Effect of plasma preheating on weld quality and tool life during friction stir welding of DH36 steel

2021 ◽  
pp. 095440542199013
Author(s):  
Avinish Tiwari ◽  
Pardeep Pankaj ◽  
Saurav Suman ◽  
Piyush Singh ◽  
Pankaj Biswas ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Tool Life ◽  
Force Measurement ◽  
Deep Understanding ◽  
High Strength ◽  
Microstructural Characterization ◽  
Stir Zone ◽  
Friction Stir ◽  
Allotriomorphic Ferrite ◽  
Fsw Parameters

Friction stir welding (FSW) of high strength materials is challenging due to high tool cost and low tool life. To address this issue, the present investigation deals with an alternative of plasma-assisted friction stir welding (PFSW) of DH36 steel with WC-10%Co tool. Plasma preheating current (13 A, 15 A, and 17 A) was varied by keeping other FSW parameters as constant. During the FSW and PFSW process, force measurement and thermal history aided in a deep understanding of the process, tool degradation mechanisms, accompanied by the mechanical and microstructural characterization of the welded joints. The stir zone hardness was increased from 140 HV0.5 to about 267 HV0.5. The yield and tensile strength of weld increased from 385 MPa and 514 MPa to about 391 MPa and 539 MPa, respectively. Weld joint elongation (%) was increased from ~10% of weld 1 to ~13.89% of weld 4. During PFSW, the process temperature was increased, the cooling rate was lowered, and the weld bead was widened. The results also revealed that the plasma-assisted weld resulted in polygonal ([Formula: see text]) and allotriomorphic ferrite as the major constituents in the stir zone. Pearlite dissolution and spheroidization were observed in the ICHAZ and SCHAZ, respectively. Additionally, the plasma preheating reduced the tungsten tool’s wear by 58% compared to FSW.

Mechanical and Corrosion Behavior of Friction Stir Welded AA 6063 Alloy

2022 ◽  
pp. 206-214
Author(s):  
Radha R. ◽  
Sreekanth D. ◽  
Tushar Bohra ◽  
Surya Bhan Pratap Singh
Keyword(s):  
Friction Stir Welding ◽  
High Strength ◽  
Metallic Alloys ◽  
Fusion Welding ◽  
Corrosion Properties ◽  
Microstructural Refinement ◽  
Significant Development ◽  
Friction Stir ◽  
Mechanical And Corrosion Properties ◽  
Fsw Parameters

Friction stir welding (FSW) is considered to be the most significant development in solid state metal joining processes. This joining technique is energy efficient, environmentally friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. The project aims to join Aluminum 6063 alloy plates by FSW and emphasize the (1) mechanisms responsible for the formation of welds without any defects, microstructural refinement, and (2) effects of FSW parameters on resultant microstructure, mechanical, and corrosion properties.

scholarly journals Research on the Friction Stir Welding of Sc-Modified AA2519 Extrusion

Metals ◽  
2019 ◽  
Vol 9 (10) ◽  
pp. 1024 ◽  
Author(s):  
Robert Kosturek ◽  
Lucjan Śnieżek ◽  
Janusz Torzewski ◽  
Marcin Wachowski
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Base Material ◽  
Stir Zone ◽  
Welding Parameters ◽  
Friction Stir ◽  
Treated Condition ◽  
Heat Treated ◽  
Heat Treated Condition ◽  
Fsw Parameters

The aim of this research was to investigate the effect of friction stir welding (FSW) parameters on microstructure and mechanical properties of Sc-modified AA2519 extrusion joints. The workpiece was welded by FSW in non-heat-treated condition with seven different sets of welding parameters. For each obtained joint macrostructure and microstructure observations were performed. Mechanical properties of joints were investigated using tensile test together with localization of fracture location. Joint efficiencies were established by comparing measured joints tensile strength to the value for base material. The obtained results show that investigated FSW joints of Sc-modified AA2519 in the non-heat-treated condition have joint efficiency within the range 87–95%. In the joints obtained with the lowest ratio of the tool rotation speed to the tool traverse speed, the occurrence of imperfections (voids) localized in the stir zone was reported. Three selected samples were subjected to further investigations consisting microhardness distribution and scanning electron microscopy fractography analysis. As the result of dynamic recrystallization, the microhardness of the base material value of 86 HV0.1 increased to about 110–125 HV0.1 in the stir zone depending on the used welding parameters. Due to lack of the strengthening phase and low strain hardening of used alloy the lack of a significantly softened zone was reported by both microhardness analysis and investigation of the fractured samples.

Effect of Shoulder Diameter on the Resulting Interfacial Regions of Friction Stir Welds between Aluminium and Copper

2011 ◽  
Vol 299-300 ◽  
pp. 1146-1150
Author(s):  
Esther Titilayo Akinlabi ◽  
Stephen Akinlabi
Keyword(s):  
Friction Stir Welding ◽  
Feed Rate ◽  
Rotational Speed ◽  
Force Feedback ◽  
Welding Process ◽  
Microstructural Characterization ◽  
Stir Zone ◽  
Vertical Force ◽  
Friction Stir ◽  
Shoulder Diameter

This paper reports the effect of shoulder diameter on the resulting interfacial regions of joints between aluminium and copper produced by the friction stir welding process. The welds were produced using three shoulder diameter tools, viz; 15, 18 and 25 mm. This paper focuses on welds produced at a constant rotational speed of 600 rpm and feed rate of 50 mm/min varying the shoulder diameters. Analysis of the force feedback revealed that the advancing force, the downward vertical force and the torque increases as the shoulder diameter increases. Microstructural characterization was conducted on the joint interfaces and it was observed that the widths of the interfacial regions comprising of the Stir Zone and the Thermo – Mechanically Affected Zone (TMAZ) increases as the shoulder size increases.

Microstructural Characterization and Mechanical Properties in Friction Stir Welding of Aa7075 Aluminium Alloy

2012 ◽  
Vol 622-623 ◽  
pp. 330-334 ◽  
Author(s):  
G. Elatharasan ◽  
V.S. Senthil Kumar
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Welding Speed ◽  
Mechanical Response ◽  
Weight Ratio ◽  
High Strength ◽  
Microstructural Characterization ◽  
Optical Microscope ◽  
Heterogeneous Distribution ◽  
Friction Stir

The heat treatable aluminium alloy AA7075 is used extensively in the aircraft industry because of its high strength to weight ratio and good ductility. In this present study the effect of process parameters on the mechanical and micro-structural properties of AA 7075 joints produced by friction stir welding was analyzed. The two sheets, aligned with perpendicular rolling directions, have been welded successively. The welded sheets have been tested under tension at room temperature in order to analyze the mechanical response with respect to the parent materials. Effects of welding speed and fixed location of base metals on microstructures, hardness distributions, and tensile properties of the welded joints were investigated. Optical microscope and SEM analysis revealed that the stir zone contains a mixed structure and onion ring pattern with a periodic change of grain size as well as a heterogeneous distribution of alloying elements. The maximum tensile strength was achieved for the joint produced at rotation speed of 800rpm and a welding speed of 20 mm/s.

Study of the Key Issues of Friction Stir Welding of Titanium Alloy

2010 ◽  
Vol 638-642 ◽  
pp. 1185-1190 ◽  
Author(s):  
Hui Jie Liu ◽  
Li Zhou ◽  
Yong Xian Huang ◽  
Qi Wei Liu
Keyword(s):  
Titanium Alloy ◽  
Friction Stir Welding ◽  
Melting Point ◽  
Titanium Alloys ◽  
Welding Process ◽  
High Strength ◽  
Liquid Cooling ◽  
Friction Stir ◽  
Key Issues ◽  
Aluminum And Magnesium Alloys

As a new solid-state welding process, friction stir welding (FSW) has been successfully used for joining low melting point materials such as aluminum and magnesium alloys, but the FSW of high melting point materials such as steels and titanium alloys is still difficult to carry out because of their strict requirements for the FSW tool. Especially for the FSW of titanium alloys, some key technological issues need to solve further. In order to accomplish the FSW of titanium alloys, a specially designed tool system was made. The system was composed of W-Re pin tool, liquid cooling holder and shielding gas shroud. Prior to FSW, the Ti-6Al-4V alloy plates were thermo-hydrogen processed to reduce the deformation resistance and tool wear during the FSW. Based on this, the thermo-hydrogen processed Ti-6Al-4V alloy with different hydrogen content was friction stir welded, and the microstructural characterizations and mechanical properties of the joints were studied. Experimental results showed that the designed tool system can fulfill the requirements of the FSW of titanium alloys, and excellent weld formation and high-strength joint have been obtained from the titanium alloy plates.

Microstructure and Mechanical Properties at the Unsteady Areas of Non-Linear Friction Stir Welding

2007 ◽  
Vol 561-565 ◽  
pp. 1059-1062 ◽  
Author(s):  
H. Takahara ◽  
Masato Tsujikawa ◽  
Sung Wook Chung ◽  
Y. Okawa ◽  
Kenji Higashi
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Parameter ◽  
Butt Joints ◽  
Friction Stir ◽  
Non Linear ◽  
Linear Friction ◽  
Fsw Parameters ◽  
Five Axis ◽  
Welding Direction

The influence of tool control in non-linear friction stir welding (FSW) on mechanical properties of joints was investigated. FSW is widely applied to linear joints. It is impossible for five axis FSW machines, however, to keep all the FSW parameters in optimum conditions at non-linear welding. Non-linear FSW joints should be made by compromise with the order of priority for FSW parameters. The tensile test results of butt joints with rectangular change in welding direction on plate plane (L-shaped butt joints) with various welding parameter change. It was found that turn to the retreating side is encouraged when welding direction change. And the method of zero inclination tool angle is effective at non-linear and plane welding.

scholarly journals The Effect of Vibration during Friction Stir Welding on Corrosion Behavior, Mechanical Properties, and Machining Characteristics of Stir Zone

Metals ◽  
2017 ◽  
Vol 7 (10) ◽  
pp. 421 ◽  
Author(s):  
Sajad Fouladi ◽  
Amir Ghasemi ◽  
Mahmoud Abbasi ◽  
Morteza Abedini ◽  
Amir Khorasani ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Corrosion Behavior ◽  
Stir Zone ◽  
Friction Stir ◽  
Machining Characteristics

Microstructural Characterization and Temperature Analysis in Friction Stir Welding of A383/5052 Dissimilar Aluminum Alloys

2007 ◽  
Vol 561-565 ◽  
pp. 279-282 ◽  
Author(s):  
Masafumi Kokubo ◽  
Shinichi Kazui ◽  
Takao Kaneuchi ◽  
Yoshimasa Takayama ◽  
Hajime Kato ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Analytical Model ◽  
Heat Generation ◽  
Microstructural Characterization ◽  
Joint Line ◽  
Experimental Temperature ◽  
Temperature Analysis ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Microstructural characterization and temperature analysis have been performed in friction stir welding (FSW) of A383 and 5052 dissimilar aluminum alloys. Marked difference in microstructure was observed between joints with different arrangements of materials. The temperature at four points on each side of the joint line was measured during FSW in various conditions. In addition, an analytical model assumed that the work generated by the rotation of the tool led to the work for stirring materials and heat generation of the material and the tool. The temperature of the retreating side (RS) for the joint of the advancing side (AS):A383/RS:5052 was about 50K higher than that of AS, while the temperatures of AS and RS for the joint of AS:5052/RS:A383 were almost the same. The experimental temperature could be calculated reasonably by using the model with assumption of the work for stirring the material.

scholarly journals Experimental and thermal investigation with optimization on friction stir welding of nylon 6A using Taguchi and microstructural analysis

2021 ◽  
Vol 13 (10) ◽  
pp. 168781402110507
Author(s):  
Gajula Sri Venkata Seshu Kumar ◽  
Anshuman Kumar ◽  
S Rajesh ◽  
Rama Bhadri Raju Chekuri ◽  
Venkatesa Prabhu Sundaramurthy
Keyword(s):  
Friction Stir Welding ◽  
Feed Rate ◽  
Optimization Technique ◽  
Microstructural Analysis ◽  
Composite Plates ◽  
Friction Stir ◽  
Thermal Investigation ◽  
Operating Process ◽  
Environmentally Friendly Process ◽  
Fsw Parameters

Friction stir welding is an environmentally friendly process of joining due to the non-usage of flux, or any shield gas. Therefore, this article proposes an experimental and thermal investigation with optimization technique for studying the process of FSW on nylon 6A or polycaprolactam polymer composite plates. Specifically, the influence of input operating process parameters such as tool rotational speed (TRS), feed rate, and pitch values on the output response parameters like ultimate tensile strength (UTS), and hardness of welded joints is examined. In addition, L27 orthogonal array of Taguchi approach is employed for the optimization of design experiments of FSW parameters. The experimental setup is carried out with various process parameter combinations like 500, 1000, and 1500 rpm as TRS, 30, 40, and 50 mm as feed rate by varying the pitch values as 1, 2, and 3 mm. Further, the analysis of variance (ANOVA) also employed for finding the significant parameters of input process using the regression analysis equations. Finally, microstructural analysis is used to assess the mixing or dispersing uniformity of composites effectively. The experimental and optimum FSW parameters for maximum UTS are obtained at a feed rate of 30 mm/min, tool pitch of 3 mm, and the TRS of 500 rpm.

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