Improvement in joint efficiency with high productivity and narrow weld formation in friction stir welding

2021 ◽  
pp. 095440892110424
Author(s):  
Noor Zaman Khan ◽  
Arshad Noor Siddiquee ◽  
Zahid A Khan ◽  
Irfan Anjum Badruddin ◽  
Sarfaraz Kamangar ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Rotational Speed ◽  
Joint Strength ◽  
Weld Bead ◽  
High Productivity ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Joint Efficiency ◽  
Shoulder Diameter

High productivity, excellent joint strength and small weld bead make friction stir welding an emerging joining technique to join difficult to weld dissimilar aluminum alloys. Effect of rotational speed, traverse speed and shoulder diameter on the joint strength and elongation of the friction stir welded dissimilar aluminum alloys (AA7475-AA2219) is investigated. In addition, parameters are optimized to obtain joint with narrow weld bead and high joint efficiency using the entropy-weighted technique for order of preference by similarity to ideal solution method. Nine experiments are performed as per the L9 orthogonal array and mechanical properties of the welded joints are measured. Results of the study reveal that optimum values of ultimate tensile strength and percentage elongation are obtained at a rotational speed of 710 rev/min, welding speed of 250 mm/min and shoulder diameter of 10 mm resulting in good joint strength, high productivity and narrow weld bead. From the selected process parameter range, tool shoulder diameter is found to be the most significant parameter. The findings of the present study are discussed in light of the friction stir welding process mechanism, available literature, mechanical testing, microstructure and fractography.

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.

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

2020 ◽  
pp. 64-68
Author(s):  
K. Anganan ◽  
R.J . Narendran ◽  
N Naveen Prabhu ◽  
R Rahul Varma ◽  
R Sivasubramaniyam
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.

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.

Evaluation of dissimilar joints properties of 5083-H12 and 6061-T6 aluminum alloys produced by tungsten inert gas and friction stir welding

2015 ◽  
Vol 231 (3) ◽  
pp. 297-308 ◽  
Author(s):  
Morteza Ghaffarpour ◽  
Mohammad Kazemi ◽  
Mohammad Javad Mohammadi Sefat ◽  
Ahmad Aziz ◽  
Kamran Dehghani
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Traverse Speed ◽  
Inert Gas ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
The Difference ◽  
Welding Processes

In the present study, friction stir welding (FSW) and tungsten inert gas (TIG) techniques were used to join the dissimilar aluminum alloys of 5083-H12 and 6061-T6. The laboratory tests were designed using design of experiment (DOE) method. Variables for the FSW process were the rotational speed, traverse speed, shoulder diameter, and pin diameter. They changed in ranges of 700–2500 r/min, 25–400 mm/min, 10–14 mm, and 2–4 mm, respectively. In the case of TIG process, the variables were current intensity, traverse speed, and tilt angle. These parameters varied from 80 to 90 A, 200 to 400 mm/min, and 3° to 12°, respectively. The optimum amounts of parameters were obtained using response surface methodology (RSM). The RSM-based model was developed to predict ultimate tensile strength (UTS) of the welds produced. In FSW, the difference between predicted and measured UTS was about 1.28% and in TIG it was 1.78%. The good agreement between experimental and predicted results indicates the high accuracy of the developed model. Mechanical properties and also the microstructure of the welds were compared after optimizing both welding processes using RSM. The results showed that the welds produced by FSW indicated a considerably higher quality and also improved mechanical properties compared to TIG. Properties of the joints obtained by FSW in single-sided joints were more desirable. In the double-sided welds obtained by FSW these differences were of an even higher significance.

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