scholarly journals A Novel Approach of Friction Stir Cladding of Aluminum on Carbon Steel Plate; Experimental Investigation and Material Characterization

2021 ◽  
Author(s):  
Mohammad Mostafa Khalili ◽  
Mohammadreza Farahani ◽  
Ali Zohrehvand ◽  
Ahmad Aminzadeh
Keyword(s):  
Carbon Steel ◽  
Rotational Speed ◽  
Steel Plate ◽  
Traverse Speed ◽  
Optical Microscope ◽  
Process Conditions ◽  
Mechanical And Thermal Properties ◽  
Friction Stir ◽  
Metallurgical Investigation ◽  
Novel Approach

Abstract Cladding is usually used to improve the material functionality (i.e. corrosion, wear, and oxidation) and to improve the mechanical and thermal properties of the components in different industries. In this study, a new cladding approach based on the friction stir processing was successfully employed on carbon steel plate with 6061-T6 Aluminum alloy. The mechanical and metallurgical properties of the cladding layer were examined at different process parameters. Metallurgical investigation of ST/Al interface was also evaluated using the Scanning electron microscope (SEM) and Optical microscope (OM). Two alloys were mixed uniformly together in the proper process conditions. Based on the results, the decrease of rotational speed from 1200 rpm to 800 rpm at a constant traverse speed of 15 mm/min, the cladding strength increased from 3.7 KN to 4.8 KN. At constant rotational speed of 800 rpm, with an increase in traverse speed from 15 mm/min to 35 mm/min, the cladding strength increased from 4.8 KN to 6.6 KN.

Fabrication of high-density polyethylene/multiwalled carbon nanotube composites via submerged friction stir processing

2016 ◽  
Vol 30 (2) ◽  
pp. 241-254 ◽  
Author(s):  
Jicheng Gao ◽  
Yifu Shen ◽  
Chao Li
Keyword(s):  
Thermal Properties ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
High Density Polyethylene ◽  
Traverse Speed ◽  
High Density ◽  
Mechanical And Thermal Properties ◽  
Scanning Calorimetry ◽  
Multiwalled Carbon ◽  
Friction Stir

The focus of this work was to study the effect of multiwalled carbon nanotubes (MWCNTs) on morphology, mechanical, and thermal properties of high-density polyethylene (HDPE) nanocomposites. MWCNTs/HDPE nanocomposites were prepared using submerged friction stir processing (SFSP) technique. The pristine MWCNTs without any pretreatment were blended with HDPE at a fixed traverse speed of 30 mm min−1 and various rotational speeds ranging from 1200 r min−1 to 2100 r min−1. The effect of rotational speed on MWCNTs dispersion in HDPE matrix was assessed using scanning electron microscopy. The experimental results showed the rotational speed affected the disperision of the MWCNTs. The mechanical properties of the composites were measured, and the results indicated that the tensile strength increased at first and then decreased with the increase of the rotation speed. The thermal properties of MWCNTs-filled HDPE nanocomposites were studied by differential scanning calorimetry, and the crystalline content of the prepared composites by the SFSP technology was increased. From the experimental research, it was found that the SFSP technique was a practical way to fabricate polymeric composites.

scholarly journals An Analysis of Microstructure and Mechanical Properties on Friction Stir Welded Joint of Dissimilar 304 Stainless Steel and Commercially Pure Aluminium

2017 ◽  
Vol 62 (3) ◽  
pp. 1813-1817 ◽  
Author(s):  
M. Balamagendiravarman ◽  
S. Kundu ◽  
S. Chatterjee
Keyword(s):  
Stainless Steel ◽  
Welded Joint ◽  
Traverse Speed ◽  
Optical Microscope ◽  
304 Stainless Steel ◽  
Interfacial Region ◽  
Mechanical And Thermal Properties ◽  
Pure Aluminium ◽  
Friction Stir ◽  
Commercially Pure

AbstractIn this study, friction stir welding of dissimilar 304 stainless steel and commercially pure aluminium was performed under the following condition of tool rotational speed 1000 rpm, traverse speed 60 mm/min and tool tilt angle 2 degree. Microstructural characterisation was carried out by optical microscope, scanning electron microscope (SEM). Optical images shows that the microstructural change is very minimum in steel side when compared to aluminium side due to the difference in mechanical and thermal properties. The intermetallic compound Al3Fe was observed at the interfacial region and stir region of the welded joint. The maximum ultimate tensile strength is 78% of commercially pure aluminium base metal. Microhardness profile was measured across the weld interface and the maximum value reaches at the stir zone due to the formation of intermettalics.

Experimental Evaluation of Wear Features of W-25%Re Pin Tool Used in Friction Stir Welding Mild Steel

2014 ◽  
Author(s):  
Zafar Iqbal ◽  
Abdel Rahman Shuaib ◽  
Fadi Al-Badour ◽  
Nesar Merah ◽  
Abdelaziz Bazoune
Keyword(s):  
Friction Stir Welding ◽  
Mild Steel ◽  
Rotational Speed ◽  
Steel Plate ◽  
Wear Behavior ◽  
Process Conditions ◽  
High Rotational Speed ◽  
Butt Welding ◽  
Friction Stir

This paper presents the results of studying butt welding of 4 mm thick mild steel plate with a W-25% Re pin tool using the relatively new friction stir welding (FSW) process. The study includes investigating the wear behavior of the pin tool and the effects of process conditions such as rotational speed on the quality of the weld, microstructures and hardness of mild steel. The results reveal that the traverse (welding) force increases with the increase in the traveled distance of the pin tool, whereas torque decreases with the increase in the travelled distance of the pin tool. The tool has shown wear resistance at lower rotational speed, but with the increase of the rotational speed, wear of the tool became prominent. All welded samples revealed grain size refining. Furthermore, at high rotational speed martensitic structure phase developed due to phase transformation. Different distinct regions of stir zones, thermomechanical heat affected zones and heat affected zones were present in the weld.

Microstructural Refinement of Pure Copper by Friction Stir Processing

2013 ◽  
Vol 787 ◽  
pp. 256-261 ◽  
Author(s):  
Salar Salahi ◽  
Vahid Rezazadeh ◽  
Ali Sharbatzadeh ◽  
Atabak Iranizad ◽  
Hamed Bouzary
Keyword(s):  
Grain Size ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Frictional Heating ◽  
Pure Copper ◽  
Traverse Speed ◽  
Work Piece ◽  
Process Conditions ◽  
Nugget Zone ◽  
Friction Stir

Recently friction stir processing (FSP) was developed as a generic implement for microstructural modification based on the principles of FSW using a rotating tool inserted in a monolithic work piece which provides frictional heating and mechanical mixing. In this paper, the microstructural evolution characteristics of nugget zone were investigated during friction stir processing (FSP) of pure copper. Pure copper plates were friction stir processed to the depth of 3.4 mm at different process conditions by varying the traverse speed from 30 to 120 mm/min at rotation speeds of 400 and 600 rpm..Defects were observed in rotational speed of 400 rpm. Grain size of NZ depended significantly on plastic deformation and heat input value. By increasing traverse speed at constant rotational speed of 600 rpm grain size of the nugget zone decreased and the hardness increased. Ultimate tensile strength increased with decrease in grain size. FSP was found as an effective method to develop fine-grained microstructure in copper plates.

Procedure to find out the optimal ranges of process parameters for friction stir welding

2021 ◽  
pp. 146442072199314
Author(s):  
Shubham Verma ◽  
Joy Prakash Misra ◽  
Meenu Gupta
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Optical Microscope ◽  
Graphical Analysis ◽  
Friction Stir ◽  
Steepest Ascent ◽  
Vertical Milling Machine

The present study deals with the application of sequential procedure (i.e. steepest ascent) to obtain the optimum values of process parameters for conducting friction stir welding (FSW) experiments. A vertical milling machine is modified by fabricating fixture and tool ( H13 material) for performing FSW operation to join AA7039 plates. The steepest ascent technique is employed to design the experiments at different rotational speed, welding speed, and tilt angle. The ultimate tensile strength is considered as a performance characteristic for deciding the optimal levels. The mechanical and metallurgical characteristics of the joints are studied by executing tensile and microhardness tests. It is concluded from the graphical analysis of the steepest ascent technique that the optimal maximum and minimum values are 1812–1325 r/min for rotational speed, 43–26 mm/min for welding speed, and 2°–1.3° for tilt angle, respectively. Besides, optical microscope and scanning electron microscope are utilized for microstructural and fractographic analyses for a better understanding of the process.

Prediction and optimization of mechanical properties of PA6/NBR/graphene nanocomposites fabricated by friction stir processing

2021 ◽  
pp. 009524432110200
Author(s):  
Ali Ghorbankhan ◽  
Mohammad Reza Nakhaei ◽  
Ghasem Naderi
Keyword(s):  
Tensile Strength ◽  
Impact Strength ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Differential Scanning Calorimetric ◽  
Butadiene Rubber ◽  
Friction Stir ◽  
Graphene Nanocomposite ◽  
Graphene Nanoparticles ◽  
Input Variables

The friction stir process (FSP) method used to prepare polyamide 6 (PA6)/nitrile-butadiene rubber (NBR) nanocomposites with 1 wt% Graphene nanoparticles. Response surface methodology (RSM) and Box-Behnken design were used to study the effects of four input variables including tool rotational speed (ω), shoulder temperature (T), traverse speed (S), and the number of passes (N) on tensile strength and impact strength of PA6/NBR/Graphene nanocomposite. In order to investigate the dispersion state of Graphene and the morphology of the PA6/NBR blend in the presence of Graphene, wide x-ray patterns (WAX), scanning electron microscopy (SEM) were performed. Furthermore and differential scanning calorimetric (DSC) was used to investigate the thermal properties of PA6/NBR containing 1 wt% Graphene nanoparticles. The results confirmed that at the optimum range of input variables, PA6/NBR/Graphene nanocomposite provided good thermal stability as well as the highest tensile strength, and impact strength. This is caused by the large surface area to volume ratio of the dispersed layered Graphene in PA6/NBR blends. Under optimal conditions of the rotational speed of 1200 rpm, traverse speed of 20 mm/min, shoulder temperature of 125°C, and number pass of 3, the maximum tensile strength and impact strength are 70.4 MPa and 70.3 J/m, respectively.

Effect of Al2O3 nanoparticles on microstructure and mechanical properties of friction stir-welded dissimilar aluminum alloys AA7075-T6 and AA6061-T6

2021 ◽  
pp. 095440892110655
Author(s):  
Sumit Jain ◽  
R.S. Mishra
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Particle Dispersion ◽  
Al2o3 Nanoparticles ◽  
Tool Rotational Speed ◽  
Micro Hardness ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

In this research, a defect-free dissimilar weld joint of AA7075-T6 and AA6061-T6 reinforced with Al2O3 nanoparticles was fabricated via friction stir welding (FSW). The influence of tool rotational speed (700, 900 and 1100 rpm), traverse speed (40, 50 and 60 mm/min) with varying volume fractions of Al2O3 nanoparticles (4%, 7% and 10%) on microstructural evolution and mechanical properties were investigated. The augmentation of various mechanical properties is based on the homogeneity of particle dispersion and grains refinement in the SZ of the FSWed joint. The findings revealed that the remarkable reduction in grain size in the SZ was observed owing to the incorporation of Al2O3 nanoparticles produces the pinning effect, which prevents the growth of grain boundaries by dynamic recrystallization (DRX). The increasing volume fraction of Al2O3 nanoparticles enhanced the mechanical properties such as tensile strength, % elongation and micro-hardness. Agglomeration of particles was observed in the SZ of the FSWed joints produced at lower tool rotational speed of 700 rpm and higher traverse speed of 60 mm/min due to unusual material flow. Homogenous particle dispersion and enhanced material mixing ensue at higher rotational speed of 1100 rpm and lower traverse speed of 40 mm/min exhibit higher tensile strength and micro-hardness.

Influence of Process Parameters on Microstructure of Friction Stir Processed Mg AZ31 Alloy

2017 ◽  
pp. 1293-1305
Author(s):  
G. Venkateswarlu ◽  
M.J. Davidson ◽  
G.R.N. Tagore ◽  
P. Sammaiah
Keyword(s):  
Plastic Deformation ◽  
Grain Refinement ◽  
Process Parameters ◽  
Tilt Angle ◽  
Friction Stir Processing ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Homogeneous Microstructure ◽  
Friction Stir ◽  
Tool Tilt Angle

Friction stir processing (FSP) has been developed on the principles of friction stir welding (FSW) as an effective and efficien new method for grain refinement and microstructural modification, providing intense plastic deformation as well as higher strain rates than other conventional severe plastic deformation methods. FSP produces an equiaxed homogeneous microstructure consisting of fine grains, resulting in the enhancement of the properties of the material at room temperature. The objective of the present paper is to examine the influence of friction stir processing (FSP) parameters namely tool rotational speed (RS), tool traverse speed (TS) and tool tilt angle (TA) on the microstructures of friction stir processed AZ31B-O magnesium alloy. This investigation has focused on the microstructural changes occurred in the dynamically recrystallised nugget zone/ stir zone and the thermo mechanically affected zone during FSP. The results presented in this work indicate that all the three FSP process parameters have a significant effect on the resulting microstructure and also found that the rotational speed has greatly influenced the homogenization of the material. The grain refinement is higher at intermediate rotational speed (1150 rpm), traverse speed (32 mm / min and tilt angle (10). It is established that FSP can be a good grain refinement method for improving the properties of the material.

Friction Stir Processing: An Operational Method to Improve Ductility in Pure Copper

2013 ◽  
Vol 818 ◽  
pp. 14-19 ◽  
Author(s):  
Vahid Rezazadeh ◽  
Ali Sharbatzadeh ◽  
Ali Hosseinzadeh ◽  
Amir Safari ◽  
Salar Salahi
Keyword(s):  
Friction Stir Processing ◽  
Rotational Speed ◽  
Pure Copper ◽  
Traverse Speed ◽  
Ultrafine Grain ◽  
Work Piece ◽  
Cavity Formation ◽  
Nugget Zone ◽  
Friction Stir ◽  
Lower Heat

mproving ductility in metals using friction stir processing (FSP) is a challenging effort and is made by means of a rotating tool inserted in a work piece providing heat transfer and plastic deformation. In this investigation, improving ductility during FSP was determined as a purpose and the microstructure and mechanical properties of nugget zone were investigated during friction stir processing (FSP) of pure copper. Ductility was measured using tensile elongations at a temperature of 20 °C. By varying the traverse speed from 40 to 100 mm/min at rotation speeds of 300 and 600 rpm, the ultrafine grain microstructure was achieved .Defects were observed in rotational speed of 300 rpm. By increasing traverse speed at constant rotational speed of 600 rpm grain size of the nugget zone decreased and ductility increased. Achievable ductility was limited by cavity formation due to lower heat input and deformation in samples with defects.

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.

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