scholarly journals An Evaluation of Optimal Friction Stir Welding Factors (FSWF) For Yellow Brass 405-20

2022 ◽  
Author(s):  
Syed Farhan Raza ◽  
Sarmad Ali Khan ◽  
Muhammad Salman Habib ◽  
Naveed Ahmed ◽  
Kashif Ishfaq ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Weld Zone ◽  
Tool Material ◽  
Traverse Speed ◽  
Microscopic Investigation ◽  
Weld Strength ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Wide Range

Abstract Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. FSW can successfully weld a wide range of materials (similar/dissimilar parent materials) including aluminum, copper, steel, different alloys from these materials, plastics, composites. FSW of brass has already been accomplished by fewer researchers. In this research, yellow brass 405-20 is, therefore, welded with FSW that was never welded before. In this study, tool material utilized was M2 HSS that was also novel. Effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters i.e., weld temperature, weld strength and weld hardness. Weld temperature developed, was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 106.37% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Based on main effects, optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in optimal temperature, optimal weld strength, and optimal hardness. Rotational speed (RS) was found to be significant to affect the weld temperature only at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. However, PCR of transverse speed was found to be maximum for affecting weld strength as compared to its PCR towards both weld temperature and weld hardness. Current study was also deepened by microscopic investigation.

scholarly journals Parametric Optimization of Friction Stir Welding Factors (FSWF) for Yellow Brass 405-20

2021 ◽  
Author(s):  
Syed Farhan Raza ◽  
Sarmad Ali Khan ◽  
Muhammad Salman Habib ◽  
Naveed Ahmed ◽  
Kashif Ishfaq ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Weld Zone ◽  
Tool Material ◽  
Traverse Speed ◽  
Weld Strength ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Wide Range ◽  
Percent Contribution

Abstract Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. Industries are really interested in adopting FSW in its various applications e.g., automobile, aerospace, marine, construction, etc. FSW can successfully weld a wide range of materials (similar/dissimilar parent materials) including aluminum, copper, steel, different alloys from these materials, plastics, composites, and this material range is subjected to extension if FSW research efforts develop further in future. FSW of brass has already been accomplished by fewer researchers. In this research, yellow brass 405-20 is, therefore, welded with FSW that was never welded before. In this study, tool material utilized was M2 HSS that was also novel. Effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters i.e., weld temperature, weld strength and weld hardness. Weld temperature was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 82.78% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Based on main effects of Anova Analysis, optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in maximum (max.)/optimal temperature, max./optimal weld strength, and minimum/optimal hardness. Rotational speed (RS) was found to be significant to affect the weld temperature only at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. Transverse speed (TS) was found to be overall insignificant for affecting weld temperature, weld strength and hardness. However, PCR of transverse speed was found to be maximum for affecting weld strength as compared to its PCR towards both weld temperature and weld hardness. Error PCR was found to be the lowest for weld zone temperature, then for weld strength, and finally the highest for weld hardness. Interaction Plots (IPs) were also made for those FSWF which were found to be insignificant and to investigate any combined effect of FSWF on output parameters causing increased error PCR towards weld temperature, weld strength, and weld hardness.

scholarly journals Influence of Mx-Trivex, A-Skew, Three Flat Threaded and Concave Shouldered Mx-Triflute Tool Pin Profiles on Tensile Properties and Fractural Behaviour of Aa 6082-T6 Weldments During Friction Stir Welding

2020 ◽  
Vol 9 (4) ◽  
pp. 1376-1384
Keyword(s):  
Friction Stir Welding ◽  
Tensile Test ◽  
Weld Zone ◽  
Base Material ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Pin ◽  
Solid State Joining ◽  
Joining Process ◽  
Brass Wire

Friction Stir Welding (FSW) is a topical and propitious solid-state joining process producing economical and strengthened joints of age-hardened and heat-treatable Aluminium Alloy AA 6082-T6. Mechanical and fractural behaviour of weldments were investigated in order to find crack initiation and necking on the weld zone thereby perceiving the complete behaviour of fracture occurred near the weld zone. Weldments are fabricated by employing four tool pin profiles namely MX-TRIVEX, A-SKEW, Three flat threaded and Concave shouldered MX-TRIFLUTE tools at various rotational speeds 1000 rpm, 1200 rpm and 1400 rpm at single traverse speed 25 mm/min. EXCETEX-EX-40 CNC wire cut EDM with 0.25 mm brass wire diameter has been employed to perform the extraction of tensile test specimens from the weldments according to ASTM E8M-04 standard. Tensile test was performed on elctromechanically servo controlled TUE-C-200 (UTM machine) according to ASTM B557-16 standards Maximum Ultimate Tensile Strength (UTS) of 172.33 MPa (55.5% of base material) and 0.2% Yield Stress (YS) of 134.10 MPa (51.5% of base material) were obtained by using A-SKEW at 1400 rpm, 25 mm/min and maximum % Elongation (%El) of 11.33 (113.3% of base material) was obtained at MX-TRIVEX at 1000 rpm, 25 mm/min. Minimum UTS of 131.16 MPa (42.30% of base material) and 0.2% YS of 105.207 MPa (40.46% of base material )were obtained by using Concave shouldered MX-TRIFLUTE at 1400 rpm, 25 mm/min. Minimum % El of 5.42 ( 54.2% of base material) was obtained by using A-SKEW at 1000 rpm, 25 mm/min.

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

2020 ◽  
Vol 17 (4) ◽  
pp. 491-507 ◽  
Author(s):  
Nitin Panaskar ◽  
Ravi Prakash Terkar
Keyword(s):  
Experimental Data ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Central Composite

Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

Microstructure and Hardness of Friction Stir Weld Bead on Steel Plate Using W-25%Re Pin Tool

2014 ◽  
Author(s):  
Z. Iqbal ◽  
A. N. Shuaib ◽  
F. Al-Badour ◽  
N. Merah ◽  
A. Bazoune
Keyword(s):  
Friction Stir Welding ◽  
Tool Material ◽  
Dissimilar Materials ◽  
Friction Stir Weld ◽  
Process Conditions ◽  
Steel Microstructure ◽  
Friction Stir ◽  
Diffusion Wear ◽  
Improve Fracture Toughness ◽  
The Right

One of the challenges that impede the use of the relatively new friction stir welding (FSW) process in joining steels and high temperature alloys, as well as dissimilar materials, is the development of the right pin tool material that can stand the severe welding conditions of these alloys. Recent developments in FSW tool materials include tungsten rhenium (W-Re) alloys. The ductile to brittle transition temperature of pure tungsten is reduced by the addition of rhenium (Re).. The addition of Re also improve fracture toughness of the alloy. The major focus of this paper is studying the process of making a friction stir welding bead on mild steel using a proprietary W-25%Re alloy pin tool and investigating the effects of process parameters (i.e. tool rotational and welding speeds) on microstructure, microhardness as well as tool reaction loads. Grain refining of the steel microstructure was observed in all beads. Certain process conditions produced a bead with needle like microstructure with the highest values of hardness. Reaction forces were found to increase with the increase in the tool welding speed and to decrease with the increase of the tool rotational speed. Although the spectroscopic analysis of the beads confirmed the diffusion wear of the tool, the overall tool has shown excellent resistance to mechanical wear.

Investigation on Friction Stir Welding Parameters of Aluminium Metal Matrix Composites

2019 ◽  
Vol 11 (2) ◽  
Author(s):  
M. Sucharitha ◽  
B. Ravisankar
Keyword(s):  
Friction Stir Welding ◽  
Metal Matrix ◽  
Rotation Speed ◽  
Friction Stir Weld ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Wide Range ◽  
Tool Rotation ◽  
Aluminium Metal

Friction stir welding could be a solid-state welding has a wide range of applications in industries like aerospace and automobile industries. In this work, the friction stir weld ability of aluminium metal matrix composite(AMMC) using H13 tool and sensitivity of parameters like tool rotation speed, traverse speed and axial force are assessed on final durability, hardness and microstructure. It was observed that the tensile strength and hardness are increased by increasing the tool rotation speed. The microstructure showed fine Al-Mg-Si eutectic particles in a matrix of Al solid solution.

Effect of Tool Rotational Speed and Traverse Speed on Friction Stir Welding of 3D-Printed Polylactic Acid Material

2021 ◽  
Author(s):  
S. M. Senthil ◽  
Manickam Bhuvanesh Kumar
Keyword(s):  
Friction Stir Welding ◽  
Polylactic Acid ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Butt Weld ◽  
Friction Stir ◽  
Welding Technology ◽  
Joint Efficiency ◽  
3D Printed

Joining of polymers are usually carried out using adhesives that has a deteriorating quality at elevated working conditions thus limiting its application areas. Friction stir welding (FSW) is a growing solid-state welding technology, with applications including the welding of lightweight materials. FSW was recently introduced for joining thermoplastics materials and found successful. This study attempts in employing FSW to join polylactic acid (PLA)-based 3D printed engineering components and assess the effect of FSW process parameters (tool rotational speed and traverse speed) on the weld property. The present work uses the FSW process to butt weld 5 mm thick 3D printed PLA sheets with taper cylindrical profiled tool. For the experimentation, three different combinations of feed rates and pin rotational speeds are considered. Based on joint efficiency evaluation, it is found that tool rotational speed of 1400 rpm combined with 10 mm/min transverse speed produces the weld with high joint efficiency of 40%.

The Extrinsic Influence of Tool Plunge Depth on Friction Stir Welding of an Aluminum Alloy

2011 ◽  
Vol 410 ◽  
pp. 206-215 ◽  
Author(s):  
K. Kandasamy ◽  
Satish V. Kailas ◽  
Tirumalai S. Srivatsan
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Rotation Speed ◽  
Tool Material ◽  
Traverse Speed ◽  
Test Machine ◽  
Plunge Depth ◽  
Friction Stir ◽  
Scientific Approach ◽  
Tool Rotation

The axial force during friction stir welding is sensitive to plunge depth of the tool and is one of the prime factors, which exercises control over heat generation during welding. Consequently, the plunge depth for a given tool rotation speed, traverse speed, material and test machine needs to be optimized so as to get a defect-free weld. In this paper, we present and briefly discuss the results of an elaborate and enriching investigation aimed at understanding the extrinsic influence of plunge depth of the tool on weld formation in aluminium alloy 7020-T6 for a range of rotation rate and traverse speed and using two different tools. The critical need for use of a scientific approach to optimize plunge depth for a given tool material and test machine in fewer number of steps is emphasized. Key Words: Friction Stir Welding, Tool Plunge, Rotation speed, Traverse speed, Aluminium Alloy 7020

Effects of friction stir welding on corrosion and mechanical properties of AA6063 in sea water

2021 ◽  
pp. 095440622199554
Author(s):  
Laxmana Raju Salavaravu ◽  
Lingaraju Dumpala
Keyword(s):  
Mechanical Properties ◽  
Electron Microscope ◽  
Friction Stir Welding ◽  
Corrosion Rate ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Pin

Submerged friction stir welding (FSW) is used to improve the weld zones mechanical properties in the present study. This research aims to obtain the optimized process parameters used to fabricate the AA6063 Submerged FSW joint. In the Submerged FSW process, the most important influential factors are tool rotational speed, traverse speed, and pin profile in a seawater environment. The different workpieces are friction stir welded while submerged in seawater at different tool rotational speeds, traverse speeds, and tool pin profiles such as square pin, cylindrical taper pin, and threaded pin. The produced weldments were tested for the mechanical properties of higher tensile strength, microhardness, corrosion rate, and the microstructure of weldments was characterized by using a scanning electron microscope, transmission electron microscope, and X-ray diffractometer. The corrosion rate is investigated by using an electrochemical analyzer by potential dynamic polarization open-circuit technique. For this investigation, The Taguchi method with the L9 orthogonal array design of experimentation is adopted. The maximum UTS was acquired in the weld joint fabricated with 1250 r/min of tool rotational speed, 45 mm/min traverse speed, and a square tool pin. The stirred zone is tested for microhardness. High hardness is achieved with high tool rotational speed and low traverse speed with a square tool pin profile. The corrosion rate is also decreased with high tool rotational speed, low traverse speed, and a square tool pin profile.

Friction Stir Welding of Carbon Steel for Application in Used Fuel Containers

2014 ◽  
Vol 783-786 ◽  
pp. 1753-1758 ◽  
Author(s):  
Murray Mahoney ◽  
Sam Sanderson ◽  
Peter Maak ◽  
Russell Steel ◽  
Jon Babb ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Room Temperature ◽  
Steel Plate ◽  
Ultrasonic Inspection ◽  
Weld Zone ◽  
Friction Stir Weld ◽  
Weld Repair ◽  
Friction Stir ◽  
Flat Steel ◽  
Two Phases

Friction Stir Welding (FSW) is being investigated as a method to fabricate a partial penetration closure weld of the steel vessel of a copper-coated used fuel container. The hemi-head is made of A516 Grade 70 steel and the cylinder body is made of A106 Grade C steel. In this initial feasibility study, the objective is to use FSW to demonstrate the merits of FSW using flat steel plate in concert with a closure weld joint designed specifically for a cylindrical container. To complete this objective, there are two initial feasibility demonstrations. First, demonstrate the capability of FSW to create defect free welds in a corner joint design with specific dimensions (10 mm deep weld nugget). Subsequently, verify the weld quality by ultrasonic inspection and metallography. Further, characterize weld zone properties by establishing mechanical properties and hardness at room temperature, and impact toughness at-5°C. Second, demonstrate the ability to use FSW to repair defects that might occur in the initial friction stir weld. Weld repair was accomplished by intentionally creating tunnel defects by FSW, performing metallography and ultrasonic inspection to characterize the morphology of the defects, performing a second friction stir weld repair over the defects, and verifying the subsequent weld integrity by repeating the metallography and ultrasonic inspections. Results on these initial two phases of this program are presented herein.

scholarly journals Parametric optimization of friction stir welding of Al-Mg-Si alloy: A case study

2021 ◽  
pp. 7-7
Author(s):  
Nasir Khan ◽  
Sandeep Rathee ◽  
Manu Srivastav
Keyword(s):  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Automobile Construction ◽  
Input Variables

Al-Mg-Si alloys have wide applications in industries such as aerospace, marine, automobile, construction. In this work, newly developed friction stir welding (FSW) was utilized for joining of AA6082-T6 alloy. The effect of major FSW process variables like rotational speed, traverse speed, and shoulder diameter of tool is studied over microstructural and mechanical characteristics of friction stir welded (FSWed) joints. Experimental design was done using Taguchi method (L9 orthogonal array). Three factors viz. rotational speed, welding speed, and diameter of tool shoulder were taken at three levels each. Mathematical modelling was developed in order to optimize the tensile strength of weld joints. Analysis of variance (ANOVA) was utilized to determine the percentage contribution of input variables. The results of present study exhibits that shoulder diameter, rotation, and welding speed of tool significantly affect the mechanical strength of FSWed joints.

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