Study on the Effect of Weld Speed and Tool Rotation Speed on the Quality of Friction Stir Welded Joints by Using XRD and EBSD

2016 ◽  
Author(s):  
Jaishree Sanjeevi Maran ◽  
Pratyush Kumar Patro ◽  
Ilangovan Murugesan ◽  
Sai Krishna Sekar ◽  
Sidhaarth Bamarani Thangaswamy
Keyword(s):  
Welded Joints ◽  
Rotation Speed ◽  
Welding Process ◽  
X Ray Diffraction ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Dissimilar Alloys ◽  
Two Parameters ◽  
Welding Processes ◽  
Tool Rotation

Friction Stir processing, a novel welding process which weld similar and dissimilar metals and alloys in solid state for joining metallic alloys and it has replaced conventional welding processes and have become an alternative welding technique. The commonly used aluminum alloys AA6061 and AA5086 were joined together using FSW. In this study, two parameters such as weld speed and tool rotation speed are taken into account. By varying these parameters the dissimilar alloys were welded together. The welded joints were analyzed for its chemical composition and phases formed due to heat produced by friction. The composition is characterized by Electron Back Scattered Diffraction technique (EBSD) and X-ray Diffraction technique (XRD). The influence of tool rotation speed and weld speed on texture has been studied.

Path Force Control for Friction Stir Welding Processes

2008 ◽  
Author(s):  
Xin Zhao ◽  
Prabhanjana Kalya ◽  
Robert G. Landers ◽  
K. Krishnamurthy
Keyword(s):  
Friction Stir Welding ◽  
Force Control ◽  
Rotation Speed ◽  
Smith Predictor ◽  
Communication Delay ◽  
Pole Placement ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Welding Processes ◽  
Tool Rotation

In Friction Stir Welding (FSW) processes, force control can be used to achieve good welding quality. This paper presents the systematic design and implementation of a FSW path force controller. The path force is modeled as a nonlinear function of the FSW process parameters (i.e., plunge depth, tool traverse rate, and tool rotation speed). An equipment model, which includes a communication delay, is constructed to relate the commanded and measured tool rotation speed. Based on the dynamic process and equipment models, a feedback controller for the path force is designed using the Polynomial Pole Placement technique. The controller is implemented in a Smith Predictor–Corrector structure to compensate for the inherent equipment communication delay and the controller parameters are tuned to achieve the best closed loop response possible given equipment limitations. In the path force controller implementation, a constant path force is maintained, even in the presence of gaps, and wormhole generation during the welding process is eliminated by regulating the path force.

scholarly journals Correlating Tensile Strength & Peak Temperatures for Magnesium Alloy AZ91 during Friction Stir Welding Using Varied Tool Geometries & FEA Tool

10.29007/6xnv ◽  
2018 ◽  
Author(s):  
Kamlesh Dhansukhlal Bhatt ◽  
Nikul Patel ◽  
Vishal Mehta
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Rotation Speed ◽  
Welding Process ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Alloy Az91 ◽  
Magnesium Alloy Az91 ◽  
Tool Rotation

Magnesium & its alloys are flammable for conventional fusion welding process. This adverse effect can be eliminated by a non-fusion solid state welding process, established by The Welding Institute (TWI) in 1991, called friction stir welding (FSW). This is applied in this investigation for joining two plates together by using non-consumable tools (three pin profiles) between two abutting plates of magnesium alloy AZ91 having 6 mm thickness. FSW process joins the plates with certain advantages such as low distortion, no shielding gas required, fine recrystallized microstructure, no fumes liberated during the process, etc. In Friction stir welding, process parameters such as welding speed, tool rotation speed, tool dimensions and axial force play an important role during the process. In the present work, the 6 mm thick plates of the said alloy are welded at traverse speed of 28 mm/min to 56 mm/min with tool rotation speed ranging from 710 rpm to 1400 rpm. Tensile strength testing & simulation of peak temperatures has been carried out for establishing correlationship between best parameters from the selected ones with temperature profiles obtained by those parameters for giving optimum structure-property relationship using different pin profiles.

scholarly journals Mechanical and Abrasive Wear Properties of Friction Stir Welded Joints of Aluminum Alloy AA6061-T6 with/Without Nickel Coating

2020 ◽  
Vol 70 (2) ◽  
pp. 21-36
Author(s):  
Shailja Bahuguna ◽  
Pradyumn K Arya ◽  
Vinay Kumar Patel
Keyword(s):  
Abrasive Wear ◽  
Welding Speed ◽  
Welded Joints ◽  
Rotation Speed ◽  
Nickel Coating ◽  
Precipitate Size ◽  
Wear Properties ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

AbstractThe purpose of this work is to examine the microstructure, mechanical and sand abrasive properties of friction stir welded joints of aluminium alloy AA6061-T6 with and without nickel coating. A total eighteen samples, six samples of AA6061-T6 plates, six samples of 10 μm thick Ni coated AA6061-T6 plates and six samples of 15 μm thick Ni coated AA6061-T6 plates were friction stir welded by using different tool rotation speed (710 rpm, 1000 rpm, 1400 rpm) and different welding speed (28 mm/min, 56 mm/min). The joints manufactured using 1400 rpm tool rotation speed and 56 mm/min welding speed generated the highest tensile strength and percent elongation with joint efficiency of 69.05% with 15 μm Ni-coated AA6061-T6 plates and joints manufactured from 10 μm Ni-coated AA6061-T6 plates using 1000 rpm tool rotation speed and 28 mm/min welding speed generated the highest impact energy and higher hardness in NZ compared to the other joints. The 15 μm Ni-coated AA6061-T6 plates exhibited better abrasive wear resistant properties than the 10 15 μm Ni-coated plates. Microstructure investigation showed the precipitate size variations and their distributions and after friction stir welding, these precipitates became slightly coarser in the HAZ but finer in the nugget region.

Microstructure and mechanical properties of interlock friction stir weld lap joint AA7475-T7 using fractional factorial design

2021 ◽  
pp. 095440622199639
Author(s):  
R Anand ◽  
VG Sridhar
Keyword(s):  
Tensile Strength ◽  
Factorial Design ◽  
Rotation Speed ◽  
Lap Joints ◽  
Lap Joint ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Lap Shear ◽  
Welding Processes ◽  
Tool Rotation

Friction stir welding (FSW) technique was preliminary developed to join various low strength and high strength alloys by considering different inputs and known to surpass the flaws which occur in conventional welding processes. The present study is focused on the FSWed interlock lap joint of AA7475-T7 using three-level three factor (33) full factorial design methodology to study the correlation among process parameters with the lap shear strength and hardness. To compare the strength and hardness of interlock lap joint, a typical lap joint has been made with an optimized input parameter obtained from the FSW interlock lap joint. Microstructure analysis, hardness and tensile strength of FSWed interlock lap joints and typical lap joints were done to analyze the robustness of the welds made. Results proved that the strength of FSWed interlock lap joints is high compared to typical lap weld with a ultimate tensile strength of 172.88 N and hardness of 200 HV when the process parameter level is at tool rotation speed of 1400 r/min, welding speed 30 mm/s plunge speed rate 0.06 mm/s. At the tool rotation speed of 1400 r/min dynamic recrystallization of the material occurs which thereby leads to the formation of fine grains in the SZ of the weld metal.

scholarly journals PENGARUH TOOL ROTATION SPEED TERHADAP SIFAT MEKANIK SAMBUNGAN ALUMINIUM PADUAN 6061-T6 PADA PROSES FRICTION STIR WELDING

2019 ◽  
Vol 25 (3) ◽  
Author(s):  
Tarmizi Tarmizi ◽  
Riki Indrawan ◽  
Irfan Irfan
Keyword(s):  
Friction Stir Welding ◽  
Rotation Speed ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

PENGARUH TOOL ROTATION SPEED TERHADAP SIFAT MEKANIK SAMBUNGAN ALUMINIUM PADUAN 6061 T6 PADA PROSES FRICTION STIR WELDING. Pengelasan aduk tekan merupakan proses pengelasan yang baru dikembangkan pada tahun 1991, hingga saat ini berbagai penelitian terus dilakukan untuk menemukan parameter yang dapat menghasilkan sambungan las yang optimum sebagai alternatif proses pengelasan fusi yang masih memiliki beberapa kekurangan. Penelitian ini bertujuan untuk mengetahui pengaruh kecepatan putar tool yang menjadi salah satu parameter penting dalam friction stir welding pada pelat aluminium paduan 6061-T6 dengan tebal 6 mm terhadap sifat mekanik sambungan las, dengan variasi kecepatan putar yang digunakan 910 rpm, 1175 rpm, 1555 rpm, 1700 rpm dan 2000 rpm untuk mendapatkan parameter yang optimum. Berdasarkan penelitian yang telah dilakukan didapatkan hasil bahwa sambungan las dengan kecepatan putaran 910 rpm, 1175 rpm dan 1555 rpm tidak terdapat cacat dan memenuhi kriteria sambungan las berdasarkan standar AWS D17.3 sedangkan sambungan las yang memiliki sifat mekanik yang paling optimum yaitu sambungan las dengan kecepatan putar tool 910 rpm karena pengkasaran butir dan larutnya presipitat tidak terlalu signifikan dibandingkan dengan kecepatan putaran lainnya.Kata kunci: Pengelasan aduk tekan, pengelasan fusi, kecepatan putar, tool, aluminium paduan 6061-T6.

Welding of Aluminum to DP600 Steel Plates by Refill Friction Stir Spot Welding Process (Refill FSSW): Preliminary Results

2014 ◽  
Vol 1082 ◽  
pp. 123-132 ◽  
Author(s):  
Roger Navarro Verastegui ◽  
José Antonio Esmerio Mazzaferro ◽  
Cíntia Cristiane Petry Mazzaferro ◽  
Telmo Roberto Strohaecker ◽  
Jorge Fernandez Dos Santos
Keyword(s):  
Spot Welding ◽  
Rotation Speed ◽  
Welding Process ◽  
Steel Plates ◽  
Mechanical Resistance ◽  
Shear Tests ◽  
Friction Stir ◽  
Lap Shear ◽  
Substantial Change ◽  
Tool Rotation

The main objective of the current work was to produce sound Refill FSSW joints between AA6181-T4 aluminum and DP600 steel plates. The steel plates were used in two different surface conditions: with and without galvanized surface layer. The Taguchi statistical method was used to find out the set of parameters indicated to produce joint with higher mechanical resistance. Then, the possibility of joining these dissimilar metals using the Refill FSSW process was verified. Tool rotation speed and welding time were varied to observe its effect over the joint behavior. The results of lap shear tests showed that galvanized layers do not cause any substantial change on the final joint mechanical resistance, even though different joining mechanisms had been observed.

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