Probeless Tool Aided Friction Stir Welding as a Fabrication Technique for Tungsten Embedded Mechanical Composite of Copper

2014 ◽  
Author(s):  
Yogita Ahuja ◽  
Raafat Ibrahim ◽  
Anna Paradowska ◽  
Daniel Riley
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Base Metal ◽  
Parametric Study ◽  
Effective Parameter ◽  
Frictional Heat ◽  
Fabrication Technique ◽  
Shear Testing ◽  
Friction Stir ◽  
Parameter Combination

Friction stir welding (FSW) is a relatively new solid state metallurgical joining technique. It flourishes on the simple principle of utilising frictional heat by the stirring motion of a non-consumable rotating tool to create the seam. Feasibility of FSW aided by a newly designed probeless tool was investigated for fabricating copper-tungsten mechanical composite. The most effective parameter combination was determined by conducting a parametric study of the probeless tool aided FSW copper. Strength of the mechanical composite fabricated at this condition was evaluated through punch shear testing. Punch shear testing established that the friction stir welded interface of the copper-tungsten composite was 87% as strong as the base metal (i.e. copper). Advantages of the designed technique have been summarised.

An Experimental Study of Process Parameters on Friction Stir Welded Aluminum Alloy 2219 Joint Properties

2017 ◽  
Vol 863 ◽  
pp. 3-7
Author(s):  
Koo Kil No ◽  
Joon Tae Yoo ◽  
Jong Hoon Yoon ◽  
Ho Sung Lee
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Process Parameters ◽  
Process Condition ◽  
Welding Process ◽  
Frictional Heat ◽  
Friction Stir ◽  
Joint Properties ◽  
Aluminum Alloy 2219

Aluminum alloy 2219 is widely used in aerospace applications since it has a unique combination of good weldability and high specific strength. Furthermore, it can provide a high strength after heat treatment with superior properties in cryogenic environment so they have been widely used for cryogenic fuel tank of space launch vehicles. It is known that solid state welding like friction stir welding can improve the joint properties of this alloy. Friction stir welding is a solid state welding technology which two materials are welded together by the frictional heat due to the rotation of the tool. In this study, friction stir welding was performed on aluminum alloy 2219 sheets. The range of welding parameter is four rotation speeds from 350 to 800 rpm and six travel speeds from 120 to 420 mm/min. The results include the microstructural change after friction stir welding. The microstructure was characterized and material in the stirred zone experience sufficient deformation and heat input which cause the complete dynamic recrystallization. The present work represents the strength at each process condition and the optimum friction stir welding process parameters. The optimum weld efficiency obtained in this study was 76.5 %.

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

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.;

scholarly journals Parametric study of friction stir welding using elastic return

2020 ◽  
Vol 40 (1) ◽  
pp. 7-11
Author(s):  
Mohamed Serier ◽  
Mohamed Berrahou ◽  
Amina Chikh
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Weld Joint ◽  
Parametric Study ◽  
Experimental Tests ◽  
Assembly Process ◽  
Folding Process ◽  
Friction Stir

AbstractAluminum alloy is a very useful material in light manufacturing. Friction stir welding (FSW) is a solid state assembly process that is achievable for this material. This work aims to characterize the quality of the weld joint by an operation of shaping (folding), it aims to study the rate of elastic return in this weld joint after a folding operation. In this context, the elastic return for the folding process has been modeled using experimental tests under optimal welding conditions.

scholarly journals The influence of friction stir welding tool shape on quality of AZ31 Magnesium welding product

2021 ◽  
Vol 10 (2) ◽  
Author(s):  
Irza Sukmana ◽  
Fauzi Ibrahim ◽  
Ahmad Yudi Eka Risano
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Base Metal ◽  
Welding Speed ◽  
Welding Process ◽  
Base Metals ◽  
Friction Stir ◽  
Tool Shape ◽  
Spiral Shape ◽  
Tool Rotation

Magnesium is one type of material that can be used as a base metal in welding. Magnesium has superior properties, including low density, good ductility, medium strength and excellent corrosion resistance. Because of its properties, the metal is widely used, ranging from household goods to aircraft components. These base metals are categorised as mild when viewed from the specific gravity of magnesium (1.74 g/cm3 and 1.83 g/cm3). Welding is the process of merging two or more base metals which are merged at the contact surface with or without additives or fillers. Welding is divided into two main categories, Liquid and Solid-State Welding. Friction Stir Welding (FSW) is an example of Solid-State Welding (Non-Fusion Welding). FSW is a friction welding process that twists the tool by utilising heat energy and pressing without additives or fillers until the base metal is in a phase change.  The welding process in this study used the cone and spiral shape with a tool rotation at 2000 rpm and a welding speed of 16 mm/min. The tests carried out are tensile and hardness testing. This study found that the tool shape, tool rotation, and welding speed significantly affect the mechanical properties of the welded AZ31 magnesium. The spiral shape will make the welding area wider. Although the cone shape will have a small area, the weld will look perfect with good tensile strength, while the hardness values for the two tool shapes are almost the same, but the cone shape is better.

Effects of tool pin profile on tensile and wear behaviour of friction stir welded AA6101-T6 and AA1350 alloys

2020 ◽  
Vol 117 (5) ◽  
pp. 503
Author(s):  
R. Ashok kumar ◽  
R. Muneeswaran ◽  
M. Saravana Mohan ◽  
Sathish Rengarajan ◽  
G.R. Raghav ◽  
...  
Keyword(s):  
Electrical Conductivity ◽  
Friction Stir Welding ◽  
Solid State ◽  
Frictional Heat ◽  
Wear Behaviour ◽  
Base Metals ◽  
High Electrical Conductivity ◽  
Wear Properties ◽  
Friction Stir ◽  
Tool Pin

In Friction Stir Welding (FSW) technique, hard rotating tool with specially profiled pin is plunged into base metals and traversed along the interface of the plates, generating the frictional heat and plasticizing the base metals. This leads to flow of materials and makes solid state joint. AA6101-T6 and AA1350 alloys are widely applied in electrical bus bars, because of their high electrical conductivity. In this present work, these two alloys are joined by varying the pin profile of the tools as circular, triangular, square and hexagonal. Of these four joints, the joint fabricated by circular pin profiled tool exhibits poor tensile and wear properties whereas hexagonal pin profiled tool exhibits better tensile and wear properties. This is due to the volume defects and grain refinement at stirred zone.

Effect of Friction Stir Welding Parameters on Thermal and Tensile Behavior of Aluminum Weldments Using Double Shoulder Tools

2012 ◽  
Vol 622-623 ◽  
pp. 323-329
Author(s):  
Ebtisam F. Abdel-Gwad ◽  
A. Shahenda ◽  
S. Soher
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Tensile Behavior ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Friction Stir ◽  
Aluminum Base ◽  
Tool Pin ◽  
Strength And Ductility

Friction stir welding (FSW) process is a solid state welding process in which the material being welded does not melt or recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters and tool pin profile play major roles in deciding the weld quality. In this investigation, an attempt has been made to understand effects of process parameters include rotation speeds, welding speeds, and pin diameters on al.uminum weldment using double shoulder tools. Thermal and tensile behavior responses were examined. In this direction temperatures distribution across the friction stir aluminum weldment were measured, besides tensile strength and ductility were recorded and evaluated compared with both single shoulder and aluminum base metal.

A Study on Friction Stir Welding Process for AA2219/AA2195 Joints

2018 ◽  
Vol 762 ◽  
pp. 339-342
Author(s):  
Ho Sung Lee ◽  
Koo Kil No ◽  
Joon Tae Yoo ◽  
Jong Hoon Yoon
Keyword(s):  
Friction Stir Welding ◽  
Welded Joints ◽  
Rotation Speed ◽  
Microstructural Analysis ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Manufacturing Cost ◽  
Significant Saving ◽  
Friction Stir ◽  
Rotation Direction

The object of this study was to study mechanical properties of friction stir welded joints of AA2219 and AA2195. AA2219 has been used as an aerospace materials for many years primarily due to its high weldability and high specific strength in addition to the excellent cryogenic property so to be successfully used for manufacturing of cryogenic fuel tank for space launcher. Relatively new Aluminum-Lithium alloy, AA2195 provides significant saving on weight and manufacturing cost with application of friction stir welding. Friction stir welding is a solid-state joining process, which use a spinning tool to produce frictional heat in the work piece. To investigate the effect of the rotation direction of the tool, the joining was performed by switching the positions of the two dissimilar alloys. The welding parameters include the travelling speed, rotation speed and rotation direction of the tool, and the experiment was conducted under the condition that the travelling speed of the tool was 120-300 mm/min and the rotation speed of the tool was 400-800 rpm. Tensile tests were conducted to study the strength of friction stir welded joints and microhardness were measured with microstructural analysis. The results indicate the failure occurred in the relatively weaker TMAZ/HAZ interface of AA2219. The optimum process condition was obtained at the rotation speed of 600-800 rpm and the travelling speed of 180-240 mm/min.

scholarly journals Innovate Method for Friction Stir Welding of Al-Mg-Si Alloy Thin Plate

2019 ◽  
Vol 269 ◽  
pp. 02006
Author(s):  
Li Fu ◽  
Fenjun Liu
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Base Metal ◽  
High Speed ◽  
Thick Plate ◽  
Welding Parameters ◽  
Butt Joints ◽  
Friction Stir ◽  
High Rotation Speed ◽  
Precipitated Phases

Al-Mg-Si (6061-T6) alloy with 0.8 mm thick plate was welded successfully by use of high speed friction stir welding (FSW) technology. The microstructural characteristics and mechanical property of the butt joints prepared by high speed FSW were analyzed in detail, the influence of welding parameters, fixture condition and after welding heat treatment were also explored. The results shown that sound surface topography and defect-free bonding interface were observed in the nugget zone (NZ). The microhardness of the as-welded joint was lower than that of the base metal because of the welding heat effect. Compared with the conventional speed FSW, the number of β-Mg2Si, Al2CuMg and Al8Fe2Si precipitated phases existed in the high speed FSWed NZ increased, which made the microhardness in the NZ improved significantly. The rod-shaped precipitates (Mg2Si) have the greatest influence on the microhardness distributions. The maximum tensile strength of 301.8 MPa, which was 85.8% of the base metal, was obtained at high rotation speed of 8000 rpm and fast welding speed of 1500 mm/min. The tensile strength of the ultra-high speed FSWed butt joints were improved significantly by post-weld artificial aging, with a maximum joint efficiency of 90.4%.

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