EXPERIMENTAL INVESTIGATION ON FRICTION STIR WELDING OF CRYOROLLED AA2219 ALUMINUM ALLOY JOINTS

2016 ◽  
Vol 24 (01) ◽  
pp. 1750001 ◽  
Author(s):  
K. KAMAL BABU ◽  
K. PANNEERSELVAM ◽  
P. SATHIYA ◽  
A. NOORUL HAQ ◽  
S. SUNDARRAJAN ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Corrosion Resistance ◽  
Friction Stir Welding ◽  
Base Material ◽  
Weld Nugget ◽  
Friction Stir ◽  
Temperature Operating ◽  
Aa2219 Aluminum Alloy ◽  
Large Clusters ◽  
Tool Pin

In this paper, experimental investigation on cryorolled aluminum AA2219-T87 plate by using friction stir welding (FSW) process is carried out. AA2219-T87 plates with a size of 200[Formula: see text]100[Formula: see text]22.4 mm were rolled and reduced to 12.2[Formula: see text]mm thickness (more than 45% of reduction in total thickness of the base material) at cryogenic temperature (operating temperature range [Formula: see text]90–[Formula: see text]30[Formula: see text]C). The cryorolled (CR) plates have reduced grain size, improved hardness and increased corrosion resistance property compared with the uncryorolled AA2219-T87 plates. FSW joints of cryorolled AA2219-T87 plates were prepared using cylindrical threaded FSW tool pin profile. Mechanical and metallurgical behaviors of friction stir welded joints were analyzed and the effects of the FSW process parameters are discussed in this paper. The variation of microhardness in the FSW joint regions were correlated with the microstructure of FSW joints. Cryorolled plate and FSW joints were tested for corrosion resistance using potentiodynamic polarization test. FSW joints shows better result during the corrosion resistance analysis compared to base AA2219-T87. The X-ray diffraction (XRD) test results showed that fine [Formula: see text]-Al grains with eutectic phase (Al2Cu) were present in the weld nugget (WN). The large clusters of strengthening precipitates were reduced in size and merged with the weld nugget portion.

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.

Behaviour of Threaded Cylinder Tool in the Friction Stir Welding of Al–ZrB2 Composite

2019 ◽  
Vol 16 (2) ◽  
pp. 719-724 ◽  
Author(s):  
P. Jayaseelan ◽  
T. V. Christy ◽  
Prabhu G. Rubesh ◽  
R. Srinivasan
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Tool Material ◽  
Hardness Test ◽  
Material Base ◽  
Matrix Composites ◽  
Friction Stir ◽  
Tool Pin ◽  
Aluminum Metal Matrix Composites ◽  
Solid State Joining

Friction Stir welding is a solid state joining process with no filler material. In this work, we specifically investigated the Tool Pin Profile, Tool Material, Base Material and the process parameters in the Aluminum metal matrix composites especially reinforced with Zirconium diboride (Al–ZrB2 . Tools of Various Materials and the corresponding tensile strength of the weld specimen, microstructure analysis and Hardness test are evaluated. Threaded Cylinder made of various materials are OHNS, HCHCr, H13 tools are carried out in the process with D/d Ratio are used. The result will be stated with the Threaded Cylinder pin with which tool material provides highest strength to the Bas material.

Microstructural Characterization and Mechanical Properties in Friction Stir Welding of AA6061 and AA6101 Aluminum Alloys

2021 ◽  
Vol 40 ◽  
pp. 1-11
Author(s):  
Gagandeep Singh ◽  
Khushdeep Goyal ◽  
Baljinder Ram ◽  
Bal Krishan
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Welding Process ◽  
Microstructural Characterization ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Fine Grain ◽  
Metal Plates ◽  
Frictional Forces ◽  
Tool Pin

In this research paper, two different metal plates of aluminum alloy viz. AA6061 and AA6101 were welded with friction stir welding process. Round tool and square tool pin profiles were used to weld the alloys. Weld microstructures, hardness, and tensile properties were evaluated in as-welded condition. The tensile strength of the joints fabricated with round tool pin profile were lower than the square tool pin profile because of the pulsating effect, in square tool pin profile this effect was produced along with the higher frictional forces. The micro-hardness of friction stir zone was higher than the base material due to active recrystallization occurrence which resulted in fine grain size in case of weld joint with round pin profile. Microstructure indicated uniformly distribution of materials with minimum heat affected zone and dense welded zone without any defects.

scholarly journals Optimization of friction stir welding parameters for improved corrosion resistance of AA2219 aluminum alloy joints

2015 ◽  
Vol 11 (4) ◽  
pp. 330-337 ◽  
Author(s):  
G. Rambabu ◽  
D. Balaji Naik ◽  
C.H. Venkata Rao ◽  
K. Srinivasa Rao ◽  
G. Madhusudan Reddy
Keyword(s):  
Corrosion Resistance ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Aa2219 Aluminum Alloy

scholarly journals Analysis of Tools used in Friction Stir Welding process

2018 ◽  
Vol 8 (6) ◽  
Author(s):  
Akshansh Mishra ◽  
Adarsh Tiwari ◽  
Mayank Kumar Shukla ◽  
A. Razal Rose
Keyword(s):  
Friction Stir Welding ◽  
Critical Role ◽  
Base Material ◽  
Welding Process ◽  
Tool Geometry ◽  
Work Piece ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Pin ◽  
Joining Process

A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminium alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material. The tool geometry plays a critical role in material flow and governs the transverse rate at which FSW can be conducted. The tool serves three primary functions, i.e., (a) heating of the work piece, (b) movement of material to produce the joint, and (c) containment of the hot metal beneath the tool shoulder. Heating is created within the work piece by friction between both the rotating tool pin and shoulder and by severe plastic deformation of the work.

Experimental Investigation on the Impact of the Tool Material & Geometry in Joining of Al 63400 Alloy Using Friction Stir Welding Process

2014 ◽  
Vol 592-594 ◽  
pp. 312-315 ◽  
Author(s):  
P. Sevvel ◽  
V. Jaiganesh
Keyword(s):  
Experimental Investigation ◽  
High Carbon Steel ◽  
Base Material ◽  
Welding Process ◽  
Tool Material ◽  
Tool Geometry ◽  
Flat Plates ◽  
Friction Stir ◽  
Tool Pin ◽  
The Impact

In this paper, a detailed experimental investigation was carried on the impact of the effects of tool pin and shoulder diameter in joining the Al 63400 aluminium alloy using FSW process. Flat plates of 6 mm thickness have been selected as the base material for obtaining single butt welded joints. The tool materials used for joining these base material plates are High Speed Steel (HSS) and High Chromium High Carbon Steel (HCHCr). This paper experimentally investigates and suggests the appropriate, suitable tool material & tool geometry for producing good quality welds in joining of Al 63400 alloy using FSW process.

Multi sensor based strategies for accurate prediction of friction stir welding of polycarbonate sheets

2020 ◽  
pp. 095440622096077
Author(s):  
Santosh K Sahu ◽  
Debasish Mishra ◽  
Kamal Pal ◽  
Surjya K Pal
Keyword(s):  
Experimental Investigation ◽  
Friction Stir Welding ◽  
Process Monitoring ◽  
High Performance ◽  
Joint Strength ◽  
Welding Process ◽  
Traverse Speed ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

High performance thermoplastic is often used in automotive and aerospace sectors. Friction stir welding (FSW) has been a suitable method for joining these thermoplastic materials. However, the process characteristics vary dynamically, even at same parametric conditions due to process disturbances. While quite a few studies have been reported in experimental investigation, the usage of sensors for the process monitoring during welding has not been explored. Therefore, the present paper focuses on various sensor-based approaches on process monitoring. The study includes an in-depth experimental investigation for joining of polycarbonate sheets using full factorial design of experiments. Three different tool pin profiles like cylindrical, square and triangular have been selected, whereas tool rotational speed and traverse speed are considered as primary process variables. Various statistical time domain features of the force and torque signals starting from average, its deviation and root mean square as well as thermal cycle based weld peak temperature and its cooling rate were found to have a strong correlation with weld bead profile. The axial force and thermal cycles were found to be the major indicators of joint strength efficiency rather than torque as per regression models developed by using response surface methodology. Finally, an attempt has been made for improving the joint strength predictability by using various sensor-based approaches. This work can be used potentially to real time welding process monitoring in industrial sectors.

CORROSION PROPERTIES OF CRYOROLLED AA2219 FRICTION STIR WELDED JOINTS USING DIFFERENT TOOL PIN PROFILES

2018 ◽  
Vol 25 (03) ◽  
pp. 1850071 ◽  
Author(s):  
K. KAMAL BABU ◽  
K. PANNEERSELVAM ◽  
P. SATHIYA ◽  
A. NOORUL HAQ ◽  
S. SUNDARRAJAN ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
Corrosion Behavior ◽  
Welded Joints ◽  
Weld Nugget ◽  
Corrosion Properties ◽  
X Ray ◽  
Friction Stir ◽  
Transmission Electron ◽  
Aa2219 Alloy ◽  
Tool Pin

The purpose of this paper is to present the corrosion behavior of the Cryorolled (CR) material and its Friction Stir Welded joints. Due to the thermal cycles of Friction Stir Welding (FSW) process, the corrosion behavior of the material gets affected. Here, the cryorolling process was carried out on AA2219 alloy and CR material was joined by FSW process using four different pin tool profiles such as cylindrical, threaded cylindrical, square and hexagonal pin. The FSW joints were analyzed by corrosion resistance with the help of potentiodynamic polarization test with 3.5% NaCl solution. From the analysis, it is found that CR AA2219 material exhibits good corrosion resistance compared to the base AA2219 material, and also a hexagonal pin profile FSW joint exhibits high corrosion resistance. Among the weld joints created by four different tools, the lowest corrosion resistance was found in the cylindrical pin tool FSW welds. Further, the corroded samples were investigated through metallurgical investigations like OM, Transmission Electron Microscopy (TEM), Energy-Dispersive X-ray Spectroscopy (EDX) and X-Ray Diffraction (XRD). It was found that the amount of dissolution of Al2Cu precipitate was present in the weld nugget. The amount of dissolution of Al2Cu precipitate is higher in the weld nugget produced by hexagonal pin tool. This is due to the enhancement of the corrosion resistance.

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.

Localized Corrosion Resistance of Dissimilar Aluminum Alloys Joined by Friction Stir Welding (FSW)

2016 ◽  
Vol 710 ◽  
pp. 41-46 ◽  
Author(s):  
Aline F.S. Bugarin ◽  
Fernanda Martins Queiroz ◽  
Maysa Terada ◽  
Hercílio G. De Melo ◽  
Isolda Costa
Keyword(s):  
Corrosion Resistance ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Weight Ratio ◽  
Base Material ◽  
High Strength ◽  
Localized Corrosion ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

2XXX and 7XXX high strength aluminum alloys are the most used materials for structural parts of aircrafts due to their high strength/weight ratio. Their joining procedure is an engineering challenge since they present low weldability. Friction Stir Welding (FSW) is a joining technology developed in the early 90 ́s. It is a solid-state welding process, without the use of fillers or gas shield, that eliminates conventional welding defects and has been considered of great interest for application in the aircraft industry. FSW of aluminum alloys results in four regions of different microstructures, specifically: the base material (BM), the heat affected zone (HAZ), the thermo-mechanically affected zone (TMAZ), and the nugget zone (NZ). The complex microstructure of the weld region leads to higher susceptibility to localized corrosion as compared to the BM even when similar alloys are joined. The welding of dissimilar alloys in its turn results in even more complex microstructures as materials with intrinsically different composition, microstructures and electrochemical properties are put in close contact. Despite the great interest in FSW, up to now, only few corrosion studies have been carried out for characterization of the corrosion resistance of dissimilar Al alloys welded by FSW. The aim of this study is to investigate the corrosion behavior of aluminum alloy 2024-T3 (AA2024-T3) welded to aluminum alloy 7475-T761 (AA7475-T761) by FSW. The evaluation was performed in 0.01 mol.L-1 by means of open circuit potential measurements, polarization techniques and surface observation after corrosion tests.

Sign in / Sign up

Export Citation Format

Share Document