Comparison of tool wear during friction stir welding of Al alloy and Al-SiC metal matrix composite

2021 ◽  
pp. 095440892110059
Author(s):  
Ashish Bist ◽  
JS Saini ◽  
Vikas Sharma
Keyword(s):  
Surface Roughness ◽  
Friction Stir Welding ◽  
Tool Wear ◽  
Rotational Speed ◽  
Welding Parameters ◽  
Aluminum Matrix Composites ◽  
Al Alloy ◽  
Friction Stir ◽  
Prolonged Contact ◽  
Tool Pin

Aluminum matrix composites have received considerable attention due to their high specific strength and specific stiffness, high hardness, and wear resistance along with being light in weight. These composites are preferably joined using friction stir welding process. The major concern in friction stir welding is the wear of the welding tool pin which is the backbone of the process. The wear is due to the prolonged contact between the tool and the harder reinforcements in the composite materials. The present work deals with the study of tool wear and its surface roughness with respect to different selected friction stir welding parameters such as rotational speed, transverse speed, length of weld, and different composition of Aluminum composite. It was found that the total amount of material removed from the tool and the surface roughness of the tool is in direct proportion to the rotational speed of the tool and the length of the weld but inversely proportional to the transverse rate. The increase in wt.% of SiC reinforcement leads to the higher tool wear but reduces the surface roughness of the tool.

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

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.

scholarly journals Thermo-mechanical analysis of linear welding stage in friction stir welding - influence of welding parameters

2021 ◽  
pp. 186-186
Author(s):  
Darko Veljic ◽  
Marko Rakin ◽  
Aleksandar Sedmak ◽  
Nenad Radovic ◽  
Bojan Medjo ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Heat Generation ◽  
Welding Speed ◽  
Reaction Force ◽  
Material Model ◽  
Element Model ◽  
Welding Parameters ◽  
Al Alloy ◽  
Friction Stir ◽  
Fsw Parameters

The influence of friction stir welding (FSW) parameters on thermo-mechanical behaviour of the material during welding is analysed. An aluminium alloy is considered (Al 2024 T351), and different rotating speed and welding speed are applied. Finite element model consists of the plate (Al alloy), backing plate and welding tool, and it is formed and solved in software package Simulia Abaqus. The influence of the welding conditions on material behaviour is taken into account by application of the Johnson-Cook material model. The rotation of the tool affects the results: if increased, it contributes to an increase of friction-generated heat intensity. The other component of the generated heat, the plastic deformation of the material, is negligibly changed. When the welding speed is increased, the intensity of friction-generated heat decreases, while the heat generation due to plastic deforming increases. Combined, these two effects cause small change of the total heat generation. For the same welded joint length, the plate welded by lower speed will be heated more intensively. The changes of the heat generation influence both the temperature field and reaction force, which are also considered.

Effect of double-sided friction stir welding on the mechanical and microstructural characteristics of AA5754 aluminium alloy

2021 ◽  
Vol 63 (9) ◽  
pp. 829-835
Author(s):  
Sare Çelik ◽  
Fatmagül Tolun
Keyword(s):  
Friction Stir Welding ◽  
Al Alloys ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Al Alloy ◽  
Test Results ◽  
Feeding Rates ◽  
Microstructural Characteristics ◽  
Friction Stir ◽  
Tool Tilt Angle

Abstract AA5754Al alloy is widely used in industry. However, as in the case of all Al alloys, the 5xxx series Al alloys cannot be easily joined through fusion welding techniques. To address this problem, in this study, the effect of double-sided friction stir welding at various tool rotational speeds (450, 710, and 900 rpm), feeding rates (40, 50, and 80 mm × min-1), and tool tilt angles (0°, 1°, 2°) on the welding parameters and mechanical and microstructural characteristics of AA5754 Al alloy was determined. Tensile strength tests and microhardness tests were performed to examine the mechanical properties of the welded specimens. The microstructures of the welded zone were examined by obtaining optical microscopy and scanning electron microscopy images. The tensile test results indicated that the specimens exhibited the highest welding performance of 95.17 % at a tool rotational speed, feed rate, and tool tilt angle of 450 rpm, 50 mm × min-1 and 1°, respectively.

Mechanical Property of Friction Stir Welded Retardant Magnesium Alloy Joint

2011 ◽  
Vol 295-297 ◽  
pp. 1929-1932
Author(s):  
Yi Min Tu ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Xin Zhang ◽  
Ke Ke Zhang
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Welding Speed ◽  
Rotational Speed ◽  
Maximum Strength ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir

In order to obtain better understanding of the friction stir weldability of the magnesium alloy and provide some foundational information for improving mechanical properties of retardant magnesium alloy joints. A retardant magnesium alloy was weld using the method of friction stir welding. The influence of welding parameters on the strength of the joint was investigated. The maximum strength of 230 MPa was obtained from the joint welded at the tool rotational speed of 1000 r/min and welding speed of 750 mm/min.

Influences of Tool pin Profile and Tool Shoulder Curvature on the Formation of Friction Stir Welding Zone in AA6061 Aluminium Alloy

2012 ◽  
Vol 445 ◽  
pp. 789-794 ◽  
Author(s):  
Vahid Moosabeiki ◽  
Ghasem Azimi ◽  
Mostafa Ghayoor
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Zone Formation ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Shoulder ◽  
Aa6061 Aluminium Alloy ◽  
Tool Pin

Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the weld quality. Friction stir tool plays a major role in friction stir welding process. In this investigation, it is tried to evaluate the effect of tool pin thread and tool shoulder curvature on FSW zone formation in AA6061 aluminium alloy. In this regard, six different tool pin geometries (threadless triangular pin with/without conical shoulder, threaded triangular pin with conical shoulder, threadless square pin with/without conical shoulder, threaded square pin with conical shoulder) are used to fabricate the joints. The formation of FSP zones are analyzed macroscopically. Tensile properties of the joints are evaluated and correlated with the FSP zone formation. Consequently, it is obtained that welding creates a higher quality compared to other tool pin profiles using the square tool with curved shoulder and having threaded pin.

Experimental investigation and optimization of mechanical properties on combination of higher and lower strength of aluminum alloys

2021 ◽  
pp. 095440892110606
Author(s):  
C Ganesan ◽  
K Manonmani
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Axial Load ◽  
Welding Process ◽  
Process Parameter ◽  
Nugget Zone ◽  
Friction Stir ◽  
Tool Pin

Friction stir welding is a high potential technology for joining similar and dissimilar aluminum materials, utilized extensively in aerospace and automotive industrial applications to eradicate the problems like hot cracking, porosity, element loss, etc. due to the fusion welding process. This Research addresses the joining of two dissimilar materials of AA 5754 – H32 and AA 8090T6511 – Al-Li and their mechanical properties analysis with the effects of friction stir welding process parameters like tool rotational speed, welding speed and axial load on weld nugget zone formation quality. The significant roles of different tool pin profiles are also emphasized. A mathematical modeling equation was formed by using regression analysis to optimize the process parameter and found the best tool pin profile for defect-free weld nugget zone and higher tensile and hardness properties. This research also portrays the contribution of various pin profiles and each process parameter on the ultimate tensile strength by response surface methodology. The results indicate that the defect-free weld joints are observed with 1800 r/min of rotational speed, welding speed of 15 mm min−1 and 8.5 kN of axial load with hexagonal pin profile.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
Anganan K ◽  
Narendran RJ ◽  
Naveen Prabhu N ◽  
Rahul Varma R ◽  
Sivasubramaniyam R
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

Optimization of process parameters for friction stir welding of joining A6061 and A6082 alloys by Taguchi method

2012 ◽  
Vol 227 (6) ◽  
pp. 1150-1163 ◽  
Author(s):  
Sanjay Kumar ◽  
Sudhir Kumar ◽  
Ajay Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Experimental Tests ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Optimization Of Process Parameters ◽  
Tool Pin

The friction stir welding is a pioneering solid-state metal joining technique for producing high-quality joints in materials. In this article, Taguchi approach is applied to analyze the optimal process parameters for optimum tensile strength and hardness of welded dissimilar A6061 and A6082 alloys. An orthogonal array of L9 is implemented and the analysis of variance is employed to investigate the importance of parameters on responses. The experimental tests, conducted according to combination of rotational speed, tool tilt and types of tool pin profile parameters. The results indicate that the rotational speed is most significant process parameter that has the highest influence on tensile strength and hardness, followed by tool pin profile and tool tilt. The optimum results verified by conducting confirmation experiments. The predicted optimal value of tensile strength and hardness of dissimilar joints produced by friction stir welding are 267.74 MPa and 80.55 HRB, respectively.

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