Effect of tool pin profile on performance of friction stir welding of brass-copper-based butt welded joint

2016 ◽  
Vol 7 (3/4) ◽  
pp. 236 ◽  
Author(s):  
Sukhwinder Singh Sekhon ◽  
Harmesh Kumar ◽  
Shankar Sehgal
Keyword(s):  
Friction Stir Welding ◽  
Welded Joint ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Pin

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 Tool pin Profile and Axial Force on Tensile Behavior in Friction Stir Welding of Dissimilar Aluminum Alloys

2011 ◽  
Vol 415-417 ◽  
pp. 1140-1146 ◽  
Author(s):  
R. Palanivel ◽  
P. Koshy Mathews ◽  
M. Balakrishnan ◽  
I. Dinaharan ◽  
N. Murugan
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Axial Force ◽  
Aluminium Alloys ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Dissimilar Aluminum Alloys ◽  
Tool Pin

Aluminium alloys generally has low weldability by traditional fusion welding process. The development of the Friction Stir Welding (FSW) has provided an alternative improved way of producing aluminium joints, in a faster and reliable manner. FSW process has several advantages, in particular the possibility to weld dissimilar aluminium alloys. This study focuses on the behavior of tensile strength of dissimilar joints of AA6351-T6 alloy to AA5083-H111 alloy produced by friction stir welding was analysed. Five different tool pin profile such as Straight Square (SS), Tapered Square (TS), Straight Hexagon (SH), Straight Octagon (SO) and Tapered Octagon (TO) with three different axial force (1tonne, 1.5tonne, 2 tonne) have been used to weld the joints. The effect of pin profiles and axial force on tensile properties and material flow behaviour of the joint was analyzed and it was found that the straight square pin profile with 1.5 tonne produced better tensile strength then other tool pin profile and axial force.

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.

Microstructural Characterization and Mechanical Properties in Friction Stir Welding of AA6061 and AA6101 Aluminum Alloys

2021 ◽  
Vol 40 ◽  
pp. 1-11
Author(s):  
Gagandeep Singh ◽  
Khushdeep Goyal ◽  
Baljinder Ram ◽  
Bal Krishan
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Welding Process ◽  
Microstructural Characterization ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Fine Grain ◽  
Metal Plates ◽  
Frictional Forces ◽  
Tool Pin

In this research paper, two different metal plates of aluminum alloy viz. AA6061 and AA6101 were welded with friction stir welding process. Round tool and square tool pin profiles were used to weld the alloys. Weld microstructures, hardness, and tensile properties were evaluated in as-welded condition. The tensile strength of the joints fabricated with round tool pin profile were lower than the square tool pin profile because of the pulsating effect, in square tool pin profile this effect was produced along with the higher frictional forces. The micro-hardness of friction stir zone was higher than the base material due to active recrystallization occurrence which resulted in fine grain size in case of weld joint with round pin profile. Microstructure indicated uniformly distribution of materials with minimum heat affected zone and dense welded zone without any defects.

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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