scholarly journals Effect of process parameters on mechanical properties of AA5052 joints using underwater friction stir welding

2020 ◽  
Vol 14 (1) ◽  
pp. 6259-6271
Author(s):  
Srinivasa Rao Pedapati ◽  
Dhanish Paramaguru ◽  
Mokhtar Awang ◽  
Hamed Mohebbi ◽  
Sharma V Korada
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Welding Parameters ◽  
Fracture Characterization ◽  
Friction Stir ◽  
Weld Joints ◽  
Underwater Friction Stir Welding

Underwater Friction Stir Welding (UFSW) is a solid-state joining technique which uses a non-consumable tool to weld metals. The objective of this investigation is to evaluate the mechanical properties of the AA5052 Aluminium alloy joints prepared by UFSW. The effect of different type of welding tools and welding parameters on the weld joint properties are studied. Square, tapered cylindrical and taper threaded cylindrical type of welding tools have been used to produce the joints with the tool rotational speed varying from 500 rpm to 2000 rpm while the welding speed varying from 50 mm/min to 150 mm/min. Tensile strength, micro-hardness distribution, fracture features, micro-and macrostructure of the fabricated weld joints have been evaluated. The effect of welding process parameters that influences the mechanical properties and fracture characterization of the joints are explained in detail. A maximum Ultimate Tensile Strength (UTS) value of 222.07 MPa is attained with a gauge elongation of 14.78%. Microstructural evaluation revealed that most of the fracture are found on the thermal mechanically affected zone (TMAZ)adjacent to the weld nugget zone (WNZ) due to bigger grain sizes. It is found that most of the joints exhibit ductile characteristics in failure. Fractography analysis has been used to find the behavior of weld joints in failure.

Prediction and optimization of the mechanical properties of dissimilar friction stir welding of aluminum alloys using design of experiments

2016 ◽  
Vol 232 (8) ◽  
pp. 1384-1394 ◽  
Author(s):  
R Palanivel ◽  
RF Laubscher ◽  
S Vigneshwaran ◽  
I Dinaharan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Ultimate Tensile Strength ◽  
Design Of Experiments ◽  
Process Parameters ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process

Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face–centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351–AA5083. Three weld parameters that influence weld quality were considered, namely, tool shoulder profile (flat grooved, partial impeller and full impeller), rotational speed and welding speed. Experimental results detailing the variation of the ultimate tensile strength as a function of the friction stir welding process parameters are presented and analyzed. An empirical model that relates the friction stir welding process parameters and the ultimate tensile strength was obtained by utilizing a design of experiments technique. The models developed were validated by an analysis of variance. In general, the full impeller shoulder profile displayed the best mechanical properties when compared to the other profiles. Electron backscatter diffraction maps were used to correlate the metallurgical properties of the dissimilar joints with the joint mechanical properties as obtained experimentally and subsequently modeled. The optimal friction stir welding process parameters, to maximize ultimate tensile strength, are identified and reported.

A Study on Grain Size, Mechanical Properties and First Mode of Metal Transfer in Underwater Friction Stir Welded AA5052-O

2018 ◽  
Vol 775 ◽  
pp. 466-472 ◽  
Author(s):  
K. Tejonadha Babu ◽  
S. Muthukumaran ◽  
C. Bharat Kumar
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Metal Transfer ◽  
Welding Parameters ◽  
Friction Stir ◽  
Second Mode ◽  
Underwater Friction Stir Welding

Friction stir welding (FSW), a new joining process is finding extensive use in the welding of aluminum alloy sheets. The metal transfer modes in the FSW cause the quality of the weld and its properties. The first mode of metal transfer is accomplished by the tool and shoulder, while the second mode occurs around the pin. In the present study, two different welding conditions, which were friction stir welding in the air (CFSW) and underwater friction stir welding (UWFSW) carried out at various welding parameters to weld the AA5052-O aluminum alloy sheets and determine the consequence of the first mode on the tensile strength of welded joints. Considerable grain refinement and enhanced mechanical properties were obtained in UWFSW joints. It Is observed that the first mode affect the tensile strength of the joint, also found that a linear correlation between the first mode and the tensile strength.

Optimization of Process Parameters of Friction Stir Welding by Taguchi Method

2019 ◽  
Vol 7 (1) ◽  
pp. 17-23
Author(s):  
Azzam Sabah Albunduqee ◽  
Hussein R Al-Bugharbee
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Taguchi Method ◽  
Process Parameters ◽  
Rotational Velocity ◽  
Welding Parameters ◽  
Optimum Process ◽  
Friction Stir ◽  
Optimization Of Process Parameters

Friction Stir Welding is one of the technologies of joining solid states, which still attracts the researchers’ interest.  In welded joints the mechanical properties are affected by a number of mechanical properties of the joined materials and by the process parameters as well. In the present study, the effect of a number of friction stir welding parameters on the tensile strength of the welded joint have been investigated using the Taguchi method and the analysis of variance (ANOVA). The study considers different levels of friction stir welding variables; namely, different rotational speeds of (2000, 1600, 1250 rpm), different welding speeds (12.5, 16, 20 mm / min), and different welding tilt angles (0, 1, 2 degrees).  The optimum process parameters and their contribution rate were selected based on the Taguchi method for test design and by using the Minitab 16 program. In this study, the best results (i.e, higher tensile strength) were obtained at a rotational velocity of 1600 rpm, linear velocity of 16 mm / min, and welding angle, 1o. The highest tensile strength was obtained under these conditions.                                                                                       

Robotic Friction Stir Welding of AA5754 Aluminum Alloy Sheets at Different Initial Temper States

2014 ◽  
Vol 622-623 ◽  
pp. 540-547 ◽  
Author(s):  
Massimo Callegari ◽  
Archimede Forcellese ◽  
Matteo Palpacelli ◽  
Michela Simoncini
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Speed ◽  
Process Condition ◽  
Hybrid Structure ◽  
Welding Parameters ◽  
Friction Stir ◽  
Robotic Friction Stir Welding

Robotic friction stir welding experiments were performed on AA5754 aluminium alloy sheets, 2.5 mm in thickness, in two different temper states (H111 and O-annealed). A six axes robot with a hybrid structure, characterised by an arm with parallel kinematics and a roll-pitch-roll wrist with serial kinematics, was used. The effect of the process parameters on the macro-and micro-mechanical properties and microstructure of joints was widely analysed. It was shown that, under the same process condition, the mechanical properties of the joints are strongly influenced by the initial temper state of the alloy. In particular, as AA5754-H111 is welded, the ultimate tensile strength is not significantly affected by the process parameters whilst the ultimate elongation significantly depends on the welding speed. In AA5754-O, both ultimate values of tensile strength and elongation are affected by the welding speed whilst a negligible effect of the rotational speed can be observed. Irrespective of the welding parameters, the H111 temper state leads to mechanical properties higher than those given by the O-annealed state. An investigation has been also carried out in order to evaluate the micro-hardness profiles and microstructure of the FSWed joints in order to understand the mechanisms operating during robotic friction stir welding.

Effects of bottom plate in friction stir welding of AA6061-T6

2020 ◽  
Vol 118 (1) ◽  
pp. 108
Author(s):  
M.A. Vinayagamoorthi ◽  
M. Prince ◽  
S. Balasubramanian
Keyword(s):  
Mechanical Properties ◽  
Axial Load ◽  
Weld Zone ◽  
Welding Process ◽  
Bottom Plate ◽  
Welding Parameters ◽  
Nugget Zone ◽  
Friction Stir ◽  
Weld Joints ◽  
Fine Grain

The effects of 40 mm width bottom plates on the microstructural modifications and the mechanical properties of a 6 mm thick FSW AA6061-T6 joint have been investigated. The bottom plates are placed partially at the weld zone to absorb and dissipate heat during the welding process. An axial load of 5 to 7 kN, a rotational speed of 500 rpm, and a welding speed of 50 mm/min are employed as welding parameters. The size of the nugget zone (NZ) and heat-affected zone (HAZ) in the weld joints obtained from AISI 1040 steel bottom plate is more significant than that of weld joints obtained using copper bottom plate due to lower thermal conductivity of steel. Also, the weld joints obtained using copper bottom plate have fine grain microstructure due to the dynamic recrystallization. The friction stir welded joints obtained with copper bottom plate have exhibited higher ductility of 8.9% and higher tensile strength of 172 MPa as compared to the joints obtained using a steel bottom plate.

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.

Optimization of Welding Process Parameters in Novel Friction Stir Welding of Polyamide 66 Joints

2019 ◽  
Vol 969 ◽  
pp. 828-833 ◽  
Author(s):  
R. Nandhini ◽  
R. Dinesh Kumar ◽  
S. Muthukumaran ◽  
S. Kumaran
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Polyamide 66 ◽  
Friction Stir ◽  
Response Characteristics ◽  
Tool Shoulder ◽  
Stereo Microscope ◽  
Friction Plate

The friction stir welding of polyamide 66 with a specially modified tool is studied. A variation of the conventional friction stir welding is investigated by incorporating a friction plate for the purpose of heating the polymer in the course of welding process through the tool shoulder. This in turn, improves the efficiency of the weld. The association of the welding process parameters and the weld performance has been investigated by the grey relational analysis with multi response characteristics like weld tensile strength, percent elongation and hardness. Macrostructure of the weld joint cross section has been explored by Stereo microscope. The maximum weld tensile strength of 63 MPa and a Shore hardness of 60 D at the weld nugget are obtained. The hardness profiles of the welded samples have been analyzed in this investigation.

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