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.

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 Experimental Investigation of Friction stir Welding Using Hybrid Alloys : A Review

2021 ◽  
pp. 308-313
Author(s):  
A. J Amroliya ◽  
Dr. D. B Jani ◽  
Dr. R. K Shukla
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Dissimilar Metals ◽  
Research Personnel ◽  
Friction Stir ◽  
Vertical Milling ◽  
Working Parameters ◽  
Fsw Parameters ◽  
Tool Pin ◽  
Solid State Joining

Friction stir welding is a solid state joining process which is used to join metals and alloys having low weldability .Study about the effect of FSW parameters like tool rpm, tool transverse speed and tool pin profile. A vertical milling head is used to produce FSW joints. In this study, solid state joining technology of friction stir welding (FSW) was carried out for Al and Mg butt joints and other dissimilar metals. This review article thoroughly highlights the influence of FSW working parameters on microstructure, mechanical properties. This effort not only sets eminent outcomes of the preceding research personnel but also proposes forthcoming guidelines for FSW of dissimilar metals.

scholarly journals Combined Response Surface Method and Modified Differential Evolution for Parameter Optimization of Friction Stir Welding

Processes ◽  
2020 ◽  
Vol 8 (9) ◽  
pp. 1080
Author(s):  
Thanatkij Srichok ◽  
Rapeepan Pitakaso ◽  
Kanchana Sethanan ◽  
Worapot Sirirak ◽  
Parama Kwangmuang
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Differential Evolution ◽  
Welding Speed ◽  
Tool Material ◽  
Optimal Parameters ◽  
Friction Stir ◽  
Surface Method ◽  
Tool Pin

In this study, we constructed a new algorithm to determine the optimal parameters for friction stir welding including rotational speed, welding speed, axial force, tool pin profile, and tool material. The objective of welding is to maximize the ultimate tensile strength of the welded aluminum. The proposed method combines the response surface method and the modified differential evolution algorithm (RSM-MDE). RSM-MDE is a method that involves both experimental and simulation procedures. It is composed of four steps: (1) finding the number of parameters and their levels that affect the efficiency of the friction stir welding, (2) using RSM to formulate the regression model, (3) using the MDE algorithm to find the optimal parameter of the regression model obtained from (2), and (4) verifying the results obtained from step (3). The optimal parameters generated by the RSM-MDE method were a rotation speed of 1417.68 rpm, a welding speed of 60.21 mm/min, an axial force of 8.44 kN, a hexagon-tapered tool pin profile, and the SKD 11 tool material. The ultimate tensile strength obtained from this set of parameters was 294.84 MPa, which was better than that of the RSM by 1.48%.

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 Friction stir welding of new electronic packaging materials SiCp/Al composite with T-joint

2018 ◽  
Vol 38 (3) ◽  
pp. 352-359
Author(s):  
Zeng Gao ◽  
Jianguang Feng ◽  
Huanyu Yang ◽  
Jukka Pakkanen ◽  
Jitai Niu
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Welding Process ◽  
Experimental Results ◽  
Homogeneous Distribution ◽  
Welding Parameters ◽  
Matrix Composites ◽  
Friction Stir ◽  
Lower Temperature ◽  
Gas Tightness

Using friction stir welding, the electronic container box and lid made from aluminium matrix composites with reinforcement of SiC particle (15 vol% SiCp/Al-MMCs) was welded successfully with T-joint. The temperature distribution of box during the process, mechanical property and microstructure of the joint as well as gas tightness of welded box was investigated. The experimental results indicated that the satisfactory T-joint can be obtained under appropriate friction stir welding parameters. During the welding process, the bottom center, which was used to place the electronic component, reached a quite lower temperature of 100°C. That can ensure safety of components in the box. After the welding process, the microstructure in stir zone was better than in base material due to the refining and homogeneous distribution of the SiC particles. The experimental results showed that the electronic container box after friction stir welding had gas tightness. The He-leakage rate was under 10-8 Pa•m3/s.

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.

scholarly journals ANALYTICAL AND NUMERICAL THERMAL ANALYSIS ON FRICTION STIR WELDING USING POLYGONAL TOOL PIN

2021 ◽  
Vol 22 (2) ◽  
pp. 352-363
Author(s):  
Stephen Leon Joseph Leon ◽  
Alfred Franklin Varghese ◽  
Joseph Michel ◽  
Gopinath Gunasekaran
Keyword(s):  
Friction Stir Welding ◽  
Weld Line ◽  
Peak Temperature ◽  
Frictional Heat ◽  
Friction Stir ◽  
Proposed Model ◽  
Pin Geometry ◽  
Transient Thermal ◽  
Tool Pin ◽  
Solid State Joining

Frictional heat generation in the tool/matrix interface followed by the stirring of material along the weld line causes plasticized solid state joining in friction stir welding. In this paper, the existing torque based thermo-mechanical model for the tools with cylindrical pins is remodified for the polygonal tool pin profile by introducing novel multiplication factors with respect to the number of sides in the tool pin geometry. The variation in the effective heat supply with respect to the chosen pin geometry was analyzed. A comparative analysis of the proposed analytical model with the existing model was also carried out to understand the accuracy of the proposed model.  Furthermore, a transient thermal numerical modelling was carried out in the view of understanding the change in process peak temperature in the stir zone and change in temperature gradient along the heat affected zone with respect to the change in pin geometry for the opted set of process input parameters. An analytically estimated heat-input-based numerical model was adopted in the present study. It was observed that the process peak temperature was directly proportional to the number of sides in the tool pin. ABSTRAK: Penjanaan haba geseran antara muka pada alat/matrik diikuti dengan pengacauan material sepanjang garis kimpalan menyebabkan keadaan plastik pepejal melekat bersama geseran kimpalan pengacau. Kajian ini berkaitan tork sedia ada berdasarkan model mekanikal-terma bagi alat pin silinder yang terubah suai bagi profil pin alat poligon dengan memperkenalkan faktor gandaan berdasarkan bilangan sisi geometri alat pin. Perubahan pada bekalan haba efektif berdasarkan geometri pin pilihan telah dikaji. Analisis bandingan pada model analitik yang dicadang bersama model sedia ada, telah dilakukan bagi memahami ketepatan model cadangan. Tambahan, model transien numerikal terma telah dibuat bagi memahami proses perubahan suhu puncak ketika zon pengacauan dan perubahan gradien suhu sepanjang zon terkena haba perubahan geometri pin pada set proses parameter input terpilih. Kajian ini mengaplikasi model numerik berdasarkan input anggaran haba secara analitik. Dapatan kajian menunjukkan suhu puncak proses adalah berkadar langsung dengan bilangan sisi pin alat.

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.

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.

Sign in / Sign up

Export Citation Format

Share Document