scholarly journals Pinless friction stir spot welding of aluminium alloy with copper interlayer

2020 ◽  
Vol 10 (1) ◽  
pp. 804-813
Author(s):  
Balsam H. Abed ◽  
Omar S. Salih ◽  
Khalid M. Sowoud
Keyword(s):  
Diffusion Process ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Tensile Shear ◽  
Plunge Depth ◽  
Friction Stir ◽  
Copper Interlayer ◽  
Cu Interlayer

AbstractSpot welding joints of Al-Mg-Si alloy (AA6061-T6) were produced with and without the addition of copper interlayer using pinless friction stir spot welding (P-FSSW). To investigate the effects of welding parameters on the metallurgical and mechanical properties of the weldment, various tool plunge depth and dwell time were used. Optical microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy (EDS) have been used for microstructural characterisation.Meanwhile, the mechanical characterisation of the welded joints was evaluated by tensile-shear test. The experimental results showed that a larger bonding area and sound joint were achieved with the addition of Cu interlayer due to the improvement in thermal distribution. Also, an alloying reaction took place between the aluminium substrate and Cu interlayer during P-FSSW, forming intermetallic compounds layer in the interface through the diffusion process. The increasing of dwell time and plunge depth to some extent were beneficial to the formation of the joint and diffusion process, and thus increasing the tensile-shear load of the joints. The observed fracture mode of the joint was either completely shear off in the interface or complete nugget pullout.

scholarly journals Investigasi dan Optimasi Parameter Proses Micro Friction Stir Spot Welding Material A1100/Cu1100P Menggunakan Metode Taguchi

2019 ◽  
Vol 3 (2) ◽  
pp. 59
Author(s):  
Pathya Rupajati ◽  
Pathya Rupajati
Keyword(s):  
Friction Stir Welding ◽  
Intermetallic Compound ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Shear Load ◽  
Tool Rotational Speed ◽  
Tensile Shear ◽  
Plunge Depth ◽  
Friction Stir

Abstrak  Salah satu karakteristik sifat mekanis yang penting untuk dianalisis adalah tensile shear load. Penelitian ini bertujuan untuk melakukan optimasi tensile shear load hasil pengelasan micro friction stir welding (µFSSW) pada material AA1100 dan Cu1100P menggunakan metode Taguchi. Rancangan percobaan yang digunakan dalam penelitian ini adalah matriks orthogonal array L8 dengan memvariasikan parameter proses pengelasan yaitu dwell time dan plunge depth yang memiliki masing-masing empat level dan dua level. Sedangkan variabel konstan yang digunakan adalah tool rotational speed sebesar 33.000 rpm. Hasil penelitian menunjukkan bahwa parameter pengelasan yang memiliki kontribusi terbesar dalam meningkatkan tensile shear load hasil pengelasan micro friction stir spot welding adalah dwell time, yang menghasilkan tensile shear load sebesar 265,12 N dengan seting kombinasi dwell time pada 5 s dan plunge depth pada 0,7 mm. Hasil struktur mikro juga menunjukkan terlihat adanya flash dan hook defect, tetapi tidak menujukkan adanya intermetallic compound dan crack. Kata kunci: A1100, µFSSW, Taguchi, Dwell time, Plunge Depth

Effect of Welding Parameters on Temperature Distribution During Friction Stir Spot Welding of Commercial Pure Copper Lap Joint

2018 ◽  
Author(s):  
Ahmed Mahgoub ◽  
Abdelaziz Bazoune ◽  
Fadi Al-Badour ◽  
Necar Merah ◽  
Abdelrahman Shuaib
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Pure Copper ◽  
Friction Stir Spot Welding ◽  
Temperature History ◽  
Welding Parameters ◽  
Deformation Model ◽  
Friction Stir ◽  
Good Agreement

In this paper, a Coupled Eulerian Lagrangian (CEL) finite element model (FEM) was developed to simulate the friction stir spot welding (FSSW) of commercial pure copper. Through simulations results, the paper presents and discusses the effect of FSSW process parameters; namely rotational speed, plunging rate and dwell time, on the developed temperatures and their distribution within the workpiece as well as material flow and deformation. Model validation showed a good agreement between predicted temperature history and the experiment one, with a maximum error of 6%. Furthermore, the predicted formation of flash was also found in good agreement with the experiment with an error of only 7%. Simulation results predicted peak temperature and plastic strain among all studied welding conditions were 920 K and 3.5 respectively at 1200 rpm rotational speed, 20 mm/min plunging rate and 4 seconds dwell time, which is approximately 70% of the melting point of pure copper.

scholarly journals Effect of Zn Interlayer Particles on Mechanical Properties and Microstructure of Friction Stir Spot Welding Aluminum Alloy

2018 ◽  
Vol 218 ◽  
pp. 04005
Author(s):  
Lingga Arti Saputra ◽  
Nurul Muhayat ◽  
Triyono
Keyword(s):  
Mechanical Properties ◽  
Spot Welding ◽  
Dwell Time ◽  
Aluminum Matrix ◽  
Friction Stir Spot Welding ◽  
Motor Vehicles ◽  
Shear Load ◽  
Tensile Shear ◽  
Friction Stir ◽  
Spot Welded

Global warming can be reduced by controlling emissions in motor vehicles. Lightweight aluminum materials can lower the engine work so as to reduce fuel consumption.The effect of dwell time on mechanical properties and microstructure friction stir spot welded AA1100 with particle interlayer Zn were investigated. The result shows that the particle interlayer Zn affect to the mechanical properties. The tensile shear load friction stir spot welded AA1100 with particle interlayer Zn is higher than hart of without particle interlayer Zn. In line with tensile shear load that the hardness of friction stir spot welded Al with particle interlayer Zn got the higher hardness than of without particle interlayer Zn. The addition of particle interlayer Zn reduce the hook defect and spread in the aluminum matrix as solid solution.

Effects of process parameters on the lap joint strength and morphology in friction stir spot welding of ABS sheets

2020 ◽  
pp. 009524432096152
Author(s):  
Asil Ayaz ◽  
Aydin Ülker
Keyword(s):  
Spot Welding ◽  
Dwell Time ◽  
Joint Strength ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Shear Load ◽  
Lap Joint ◽  
Friction Stir ◽  
Joint Shear ◽  
Tool Rotation

In this study, a new method was proposed to reduce the keyhole volume with friction stir spot welding process and improve the lap joint shear load-carrying capacity of the weld by analyzing the effects of tool rotation speed, plunge depth and dwell time on the weld. Single lap shear tests were carried out to determine the influences of the welding parameters on the mechanical behavior of the welds. The quality of the joint was evaluated by examining the characteristics of the joint as a result of the lap joint shear load. For friction stir spot welding of the acrylonitrile butadiene styrene samples, the experiments were designed according to Taguchi’s L9 orthogonal array in a randomized way. From the analysis of variance and the signal-to-noise ratio, the significant parameters and the optimum combination level of the parameters were obtained. It was found that using a tool rotation of 1000 rpm, plunge depth 11.5 mm and dwell time of 40 s, an improved joint strength can be obtained. The results showed that joint strength was improved by an amount of 20% as compared with the optimum welding parameters to the initial welding parameters. Macrostructure examination plays an important role to determine the joint strength and evaluate the influences of each welding parameters. So, weld morphology was investigated by morphological analysis and visual comparisons. It was also observed failure modes for fractured samples having the highest, moderate and lowest lap joint shear load.

Effect of Welding Conditions on Sheets’ Interface Properties in Friction Stir Spot Welding of Copper

2019 ◽  
Author(s):  
Ahmed Mahgoub ◽  
Neçar Merah ◽  
Abdelaziz Bazoune
Keyword(s):  
Surface Morphology ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Tensile Failure ◽  
Welding Parameters ◽  
Welding Condition ◽  
Friction Stir ◽  
Joint Fracture

Abstract Friction Stir Spot Welding (FSSW) is a solid-state joining technique widely applied to high conductive metals. In this paper, the effects of FSSW parameters, namely, rotational speed (N), plunging rate (V) and dwell time (DT) on the joint fracture mode and fractured surface morphology were investigated using scanning electron microscopy (SEM). The effect of the abovementioned welding parameters on the microhardness profile along the sheets’ interface was also investigated to gain insight into the strength of the joint and the width of the bonding ligament. Two conditions were considered for each parameter 1200 rpm and 900 rpm for N, 60 mm/min and 20 mm/min for V, 4 and 2 seconds for DT. The welding condition 1200 rpm rotational speed, 20 mm/min plunging rate and 2 seconds dwell time showed a wider bonding ligament, relatively higher elongation, higher tensile failure load, and greater microhardness on the sheets’ interface. Dimple surface morphology (DSM) with regular dimples along the stir zone was also observed at the abovementioned set of process parameters.

scholarly journals Simulation of Friction Stir Spot Welding of Copper and Aluminium During Plunging Phase

2021 ◽  
Vol 2129 (1) ◽  
pp. 012002
Author(s):  
N N S M Shobri ◽  
S R Pedapati ◽  
M Awang
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
Regression Line ◽  
Friction Stir Spot Welding ◽  
Peak Temperature ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Explicit Analysis ◽  
Residual Plots

Abstract Simulation is limited and remains briefly addressed in the literature of friction stir spot welding (FSSW) process in joining dissimilar copper and aluminium. Thus, this study simulated the FSSW process of copper and aluminium to investigate the peak temperature during the plunging phase produced by all possible combinations of levels for tool rotational speed, plunge rate, and plunge depth according to the full factorial design. The modeling was established by Coupled Eulerian-Lagrangian (CEL) model and ‘dynamic, temperature-displacement, explicit’ analysis. The highest peak temperature of 994.4 oC was produced by 2400 rpm rotational speed, 100 mm/min plunge rate, and 1.6 mm plunge depth. The combination was suggested to be the optimum welding parameters in joining copper to aluminium as sufficient heat input was essential to soften the area around the welding tool and adequately plasticize the material. Three sets of confirmation tests presented consistent responses with a mean peak temperature of 994.4 °C, which validated that the response produced by the suggested optimum welding parameters was reliable. The statistical result reported that the variability in the factors could explain 84.12% of the variability in the response. However, only the rotational speed and plunge depth were statistically significant. The residual plots showed that the regression line model was valid.

scholarly journals EFFECT OF ROTATIONAL SPEED AND DWELL TIME ON PHYSICAL AND MECHANICAL PROPERTIES OF FRICTION STIR SPOT WELDING ALUMINIUM 1100 WITH ZN POWDER INTERLAYER ADDITION

2019 ◽  
Vol 18 (1) ◽  
Author(s):  
Aditya Noor ◽  
Nurul Muhayat ◽  
. Triyono
Keyword(s):  
Mechanical Properties ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Physical And Mechanical Properties ◽  
Friction Stir Spot Welding ◽  
Shear Load ◽  
Tensile Shear ◽  
Lightweight Materials ◽  
Friction Stir

<p><em>Friction stir spot welding (FSSW) is one of the development of solid state welding to joint lightweight materials such as aluminium. In the automotive industry, lightweight materials are needed in the structure of vehicle construction to improve efficiency in vehicles. This research aims to find out how the effect of rotational speed and dwell time on physical and mechanical properties on the weld joint of aluminium 1100 with Zn interlayer addition. Variations used in rotational speed 1000, 1250, 1600 rpm and dwell time 6, 7, 8 s. Pullout fracture occur in tensile tests that are getting bigger with increasing rotational speed and dwell time. The results of SEM and EDS observations showed that the metallurgical bonded zone increased and kept the hook defect away. The spread of Zn in the stir zone area causes the formation of solid Al-Zn phase in a solid solution. The hook defect filled with Zn can minimize cracks that occur, so increased the tensile shear load. The highest tensile shear load value of FSSW AA1100 without Zn interlayer is 3.61 kN, while the FSSW AA1100 with Zn interlayer addition is 4.34 kN.</em></p>

scholarly journals Refill Friction Stir Spot Welding of Dissimilar 6061/7075 Aluminum Alloy

2019 ◽  
Vol 38 (2019) ◽  
pp. 69-75 ◽  
Author(s):  
Zhenlei Liu ◽  
Kang Yang ◽  
Dejun Yan
Keyword(s):  
Aluminum Alloy ◽  
Spot Welding ◽  
Joint Strength ◽  
Shear Failure ◽  
Failure Load ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Lap Shear

AbstractRefill friction stir spot welding (RFSSW) was used to join 6061-T6 and 7075-T6 aluminum alloys in this work. Different sheet configurations and welding parameters were used to optimize joint strength. The effect of sleeve plunge depth on the microstructure and mechanical properties of the joints were investigated. The results showed that no defects were obtained when 6061-T6 aluminum alloy was placed as the upper sheet. The lap shear failure load of the joint using 6061-T6 aluminum alloy as the upper sheet was higher than that using 7075-T6 as the upper sheet. The maximum failure load of 12,892 N was attained when using the sleeve plunge depth of 3.6 mm. The joint failed at the upward flowing 7075 near the hook.

scholarly journals Study the microstructure and mechanical properties of dissimilar friction stir spot welding of carbon steel 1006 to aluminum alloy aa2024-t3

2018 ◽  
Vol 7 (4.1) ◽  
pp. 3037
Author(s):  
Isam Tareq Abdullah ◽  
Zaman Khalil Ibrahim ◽  
Ahmed Ibrahim Razooqi
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Carbon Steel ◽  
Spot Welding ◽  
Dwell Time ◽  
Dissimilar Materials ◽  
Friction Stir Spot Welding ◽  
Shear Load ◽  
Tensile Shear ◽  
Friction Stir

Friction stir spot welding-FSSW has been suggested as effectual process to welding difficult materials such as dissimilar materials and thin sheet of metal alloys. In this study, using dissimilar materials were welded carbon steel-1006 on upper plate and aluminum alloy AA2024-T3 on lower plate. Macrostructure, micro-structural analysis and mechanical properties of the joints are done. The effect of penetration depth, dwell time and spindle speed on tensile shear load are investigated with invariable of other parameter during welding process. The maximum tensile shear load (3.31KN) was occurred when using 0.4mm of penetration depth, 10 sec of dwell time and 1400 rpm of spindle speed. Also, two type of failure shape was observed interfacial fracture of carbon steel sheet and pull-out fracture of AA2024-T3 sheet.

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