scholarly journals EFFECT OF TOOL PIN PROFILES OVER SQUARE WAVE TOOL PATH PATTERN ON FRICTION STIR WELDING OF AA6061-CU DISSIMILAR ALLOYS

2021 ◽  
Vol 55 (5) ◽  
Author(s):  
Loganathan Prabhu ◽  
Satish Shanmugam ◽  
Thiagarajan Chandrasekaran
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Movement Pattern ◽  
Step Size ◽  
Square Wave ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Friction Stir Welding Process ◽  
Uniform Dispersion ◽  
Tool Pin

In this present work friction stir welding of Al6061-annealed pure copper dissimilar metals with square wave pattern tool pin movementwas investigated.  The aim of this experiment is to identify the significance square wave tool movement on friction stir welding process along with three different tool pin profiles. Different tool pin profiles of square, round and hexaspiral shapes were selected and their significant outcomes were unveiled. Friction stir welding process parameters of 1500 and 2000rpm & tool pin movement step size of 1.0mm and 2.0mm & weaving rate of 100mm/min and 150mm/min were selected. The advantages of tool movement pattern and tool pin profile shape wereexamined by mechanical testing, microstructure analysis. The mechanical results were showed that process parameter of 1500 rpm, 1.0mm step size, weldingrate of 150mm/min and square tool pin profile combination gives better mechanical properties. Micro structural results unveiled achievement of better grain refinement and uniform dispersion of micro constituents by implementation of square wave tool pin movement pattern along with square tool pin profile.The EDAX report confirms that the weld nugget contains both aluminum and copper as equal percentage, which indicates fine mixing of two parent metals.

Proposing a new relation for selecting tool pin length in friction stir welding process

Measurement ◽  
2018 ◽  
Vol 129 ◽  
pp. 112-118 ◽  
Author(s):  
Noor Zaman Khan ◽  
Arshad Noor Siddiquee ◽  
Zahid A. Khan
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

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.

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.

Multi Response Optimization of Submerged Friction Stir Welding Process Parameters Using TOPSIS Approach

2015 ◽  
Author(s):  
Senthil Kumar Velukkudi Santhanam ◽  
Lokesh Rathinaraj ◽  
Rathinasuriyan Chandran ◽  
Shankar Ramaiyan
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Response Characteristics ◽  
Response Optimization ◽  
Topsis Approach ◽  
Tool Pin

Friction stir welding (FSW) is a solid-state welding process which is used to join high-strength aircraft aluminum alloys and other metallic alloys which are difficult to weld by conventional fusion welding. In this paper, AA6063-O alloy of 6mm thickness was taken and friction stir welded under the water in order to improve the joint properties. The process parameters considered as rotational speed, welding speed and tool pin profiles (cylindrical, threaded and tapered) are optimized with multi response characteristics including hardness, tensile strength and % elongation. In order to solve a multi response optimization problem, the traditional Taguchi approach is insufficient. To overcome this constraint, a multi criteria decision making approach, namely, techniques for order preference by similarity to ideal solution (TOPSIS) is applied in the present study [13]. The optimal result indicates that the multi response characteristics of the AA6063-O during the submerged friction stir welding process can be enhanced through the TOPSIS approach. The Analysis of Variance (ANOVA) was carried out to investigate the significant parameter for the submerged friction stir welding process. The mechanical properties of the submerged FSW are compared with normal FSW joints.

An analytical and experimental investigation considering the effect of material flow velocity on tensile strength of a steel alloy joint produced by friction stir welding process

2020 ◽  
pp. 095440622093631
Author(s):  
Behzad Hadi ◽  
ME Aalami-Aleagha ◽  
Saeed Feli
Keyword(s):  
Friction Stir Welding ◽  
Flow Velocity ◽  
Analytical Method ◽  
Rotational Speed ◽  
Material Flow ◽  
Welding Process ◽  
Linear Speed ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

In this paper, the effects of linear speed, rotational speed, and tool radius of the pin and shoulder are investigated on the material flow velocity in friction stir welds. To obtain the maximum material flow velocity by an analytical method, a suggested relation is introduced for the rotational speed and tool optimum radius. The derived relation is based on the assumption of a velocity field in the stirring region. Besides, the effect of the linear speed on material flow velocity is investigated based on continuity and momentum equations. Finally, by using the experimental method and checking the mechanical properties of the welded parts obtained with different rotational speed, linear speed, and tool dimensions, the proposed analytical model is validated. The results indicate that in the friction stir welding process, the significant component effect on the stirring process is generated through the tool pin radius size. Besides, increasing the material flow velocity in the boundary layer increases the yield and ultimate strength of welds. To achieve the high-quality welds, rotational speed and other tool dimensions must be selected considering the equation extracted from the analytical method. Also, to make the maximum life for the pin and its components in friction stir welding of high melting point metals such as steel alloys, the operation is adjusted at a lower linear speed to prevent the destruction of the tool and improve the quality of the joint.

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