and rib plates exhibit W- or N-shaped hardness distribution patterns. The hardness of the weld nugget zone (WNZ) was high but was lower than that of the base material. The second weld’s annealing effect contributed to the precipitation and coarsening of the precipitated phase in the first weld nugget zone (WNZ1). The hardness of the heat affect zone (HAZ) in the vicinity of the thermo-mechanically affected zone (TMAZ) dropped to the minimum. As the stirring pin's rotation speed increased, the tensile strengths of the base and rib plates first increased and then dropped. The base and rib plates exhibited ductile and brittle/ductile fracture patterns, respectively.

A Thermo-Fluid Analysis of the Friction Stir Welding Process

2007 ◽  
Vol 539-543 ◽  
pp. 3832-3837 ◽  
Author(s):  
D. Jacquin ◽  
Christophe Desrayaud ◽  
Frank Montheillet
Keyword(s):  
Friction Stir Welding ◽  
Bulk Material ◽  
Welding Process ◽  
Vertical Motion ◽  
Velocity Fields ◽  
Fluid Simulation ◽  
Metal Sheet ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Fluid Analysis

The thermo-mechanical simulation of Friction Stir Welding focuses the interest of the welding scientific and technical community. However, literature reporting material flow modeling is rather poor. The present work is based on the model developed by Heurtier [2004] and aims at improving this thermo-fluid simulation developed by means of fluid mechanics numerical and analytical velocity fields combined together. These various velocity fields are investigated separately and especially according to the power dissipated during the flow. Boundary conditions are considered through a new approach based on the kinematic analysis of the thread of the pin. An equilibrium is established between the vertical motion of the bulk material dragged in the depth of the metal sheet, and its partial circulation around the pin. The analyses of the obtained velocity fields enable the understanding of the welded zone asymmetry and highlights the bulk material mixing between the welded coupons in the depth of the sheet. A regression is performed on the relative sliding velocity of the aluminium according to the surface of the tool: shoulder and pin. Two dimension flow lines in the depth of the metal sheet are then obtained and successfully compared with the results obtained by Colegrove (2004) [1].

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