Effects of process parameters on the lap joint strength and morphology in friction stir spot welding of ABS sheets

2020 ◽  
pp. 009524432096152
Author(s):  
Asil Ayaz ◽  
Aydin Ülker
Keyword(s):  
Spot Welding ◽  
Dwell Time ◽  
Joint Strength ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Shear Load ◽  
Lap Joint ◽  
Friction Stir ◽  
Joint Shear ◽  
Tool Rotation

In this study, a new method was proposed to reduce the keyhole volume with friction stir spot welding process and improve the lap joint shear load-carrying capacity of the weld by analyzing the effects of tool rotation speed, plunge depth and dwell time on the weld. Single lap shear tests were carried out to determine the influences of the welding parameters on the mechanical behavior of the welds. The quality of the joint was evaluated by examining the characteristics of the joint as a result of the lap joint shear load. For friction stir spot welding of the acrylonitrile butadiene styrene samples, the experiments were designed according to Taguchi’s L9 orthogonal array in a randomized way. From the analysis of variance and the signal-to-noise ratio, the significant parameters and the optimum combination level of the parameters were obtained. It was found that using a tool rotation of 1000 rpm, plunge depth 11.5 mm and dwell time of 40 s, an improved joint strength can be obtained. The results showed that joint strength was improved by an amount of 20% as compared with the optimum welding parameters to the initial welding parameters. Macrostructure examination plays an important role to determine the joint strength and evaluate the influences of each welding parameters. So, weld morphology was investigated by morphological analysis and visual comparisons. It was also observed failure modes for fractured samples having the highest, moderate and lowest lap joint shear load.

Joint strength optimization and morphological analysis for friction stir spot welding of the dissimilar thermoplastics ABS and PC

2020 ◽  
Vol 62 (11) ◽  
pp. 1109-1117
Author(s):  
Aydın Ülker ◽  
Asil Ayaz
Keyword(s):  
Spot Welding ◽  
Morphological Analysis ◽  
Acrylonitrile Butadiene Styrene ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Shear Load ◽  
Lap Joint ◽  
Friction Stir ◽  
Joint Shear ◽  
Butadiene Styrene

Abstract The present study aims to investigate the feasibility of friction stir spot welding two dissimilar polymers, acrylonitrile butadiene styrene and polycarbonate. Welding parameters are effective on lap joint shear load. This study also investigated the influences of welding parameters such as rotational speed, plunge depth, and dwell time on the joint morphology and mechanical characterization. In addition, a common problem in friction stir spot welding is the forming of characteristic keyholes in the joint,s a problem that has an important effect on mechanical test results. For this reason, a polycarbonate filler sheet was used to improve the lap joint shear load by reducing the size of the keyhole in this study. The quality of the welded specimens was examined after lap joint shear tests. Experiments were carried out according to Taguchi L9 orthogonal array using a randomized approach for arranging optimum welding parameters. Signal-to-noise ratio and the analysis of variance were used to determine the influences of each process parameter on the lap joint shear load. Results indicated that the friction stir spot welding of acrylonitrile butadiene styrene with polycarbonate is feasible and welding parameters significantly affected joint quality. From the experiments, a 57 % improvement was achieved in the lap joint shear load from the initial welding parameters to the optimal welding parameters. Furthermore, weld morphology was investigated by morphological analysis and visual comparisons. Finally, the failure modes of the fractured samples were observed and classified for highest, moderate, and lowest lap joint shear loads.

Effects of High Speed Tool Rotation in Micro Friction Stir Spot Welding of Aluminum A1100

2014 ◽  
Vol 493 ◽  
pp. 739-742 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
Suwarsono ◽  
Gandjar Kiswanto ◽  
Winarto
Keyword(s):  
Shear Strength ◽  
Spot Welding ◽  
High Speed ◽  
Tool Material ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Processes ◽  
Tool Rotation

Technology of Friction Stir Welding (FSW) is a relatively new technique for joining metal. In some cases on Aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and less distortion. The purpose of this study is to analyze the parameters effect of high speed tool rotation onmicro Friction Stir Spot Welding(μFSSW) to theshear strengthof welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. The spindle speed was fixed at 30000 rpm. Tool shoulder diameter was 3 mm, and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of pin diameter (1.5 mm, 2.0 mm, and 2.5 mm), a variable ofplunge speed(2 mm/min, 4 mm/min, 6 mm/min), and the variable ofdwell time(2 seconds, 4 seconds, 6 seconds). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was theshear strength.Response Surface Methods(RSM) was used to analyze μFSSW parameters with theshear strengthof welds. From the result of experiment and analysis, it is shown that the important welding parameters in high speed μFSSW process are pin diameter and plunge speed.

Effect of Welding Parameters on Temperature Distribution During Friction Stir Spot Welding of Commercial Pure Copper Lap Joint

2018 ◽  
Author(s):  
Ahmed Mahgoub ◽  
Abdelaziz Bazoune ◽  
Fadi Al-Badour ◽  
Necar Merah ◽  
Abdelrahman Shuaib
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Pure Copper ◽  
Friction Stir Spot Welding ◽  
Temperature History ◽  
Welding Parameters ◽  
Deformation Model ◽  
Friction Stir ◽  
Good Agreement

In this paper, a Coupled Eulerian Lagrangian (CEL) finite element model (FEM) was developed to simulate the friction stir spot welding (FSSW) of commercial pure copper. Through simulations results, the paper presents and discusses the effect of FSSW process parameters; namely rotational speed, plunging rate and dwell time, on the developed temperatures and their distribution within the workpiece as well as material flow and deformation. Model validation showed a good agreement between predicted temperature history and the experiment one, with a maximum error of 6%. Furthermore, the predicted formation of flash was also found in good agreement with the experiment with an error of only 7%. Simulation results predicted peak temperature and plastic strain among all studied welding conditions were 920 K and 3.5 respectively at 1200 rpm rotational speed, 20 mm/min plunging rate and 4 seconds dwell time, which is approximately 70% of the melting point of pure copper.

scholarly journals Effect of Zn Interlayer Particles on Mechanical Properties and Microstructure of Friction Stir Spot Welding Aluminum Alloy

2018 ◽  
Vol 218 ◽  
pp. 04005
Author(s):  
Lingga Arti Saputra ◽  
Nurul Muhayat ◽  
Triyono
Keyword(s):  
Mechanical Properties ◽  
Spot Welding ◽  
Dwell Time ◽  
Aluminum Matrix ◽  
Friction Stir Spot Welding ◽  
Motor Vehicles ◽  
Shear Load ◽  
Tensile Shear ◽  
Friction Stir ◽  
Spot Welded

Global warming can be reduced by controlling emissions in motor vehicles. Lightweight aluminum materials can lower the engine work so as to reduce fuel consumption.The effect of dwell time on mechanical properties and microstructure friction stir spot welded AA1100 with particle interlayer Zn were investigated. The result shows that the particle interlayer Zn affect to the mechanical properties. The tensile shear load friction stir spot welded AA1100 with particle interlayer Zn is higher than hart of without particle interlayer Zn. In line with tensile shear load that the hardness of friction stir spot welded Al with particle interlayer Zn got the higher hardness than of without particle interlayer Zn. The addition of particle interlayer Zn reduce the hook defect and spread in the aluminum matrix as solid solution.

scholarly journals Investigasi dan Optimasi Parameter Proses Micro Friction Stir Spot Welding Material A1100/Cu1100P Menggunakan Metode Taguchi

2019 ◽  
Vol 3 (2) ◽  
pp. 59
Author(s):  
Pathya Rupajati ◽  
Pathya Rupajati
Keyword(s):  
Friction Stir Welding ◽  
Intermetallic Compound ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Shear Load ◽  
Tool Rotational Speed ◽  
Tensile Shear ◽  
Plunge Depth ◽  
Friction Stir

Abstrak  Salah satu karakteristik sifat mekanis yang penting untuk dianalisis adalah tensile shear load. Penelitian ini bertujuan untuk melakukan optimasi tensile shear load hasil pengelasan micro friction stir welding (µFSSW) pada material AA1100 dan Cu1100P menggunakan metode Taguchi. Rancangan percobaan yang digunakan dalam penelitian ini adalah matriks orthogonal array L8 dengan memvariasikan parameter proses pengelasan yaitu dwell time dan plunge depth yang memiliki masing-masing empat level dan dua level. Sedangkan variabel konstan yang digunakan adalah tool rotational speed sebesar 33.000 rpm. Hasil penelitian menunjukkan bahwa parameter pengelasan yang memiliki kontribusi terbesar dalam meningkatkan tensile shear load hasil pengelasan micro friction stir spot welding adalah dwell time, yang menghasilkan tensile shear load sebesar 265,12 N dengan seting kombinasi dwell time pada 5 s dan plunge depth pada 0,7 mm. Hasil struktur mikro juga menunjukkan terlihat adanya flash dan hook defect, tetapi tidak menujukkan adanya intermetallic compound dan crack. Kata kunci: A1100, µFSSW, Taguchi, Dwell time, Plunge Depth

Effect of Welding Conditions on Sheets’ Interface Properties in Friction Stir Spot Welding of Copper

2019 ◽  
Author(s):  
Ahmed Mahgoub ◽  
Neçar Merah ◽  
Abdelaziz Bazoune
Keyword(s):  
Surface Morphology ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Tensile Failure ◽  
Welding Parameters ◽  
Welding Condition ◽  
Friction Stir ◽  
Joint Fracture

Abstract Friction Stir Spot Welding (FSSW) is a solid-state joining technique widely applied to high conductive metals. In this paper, the effects of FSSW parameters, namely, rotational speed (N), plunging rate (V) and dwell time (DT) on the joint fracture mode and fractured surface morphology were investigated using scanning electron microscopy (SEM). The effect of the abovementioned welding parameters on the microhardness profile along the sheets’ interface was also investigated to gain insight into the strength of the joint and the width of the bonding ligament. Two conditions were considered for each parameter 1200 rpm and 900 rpm for N, 60 mm/min and 20 mm/min for V, 4 and 2 seconds for DT. The welding condition 1200 rpm rotational speed, 20 mm/min plunging rate and 2 seconds dwell time showed a wider bonding ligament, relatively higher elongation, higher tensile failure load, and greater microhardness on the sheets’ interface. Dimple surface morphology (DSM) with regular dimples along the stir zone was also observed at the abovementioned set of process parameters.

scholarly journals EFFECT OF ROTATIONAL SPEED AND DWELL TIME ON PHYSICAL AND MECHANICAL PROPERTIES OF FRICTION STIR SPOT WELDING ALUMINIUM 1100 WITH ZN POWDER INTERLAYER ADDITION

2019 ◽  
Vol 18 (1) ◽  
Author(s):  
Aditya Noor ◽  
Nurul Muhayat ◽  
. Triyono
Keyword(s):  
Mechanical Properties ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Physical And Mechanical Properties ◽  
Friction Stir Spot Welding ◽  
Shear Load ◽  
Tensile Shear ◽  
Lightweight Materials ◽  
Friction Stir

<p><em>Friction stir spot welding (FSSW) is one of the development of solid state welding to joint lightweight materials such as aluminium. In the automotive industry, lightweight materials are needed in the structure of vehicle construction to improve efficiency in vehicles. This research aims to find out how the effect of rotational speed and dwell time on physical and mechanical properties on the weld joint of aluminium 1100 with Zn interlayer addition. Variations used in rotational speed 1000, 1250, 1600 rpm and dwell time 6, 7, 8 s. Pullout fracture occur in tensile tests that are getting bigger with increasing rotational speed and dwell time. The results of SEM and EDS observations showed that the metallurgical bonded zone increased and kept the hook defect away. The spread of Zn in the stir zone area causes the formation of solid Al-Zn phase in a solid solution. The hook defect filled with Zn can minimize cracks that occur, so increased the tensile shear load. The highest tensile shear load value of FSSW AA1100 without Zn interlayer is 3.61 kN, while the FSSW AA1100 with Zn interlayer addition is 4.34 kN.</em></p>

Effect of Welding Parameters on the Mechanical and Metallurgical Properties of Friction Stir Spot Welding of Copper Lap Joint

2018 ◽  
Vol 44 (2) ◽  
pp. 1283-1292 ◽  
Author(s):  
Ahmed Mahgoub ◽  
Abdelaziz Bazoune ◽  
Neçar Merah ◽  
Fadi Al-Badour ◽  
Adelrahman Shuaib
Keyword(s):  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Lap Joint ◽  
Friction Stir ◽  
Metallurgical Properties

Experimental Study and Numerical Modeling of Friction Stir Spot Welding of Pure Copper Lap Joint

2014 ◽  
Author(s):  
Ahmed Kamal Mahgoub ◽  
Abdelaziz Bazoune ◽  
Fadi A. A. Al-Badour ◽  
Abdelrahman Shuaib ◽  
Gihad Mohamed Karrar
Keyword(s):  
Experimental Study ◽  
Spot Welding ◽  
Dwell Time ◽  
Pure Copper ◽  
Friction Stir Spot Welding ◽  
Fusion Welding ◽  
Weld Strength ◽  
Tool Rotational Speed ◽  
Lap Joint ◽  
Friction Stir

Friction stir spot welding (FSSW) is an appropriate process to join materials that are difficult to weld using fusion welding, such as copper. In this paper, an experimental study to weld lap joint of pure copper plates having a dimensions of 100 × 30 × 2 mm is performed, successful spot weld is obtained at tool rotational speed of 1200 rpm, feed rate of 20 mm/min for dwell time of 2 seconds. The tool used in the FSSW has a threaded pin of 5 mm diameter, length of 3.7 mm, and a scrolled shoulder of 11.52 mm diameter. Tensile test and microhardness were performed for the joint and it showed reasonable weld strength. In addition, a numerical model was developed, and the estimated temperatures as well as weld macrostructure matched very well with experimental results.

Sign in / Sign up

Export Citation Format

Share Document