Effect of Tool Rotational Speed and Traverse Speed on Friction Stir Welding of 3D-Printed Polylactic Acid Material

2021 ◽  
Author(s):  
S. M. Senthil ◽  
Manickam Bhuvanesh Kumar
Keyword(s):  
Friction Stir Welding ◽  
Polylactic Acid ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Butt Weld ◽  
Friction Stir ◽  
Welding Technology ◽  
Joint Efficiency ◽  
3D Printed

Joining of polymers are usually carried out using adhesives that has a deteriorating quality at elevated working conditions thus limiting its application areas. Friction stir welding (FSW) is a growing solid-state welding technology, with applications including the welding of lightweight materials. FSW was recently introduced for joining thermoplastics materials and found successful. This study attempts in employing FSW to join polylactic acid (PLA)-based 3D printed engineering components and assess the effect of FSW process parameters (tool rotational speed and traverse speed) on the weld property. The present work uses the FSW process to butt weld 5 mm thick 3D printed PLA sheets with taper cylindrical profiled tool. For the experimentation, three different combinations of feed rates and pin rotational speeds are considered. Based on joint efficiency evaluation, it is found that tool rotational speed of 1400 rpm combined with 10 mm/min transverse speed produces the weld with high joint efficiency of 40%.

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

2020 ◽  
Vol 17 (4) ◽  
pp. 491-507 ◽  
Author(s):  
Nitin Panaskar ◽  
Ravi Prakash Terkar
Keyword(s):  
Experimental Data ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Central Composite

Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

Effects of friction stir welding on corrosion and mechanical properties of AA6063 in sea water

2021 ◽  
pp. 095440622199554
Author(s):  
Laxmana Raju Salavaravu ◽  
Lingaraju Dumpala
Keyword(s):  
Mechanical Properties ◽  
Electron Microscope ◽  
Friction Stir Welding ◽  
Corrosion Rate ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Pin

Submerged friction stir welding (FSW) is used to improve the weld zones mechanical properties in the present study. This research aims to obtain the optimized process parameters used to fabricate the AA6063 Submerged FSW joint. In the Submerged FSW process, the most important influential factors are tool rotational speed, traverse speed, and pin profile in a seawater environment. The different workpieces are friction stir welded while submerged in seawater at different tool rotational speeds, traverse speeds, and tool pin profiles such as square pin, cylindrical taper pin, and threaded pin. The produced weldments were tested for the mechanical properties of higher tensile strength, microhardness, corrosion rate, and the microstructure of weldments was characterized by using a scanning electron microscope, transmission electron microscope, and X-ray diffractometer. The corrosion rate is investigated by using an electrochemical analyzer by potential dynamic polarization open-circuit technique. For this investigation, The Taguchi method with the L9 orthogonal array design of experimentation is adopted. The maximum UTS was acquired in the weld joint fabricated with 1250 r/min of tool rotational speed, 45 mm/min traverse speed, and a square tool pin. The stirred zone is tested for microhardness. High hardness is achieved with high tool rotational speed and low traverse speed with a square tool pin profile. The corrosion rate is also decreased with high tool rotational speed, low traverse speed, and a square tool pin profile.

Comparative assessment on weldability of Al 6061 to polycarbonate for dissimilar sheets placement in friction stir lap welding using sensor signals

2021 ◽  
pp. 095440622110426
Author(s):  
Nisith Goswami ◽  
Kamal Pal
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Rotational Speed ◽  
Weight Ratio ◽  
Weld Interface ◽  
Fusion Welding ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Joint Efficiency ◽  
Welding Processes

The thermoplastic polymers and precipitation hardened aluminium alloys are highly popular in the aerospace and automobile sectors as a replacement of metallic materials to improve the strength to weight ratio. Thus, the unlike aluminium alloy to polycarbonate assembled structures are often necessary for which mechanical fastening and adhesive bonding are the primary methods for joining as fusion welding processes are inadequate. However, the dissimilar joint efficiency is found to be less. Thus, the ultrasonic and friction welding processes are developed. The friction stir welding is one such advanced material stirring technique without any melting of base materials. The present work addresses metallic aluminium (Al6061) to polycarbonate sheet materials joining using friction stir welding in overlap configuration using tapered H13 tool steel. The thrust force with associated tool stirring torque has been acquired in real time during plunging followed by welding phase. The weld bead profile with respective force-torque signals was analysed for the process monitoring. The tensile test has been carried out on the lap welds. The weld interface of the unlike sheets have also been scrutinised. Initially, the aluminium sheet was partially overlapped on polycarbonate for the parametric study. The highest joint efficiency was found to be 40.2% at 1400 rpm tool rotational speed and 75 mm/min traverse speed due to improper material mixing at the weld interface. Therefore, the feasibility of the process have been tested by placing thermoplastic polycarbonate over aluminium alloy through which the joint efficiency was further improved (48.57%) at comparatively low tool rotational speed (1100 rpm) with lower welding speed (55 mm/min) as the minute metallic particles uniformly mixed with melted and solidified polycarbonate due to more uniform torque in the welding phase. The tool stirring torque and axial thrust was found to be higher in this overlap position.

scholarly journals Parametric Optimization of Mechanical Properties via FSW on AA5052 Using Taguchi Based Grey Relational Analysis

2021 ◽  
Vol 13 (2) ◽  
pp. 21-30
Author(s):  
C. CHANAKYAN ◽  
S. SIVASANKAR ◽  
M. MEIGNANAMOORTHY ◽  
S. V. ALAGARSAMY
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Grey Relational Analysis ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Relational Analysis ◽  
Grey Relational ◽  
Tool Pin

The Friction stir processing benefits of aluminium composites contain advanced exploration in the region of aluminium alloy Friction Stir Welding - FSW. The modern advancements in Friction Stir Welding are concentrated on the optimization of welding parameters for multi response attributes. The investigations were carried out with the tool pin profiles, tool rotational speed and traverse speed as predictable process parameters for multi response optimization in Friction Stir Welding of 5052 aluminium alloy. GRG (grey relational grade) was obtained by the grey relational analysis of the friction stir welding process through different qualities, particularly, UTS-ultimate tensile strength and micro hardness. The significant process variables on GRG and most substantial parameters traverse speed and tool pin profiles are examined by ANOVA. Excluding tool rotational speed, tool pin profiles and traverse speed were likewise observed to be significant. To approve the investigation, verification of tests was completed at optimal parameters arrangement and predicted outcomes were observed to be in great concurrence with test values.

scholarly journals 3D-Printed Tool Shoulder Design for the Analogue Modelling of Bobbin Friction Stir Weld Joint Quality

2021 ◽  
Vol 21 (1) ◽  
pp. 27-42
Author(s):  
A. Tamadon ◽  
D. J. Pons ◽  
K. Chakradhar ◽  
J. Kamboj ◽  
D. Clucas
Keyword(s):  
Friction Stir Welding ◽  
Cross Sections ◽  
Weld Joint ◽  
Flow Patterns ◽  
Friction Stir Weld ◽  
Butt Weld ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Analogue Modelling ◽  
3D Printed

Abstract A variety of tool shoulder designs comprising three families i.e. blade, spiral and circular shaped scrolls, were produced to improve the material flow and restrictions to avoid the tunnel void. The bobbin tools were manufactured by 3D printing additive manufacturing technology using solid filament. The butt weld joint was produced by each tool using plasticine as the workpiece material. The apparent surface features and bi-colour cross-sections provided a physical flow comparison among the shoulder designs. For the bobbin friction stir welding (BFSW), the tool shoulder with a three-spiral design produced the most stability with the best combination of the flow patterns on surface and cross-sections. The circular family tools showed a suitable intermixing on the surface pattern, while the blade scrolls showed better flow features within the cross-sections. The flow-driven effect of the shoulder features of the bobbin-tool design (inscribed grooves) was replicated by the 3D-printed tools and the analogue modelling of the weld samples. Similar flow patterns were achieved by dissimilar aluminium-copper weld, validating the accuracy of the analogue plasticine for the flow visualization of the bobbin friction stir welding.

Effect of Al2O3 nanoparticles on microstructure and mechanical properties of friction stir-welded dissimilar aluminum alloys AA7075-T6 and AA6061-T6

2021 ◽  
pp. 095440892110655
Author(s):  
Sumit Jain ◽  
R.S. Mishra
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Particle Dispersion ◽  
Al2o3 Nanoparticles ◽  
Tool Rotational Speed ◽  
Micro Hardness ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

In this research, a defect-free dissimilar weld joint of AA7075-T6 and AA6061-T6 reinforced with Al2O3 nanoparticles was fabricated via friction stir welding (FSW). The influence of tool rotational speed (700, 900 and 1100 rpm), traverse speed (40, 50 and 60 mm/min) with varying volume fractions of Al2O3 nanoparticles (4%, 7% and 10%) on microstructural evolution and mechanical properties were investigated. The augmentation of various mechanical properties is based on the homogeneity of particle dispersion and grains refinement in the SZ of the FSWed joint. The findings revealed that the remarkable reduction in grain size in the SZ was observed owing to the incorporation of Al2O3 nanoparticles produces the pinning effect, which prevents the growth of grain boundaries by dynamic recrystallization (DRX). The increasing volume fraction of Al2O3 nanoparticles enhanced the mechanical properties such as tensile strength, % elongation and micro-hardness. Agglomeration of particles was observed in the SZ of the FSWed joints produced at lower tool rotational speed of 700 rpm and higher traverse speed of 60 mm/min due to unusual material flow. Homogenous particle dispersion and enhanced material mixing ensue at higher rotational speed of 1100 rpm and lower traverse speed of 40 mm/min exhibit higher tensile strength and micro-hardness.

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.

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