High-Frequency Induction Assisted Hybrid Friction Stir Welding of Inconel 718 Plates

2021 ◽  
pp. 1-36
Author(s):  
Sanjay Raj ◽  
Pankaj Biswas
Keyword(s):  
Friction Stir Welding ◽  
Tool Life ◽  
High Frequency ◽  
Inconel 718 ◽  
Weld Zone ◽  
Base Material ◽  
Frictional Heat ◽  
Weld Strength ◽  
Friction Stir ◽  
High Frequency Induction

Abstract The preheating system is a promising approach to decrease the axial load, improve the weld quality, and enhance the tool life during the friction stir welding of high strength material. In the present work, conventional friction stir welding (FSW) and high-frequency induction heating-assisted friction stir welding (I-FSW) systems were used to join 3 mm thick Inconel 718 plates with a WC-10%Co tool and studied their performances. The welding was carried out at a constant rotational speed of 300 rpm, including varying traverse speeds of 90 mm/min and 140 mm/min and varying preheating temperatures (310 oC, 410 oC, and 700 oC). The results show that good weld joints were possible at high traverse speed (i.e., 140 mm/min) using the I-FSW at low preheating temperature (i.e., 310 oC). Grain refinement in the weld zone with and without preheated FSW led to improved mechanical properties. The increased size of intermetallic phases and carbide particles due to induction preheating in I-FSW were most likely to be responsible for the enhancement of the weld strength. The hardness of the stir zone was increased from 250 HV to 370 HV, and the ultimate tensile strength of the I-FSW joint reaches 740 MPa, which was 98.8 % of the base material. The results also revealed that preheating affected the process temperature results lowering the axial force and frictional heat, which improved the tool life.

scholarly journals Influence of Mx-Trivex, A-Skew, Three Flat Threaded and Concave Shouldered Mx-Triflute Tool Pin Profiles on Tensile Properties and Fractural Behaviour of Aa 6082-T6 Weldments During Friction Stir Welding

2020 ◽  
Vol 9 (4) ◽  
pp. 1376-1384
Keyword(s):  
Friction Stir Welding ◽  
Tensile Test ◽  
Weld Zone ◽  
Base Material ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Pin ◽  
Solid State Joining ◽  
Joining Process ◽  
Brass Wire

Friction Stir Welding (FSW) is a topical and propitious solid-state joining process producing economical and strengthened joints of age-hardened and heat-treatable Aluminium Alloy AA 6082-T6. Mechanical and fractural behaviour of weldments were investigated in order to find crack initiation and necking on the weld zone thereby perceiving the complete behaviour of fracture occurred near the weld zone. Weldments are fabricated by employing four tool pin profiles namely MX-TRIVEX, A-SKEW, Three flat threaded and Concave shouldered MX-TRIFLUTE tools at various rotational speeds 1000 rpm, 1200 rpm and 1400 rpm at single traverse speed 25 mm/min. EXCETEX-EX-40 CNC wire cut EDM with 0.25 mm brass wire diameter has been employed to perform the extraction of tensile test specimens from the weldments according to ASTM E8M-04 standard. Tensile test was performed on elctromechanically servo controlled TUE-C-200 (UTM machine) according to ASTM B557-16 standards Maximum Ultimate Tensile Strength (UTS) of 172.33 MPa (55.5% of base material) and 0.2% Yield Stress (YS) of 134.10 MPa (51.5% of base material) were obtained by using A-SKEW at 1400 rpm, 25 mm/min and maximum % Elongation (%El) of 11.33 (113.3% of base material) was obtained at MX-TRIVEX at 1000 rpm, 25 mm/min. Minimum UTS of 131.16 MPa (42.30% of base material) and 0.2% YS of 105.207 MPa (40.46% of base material )were obtained by using Concave shouldered MX-TRIFLUTE at 1400 rpm, 25 mm/min. Minimum % El of 5.42 ( 54.2% of base material) was obtained by using A-SKEW at 1000 rpm, 25 mm/min.

scholarly journals Parametric Optimization of Friction Stir Welding Factors (FSWF) for Yellow Brass 405-20

2021 ◽  
Author(s):  
Syed Farhan Raza ◽  
Sarmad Ali Khan ◽  
Muhammad Salman Habib ◽  
Naveed Ahmed ◽  
Kashif Ishfaq ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Weld Zone ◽  
Tool Material ◽  
Traverse Speed ◽  
Weld Strength ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Wide Range ◽  
Percent Contribution

Abstract Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. Industries are really interested in adopting FSW in its various applications e.g., automobile, aerospace, marine, construction, etc. FSW can successfully weld a wide range of materials (similar/dissimilar parent materials) including aluminum, copper, steel, different alloys from these materials, plastics, composites, and this material range is subjected to extension if FSW research efforts develop further in future. FSW of brass has already been accomplished by fewer researchers. In this research, yellow brass 405-20 is, therefore, welded with FSW that was never welded before. In this study, tool material utilized was M2 HSS that was also novel. Effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters i.e., weld temperature, weld strength and weld hardness. Weld temperature was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 82.78% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Based on main effects of Anova Analysis, optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in maximum (max.)/optimal temperature, max./optimal weld strength, and minimum/optimal hardness. Rotational speed (RS) was found to be significant to affect the weld temperature only at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. Transverse speed (TS) was found to be overall insignificant for affecting weld temperature, weld strength and hardness. However, PCR of transverse speed was found to be maximum for affecting weld strength as compared to its PCR towards both weld temperature and weld hardness. Error PCR was found to be the lowest for weld zone temperature, then for weld strength, and finally the highest for weld hardness. Interaction Plots (IPs) were also made for those FSWF which were found to be insignificant and to investigate any combined effect of FSWF on output parameters causing increased error PCR towards weld temperature, weld strength, and weld hardness.

Utilization of a Curly Toolpath in Friction Stir Welding

2021 ◽  
Vol 1165 ◽  
pp. 15-29
Author(s):  
Tyler J. Grimm ◽  
Derek Shaffer ◽  
Ihab Ragai
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tool Path ◽  
Base Material ◽  
The Other ◽  
Weld Strength ◽  
Mechanical Mixing ◽  
Material Interface ◽  
Friction Stir ◽  
High Level

Friction stir welding (FSW) is an advanced solid-state metal joining technique. This operation fuses adjacent materials through the use of a non-consumable, rotating tool, which is plunged into and travels along the seam of the materials. Since this joining method avoids the bulk melting of the base materials, it is considered a relatively energy efficient process. Additionally, the strength of the base material is often improved due to significant grain refinement resulting from the stirring action of the tool at relatively low temperatures. Another inherent benefit is that the joint thickness, which is dependent on the length of the pin, can be much greater than most other joining processes and can also be well controlled. This joining method conventionally relies on the friction at the tool-base material interface to stir materials. Other research has implemented complex tooling to mechanically enhance this stirring action. However, these tools are often expensive, requiring a high level of capability within industry. In order to improve the weld strength of FSW, a novel toolpath is utilized which significantly improves the mechanical mixing of the constituent materials without the need for complex tooling, such as tools with threaded pins. The path currently investigated forms a curl as it travels both perpendicular and parallel to the joint. This motion is used to extend the stirring action of the tool to regions outside the immediate joint area. It was found that this tool path is effective in improving weld strength under specific process parameters. Constraining the tool's axis normal to the workpiece surface resulted in a void that was formed in the majority of tests; however, this void was eliminated with modification of the process parameters. An uneven distribution of heat was recognized within this testing in which one side of the joint was hotter than the other. This observation may be used in future studies to perform multi-material joining where it is often necessary to increase the temperature of one material more than the other.

Effect of PWHT on Behaviors of Precipitates and Hardness Distribution of 6061 Al Alloy Joints by Friction Stir Welding Method

2004 ◽  
Vol 449-452 ◽  
pp. 601-604 ◽  
Author(s):  
Won Bae Lee ◽  
Hyung Sun Jang ◽  
Yun Mo Yeon ◽  
Seung Boo Jung
Keyword(s):  
Friction Stir Welding ◽  
Base Metal ◽  
Dynamic Recovery ◽  
Weld Zone ◽  
Frictional Heat ◽  
Al Alloy ◽  
Hardness Distribution ◽  
Friction Stir ◽  
Heat Treated ◽  
6061 Al Alloy

The hardness distribution related to the precipitates behaviors as friction stir welded and PWHT (post weld heat treated) 6061 Al alloy have been investigated. Frictional heat and plastic flow during friction stir welding created a fine, eqiuaxed and elongated microstructure near the weld zone due to dynamic recovery and recrystallization. A softened region which had been formed near the weld zone couldn't be avoidable due to the dissolution and coarsening of the strengthening precipitates. PWHT (SHT+ Aging) homogeneously recovered the hardness distribution over that of the base metal without softening region, resulted from non-homogeneously distributed hardness only aging treated. 36ks aging followed by SHT gave a higher hardness overall weld than that of the base metal due to a higher density of the spherical shaped precipitate.;

Friction Stir Welding of Al-Li AA2199: Parameters, Precipitates and Post Weld Heat Treatment

2011 ◽  
Vol 409 ◽  
pp. 853-858
Author(s):  
Rosen Ivanov ◽  
Julien Boselli ◽  
Diana Denzer ◽  
Daniel Larouche ◽  
Raynald Gauvin ◽  
...  
Keyword(s):  
Heat Treatment ◽  
High Temperature ◽  
Friction Stir Welding ◽  
Weld Zone ◽  
Base Material ◽  
Post Weld Heat Treatment ◽  
Second Phase ◽  
Friction Stir ◽  
Tool Rotation ◽  
Weld Heat

The aerospace industry strives to develop materials allowing an increase in payload and reducing fuel consumption. Al-Li alloys, with their low density and high strength are currently in use for such applications and have potential for additional applications. When compared to composites, utilizing Al-Li alloy products is cost effective for aerospace companies as they do not need to redesign pre-existing fabrication facilities. The joining of these alloys by conventional methods is limited by segregation of alloying elements and the formation of oxides during high temperature exposure. This study focuses on solid state joining method that has the potential to generate low heat and be defect free - Friction Stir Welding (FSW). AA2199 sheets were joined by FSW. Process variables included table force, tool rotation speed and weld travel speed. A post weld heat treatment (PWHT) was applied to improve the mechanical properties by precipitation of strengthening phases. An increase in hardness of the weld zone from 95HV to 125HV upon PWHT was recorded for selected welding conditions. The type and morphology of second phase precipitates is deemed responsible for this effect. It is suggested that the high temperature and high strain levels characteristic of welds with fast tool rotation allow for the dissolution of precipitates during welding. The re-precipitation of these second phases during PWHT allowed the welds to recover strength to the level of the base material.

scholarly journals Friction-Stir Welding of a Wrought Al-Si-Mg Alloy in As-Fabricated and Heat-Treatment States

Materials ◽  
2020 ◽  
Vol 13 (4) ◽  
pp. 861
Author(s):  
Chunxia Wang ◽  
Hongbo Cui ◽  
Xin Tang ◽  
Kezhun He
Keyword(s):  
Heat Treatment ◽  
Friction Stir Welding ◽  
Solution Treatment ◽  
Base Material ◽  
Welding Process ◽  
Age Hardening ◽  
Weld Strength ◽  
Friction Stir ◽  
Joint Efficiency ◽  
Al Matrix

A wrought Al-11.3Si-0.6Mg alloy under hot extrusion (T1), solution treatment (T4), and solution treatment + artificial aging (T6) states were friction stir welded at welding speed of 100 mm/min and rotation rate of 800 rpm. The effect of prior heat-treatment on the microstructure and mechanical properties of the welds were investigated. The results show that the microstructures of the nugget zones have little dependence on the initial states of the base material. In the nugget zones, complete recrystallized structures with equaxied grains in the Al matrix were formed under all conditions. The Si particles in the nugget zones are almost unchanged compared with those of their base materials (BMs) in the three states. In contrast, the joint efficiency of the obtained welds was very sensitive to the initial material condition. The joint efficiency under the T1 state is more than 90% due to the fact that the microstructure is almost unchanged, except for the slight coarsening of the Al matrix grains and some of the Mg2Si phases during the friction stir welding process. However, the joint efficiency in the T4 and T6 conditions is only 77.22% and 62.03%, respectively. The relatively low weld strength in the T4 and T6 conditions is due to the elimination of the solid solution strengthening and age hardening effects during friction stir welding. The hardness distributions along the cross section of joints are all W-shaped under T1, T4, and T6 conditions.

Friction Stir Welding on Light-Weight Metal - Aluminum Alloy Al6061

2016 ◽  
Vol 879 ◽  
pp. 1233-1238
Author(s):  
Vasanth Chakravarthy Shunmugasamy ◽  
Bilal Mansoor
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Yield Strength ◽  
Base Material ◽  
Frictional Heat ◽  
Tensile Yield Strength ◽  
Impact Properties ◽  
Friction Stir ◽  
Tool Pin ◽  
The Impact

Friction stir welding (FSW) is a solid state joining process in which metals are joined together using frictional heat and severe plastic deformation. The heating and the mixing of the metals is performed using a hardened tool with a shoulder and pin. FSW of lightweight metal alloy Al6061 has been carried out in the present study. For welding aluminum the parameters used were a constant tool rotation speed of 1600 rpm and varying tool translation speeds of 250, 500, 750 and 1000 mm/min. The welded coupons were characterized for microstructural observations and mechanical properties such as tensile and Charpy impact properties. The tensile and impact properties were studied at two different temperature namely, room temperature (RT) and 300°C. The FS welded aluminum specimens showed 86% – 98% tensile yield strength, in comparison to the base material at RT. At 300°C, the yield strength was observed to be 85% to 93% of the base material value. For the impact properties, the Al specimens showed 60% – 140% specific impact energy, in comparison to their respective base materials. Based on the mechanical properties and microstructural examination, the optimal weld parameter was identified as 1600 rpm and 250 mm/min which is dependent on the tool pin and shoulder design utilized in the study.

scholarly journals Optimization of process parameters on friction stir welding of 2014 aluminum alloy plates

2017 ◽  
Vol 7 (1.1) ◽  
pp. 9 ◽  
Author(s):  
V. Jaiganesh ◽  
D. Srinivasan ◽  
P. Sevvel
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
High Strength ◽  
Frictional Heat ◽  
Weld Strength ◽  
Electron Interaction ◽  
Welding Parameters ◽  
Work Piece ◽  
Friction Stir

Aluminum Alloy 2014 is a light weight high strength alloy used widely in the aerospace and also in other industries. 2014 is the second most popular of the 2000-series aluminium alloys, after 2024 aluminium alloy. However, it is difficult to weld, as it is subject to cracking. Joining of 2014 aluminium alloy in friction stir welding which is based on frictional heat generated through contact between a rotating tool and the work piece. Determination of the welding parameters such as spindle speed, transverse feed , tilt angle plays an important role in weld strength. The whole optimization process is carried out using Taguchi technique. The SEM analysis is done to check the micro structure of the material after welding by electron interaction with the atoms in the sample. Tensile test have been conducted and the s-n ratio curve is generated. The test is conducted and analysed on the basis of ASTM standards.

Experimental Investigation of Double Side Friction Stir Welding (FSW) on High Density Polyethylene Blanks

2010 ◽  
Author(s):  
S. Saeedy ◽  
M. K. Besharati Givi
Keyword(s):  
Friction Stir Welding ◽  
Weld Zone ◽  
Base Material ◽  
Material Strength ◽  
Welding Condition ◽  
Friction Stir ◽  
Factorial Method ◽  
Tool Tilt Angle ◽  
Crystallinity Changes ◽  
Side Friction

The effect of double side technique in friction stir welding of polyethylene blanks has been studied. Experiments have been designed and analyzed with the full factorial method. The process parameters were rotation speed and tool tilt angle. The optimum welding condition has been determined. It has been demonstrated that double side FSW can improve the weld quality by decreasing the problem of stress concentration in the root of the joint. By applying this technique, 80% of the base material strength is achieved. Considerable reduction in elongation and toughness of the seam weld is due to crystallinity changes of the weld zone which are indicated in the DSC test results.

Sign in / Sign up

Export Citation Format

Share Document