scholarly journals Experimental investigations of friction stir welded AA6063 aluminum matrix composite

2018 ◽  
Vol 12 (4) ◽  
pp. 4127-4140
Author(s):  
Narinder Kaushik ◽  
Sandeep Singhal ◽  
Rajesh Rajesh ◽  
Pardeep Gahlot ◽  
B. N Tripathi
Keyword(s):  
Friction Stir Welding ◽  
Matrix Composite ◽  
Aluminum Matrix ◽  
High Speed Steel ◽  
Metal Composite ◽  
Composite Matrix ◽  
Friction Stir ◽  
Sic Particles ◽  
Tool Pin ◽  
The Impact

The advancement of friction stir welding for joining of aluminum alloys and aluminum centered matrix composite has replaced the traditional welding techniques. In this experimental study, AA6063/10.5wt%SiC composite has been produced by employing enhanced stir casting technique with the assistance of Mg metal powder. Specimen composite plates having thickness 6 mm were friction stir welded successfully. The impact of welding variables on mechanical and microstructural characteristics of weldments has been studied. The friction stir welding (FSW) was carried out at a rotation rate of tool of 1400 rpm with a tool transverse rate of 124 mm/min. A cylindrical tool fabricated of high-speed steel (HSS) with square pin shape has been used for FSW. The results revealed that the ultimate tensile strength of the welded joint was 163 MPa, which was very close to the strength of the as-cast composite matrix. The microstructural study showed the reason for higher joint strength and microhardness. The welded butt joint exhibited a change in the microstructure at various four welding zones which transforms the mechanical characteristics of welded joints has been due to the asymmetrical flow of material and thermal cycles around the pin. The intense stirring action of the tool pin during FSW cracked the SiC particles in the weld nugget.  In the weld region, a fine-grained structure and homogeneous dispersion of SiC particles have been observed. The micro porosities associated with the base metal composite matrix were eliminated after FSW.

scholarly journals Experimental analysis on friction stir welding using flat-faced pins in AA2024-T3 plate

2021 ◽  
Vol 49 (1) ◽  
pp. 78-86
Author(s):  
Stephen Leon ◽  
G. Bharathiraja ◽  
V. Jayakumar
Keyword(s):  
Friction Stir Welding ◽  
Tool Life ◽  
Thermal Environment ◽  
Softening Temperature ◽  
Peak Temperature ◽  
Friction Stir ◽  
Pin Geometry ◽  
Tool Pin ◽  
The Impact ◽  
Dwell Period

In friction stir welding, lesser tool life restricts the usage of non-circular pin in friction stir welding tool eventhough it delivers comparatively better weld joints than circular pin. Process peak temperature during the process affects the shear strength of the flowing material around the tool pin. Maintaining the process peak temperature as low as possible improves the properties in heat affected zone but on the other hand it increases the stress on the tool pin.Especially on the usage of non-circular pin, the pin surface experiences uneven stress distribution and causes premature tool failure. In this paper, optimum thermal environment through proper selection of process parameters and dwell period with respect to the pin geometry are analysed. A comparative analysis is also made to understand the impact of increase in flat surfaces in the pin surface on weld quality in the view of developing a suitable thermal environment that can improve tool life without compromising joint strength. Apart from this, optimum dwell period for the chosen tool pin geometry is analysed based on the empirical softening temperature of the material.

Friction Stir Welding on Light-Weight Metal - Aluminum Alloy Al6061

2016 ◽  
Vol 879 ◽  
pp. 1233-1238
Author(s):  
Vasanth Chakravarthy Shunmugasamy ◽  
Bilal Mansoor
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Yield Strength ◽  
Base Material ◽  
Frictional Heat ◽  
Tensile Yield Strength ◽  
Impact Properties ◽  
Friction Stir ◽  
Tool Pin ◽  
The Impact

Friction stir welding (FSW) is a solid state joining process in which metals are joined together using frictional heat and severe plastic deformation. The heating and the mixing of the metals is performed using a hardened tool with a shoulder and pin. FSW of lightweight metal alloy Al6061 has been carried out in the present study. For welding aluminum the parameters used were a constant tool rotation speed of 1600 rpm and varying tool translation speeds of 250, 500, 750 and 1000 mm/min. The welded coupons were characterized for microstructural observations and mechanical properties such as tensile and Charpy impact properties. The tensile and impact properties were studied at two different temperature namely, room temperature (RT) and 300°C. The FS welded aluminum specimens showed 86% – 98% tensile yield strength, in comparison to the base material at RT. At 300°C, the yield strength was observed to be 85% to 93% of the base material value. For the impact properties, the Al specimens showed 60% – 140% specific impact energy, in comparison to their respective base materials. Based on the mechanical properties and microstructural examination, the optimal weld parameter was identified as 1600 rpm and 250 mm/min which is dependent on the tool pin and shoulder design utilized in the study.

Friction Stir Welding of SiCp/Al Composite and 2024 Al Alloy

2010 ◽  
Vol 638-642 ◽  
pp. 1500-1505 ◽  
Author(s):  
B.L. Xiao ◽  
Dong Wang ◽  
J. Bi ◽  
Z. Zhang ◽  
Z.Y. Ma
Keyword(s):  
Friction Stir Welding ◽  
Heat Affected Zone ◽  
Volume Fraction ◽  
Ring Structure ◽  
Al Alloy ◽  
Friction Stir ◽  
Sic Particles ◽  
Al Composite ◽  
Clad Layer ◽  
Tool Pin

6 mm thick SiCp/2009Al composite and 2024Al-T351 alloy plates were successfully joined by friction stir welding (FSW) with and without the tool pin offsetting to the 2024Al side (denoted as NOS and OS samples, respectively), producing defect-free joints. The SiC particles from the composite were distributed along a ring structure in the nugget and the volume fraction of the SiC particles decreased as the tool pin offset to the 2024Al side. The Al-clad layer on the 2024Al plate was aggregated on the retreating side of the nugget after FSW. For the OS sample, the Al formed a layer along the nugget boundary. The strength of the NOS sample reached up to 85% of the 2024Al alloy with the joint failing in the heat affected zone on the 2024Al side. The strength of the OS samples was 47% of the 2024Al alloy due to the aggregated Al layer on the retreating side of the nugget which decreased the strength of the joint.

Microstructural and Mechanical Behaviour Evaluation of Mg-Al-Zn Alloy Friction Stir Welded Joint

2020 ◽  
Vol 17 (3) ◽  
pp. 8150-8159
Author(s):  
Kulwant Singh ◽  
Gurbhinder Singh ◽  
Harmeet Singh
Keyword(s):  
Heat Treatment ◽  
Friction Stir Welding ◽  
Magnesium Alloys ◽  
Mechanical Performance ◽  
Fuel Efficiency ◽  
Research Work ◽  
Grain Structure ◽  
Tensile Fracture ◽  
Friction Stir ◽  
The Impact

The weight reduction concept is most effective to reduce the emissions of greenhouse gases from vehicles, which also improves fuel efficiency. Amongst lightweight materials, magnesium alloys are attractive to the automotive sector as a structural material. Welding feasibility of magnesium alloys acts as an influential role in its usage for lightweight prospects. Friction stir welding (FSW) is an appropriate technique as compared to other welding techniques to join magnesium alloys. Field of friction stir welding is emerging in the current scenario. The friction stir welding technique has been selected to weld AZ91 magnesium alloys in the current research work. The microstructure and mechanical characteristics of the produced FSW butt joints have been investigated. Further, the influence of post welding heat treatment (at 260 °C for 1 h) on these properties has also been examined. Post welding heat treatment (PWHT) resulted in the improvement of the grain structure of weld zones which affected the mechanical performance of the joints. After heat treatment, the tensile strength and elongation of the joint increased by 12.6 % and 31.9 % respectively. It is proven that after PWHT, the microhardness of the stir zone reduced and a comparatively smoothened microhardness profile of the FSW joint obtained. No considerable variation in the location of the tensile fracture was witnessed after PWHT. The results show that the impact toughness of the weld joints further decreases after post welding heat treatment.

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.

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