scholarly journals Influences of Welding Parameters on Friction Stir Welding of Aluminum and Magnesium: A Review

2021 ◽  
Keyword(s):  
Friction Stir Welding ◽  
Industrial Applications ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Welding Quality ◽  
Micro Hardness ◽  
Friction Stir ◽  
Increasing Demand ◽  
Aluminum And Magnesium Alloys ◽  
Joining Process

Abstract. Friction stir welding (FSW) is an important joining process wherein two dissimilar metals and alloys are welded together using frictional heat produced in a revolving tool and workpiece. FSW is playing an important role in dissimilar material joining of Magnesium (Mg) and Aluminum (Al) materials due to the increasing demand for their industrial applications. In this review article, the research background of FSW processes, and influences of joining factors on tensile strength, micro-hardness, and microstructures of FSW of Al-Mg alloy materials have been studied. The effects of joining factors for example axial force, tool revolving speed, tool incline, speed, and offset on welding characterizes have been enlightened to make defect-free FSW of aluminum and magnesium alloys. The microstructural behaviors of intermetallic formation and material drift in FSW zones of Al-Mg were also studied to find the scope to improve the welding quality.

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.

A Study on Friction Stir Welding Process for AA2219/AA2195 Joints

2018 ◽  
Vol 762 ◽  
pp. 339-342
Author(s):  
Ho Sung Lee ◽  
Koo Kil No ◽  
Joon Tae Yoo ◽  
Jong Hoon Yoon
Keyword(s):  
Friction Stir Welding ◽  
Welded Joints ◽  
Rotation Speed ◽  
Microstructural Analysis ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Manufacturing Cost ◽  
Significant Saving ◽  
Friction Stir ◽  
Rotation Direction

The object of this study was to study mechanical properties of friction stir welded joints of AA2219 and AA2195. AA2219 has been used as an aerospace materials for many years primarily due to its high weldability and high specific strength in addition to the excellent cryogenic property so to be successfully used for manufacturing of cryogenic fuel tank for space launcher. Relatively new Aluminum-Lithium alloy, AA2195 provides significant saving on weight and manufacturing cost with application of friction stir welding. Friction stir welding is a solid-state joining process, which use a spinning tool to produce frictional heat in the work piece. To investigate the effect of the rotation direction of the tool, the joining was performed by switching the positions of the two dissimilar alloys. The welding parameters include the travelling speed, rotation speed and rotation direction of the tool, and the experiment was conducted under the condition that the travelling speed of the tool was 120-300 mm/min and the rotation speed of the tool was 400-800 rpm. Tensile tests were conducted to study the strength of friction stir welded joints and microhardness were measured with microstructural analysis. The results indicate the failure occurred in the relatively weaker TMAZ/HAZ interface of AA2219. The optimum process condition was obtained at the rotation speed of 600-800 rpm and the travelling speed of 180-240 mm/min.

Influences of Tool pin Profile and Tool Shoulder Curvature on the Formation of Friction Stir Welding Zone in AA6061 Aluminium Alloy

2012 ◽  
Vol 445 ◽  
pp. 789-794 ◽  
Author(s):  
Vahid Moosabeiki ◽  
Ghasem Azimi ◽  
Mostafa Ghayoor
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Zone Formation ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Shoulder ◽  
Aa6061 Aluminium Alloy ◽  
Tool Pin

Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the weld quality. Friction stir tool plays a major role in friction stir welding process. In this investigation, it is tried to evaluate the effect of tool pin thread and tool shoulder curvature on FSW zone formation in AA6061 aluminium alloy. In this regard, six different tool pin geometries (threadless triangular pin with/without conical shoulder, threaded triangular pin with conical shoulder, threadless square pin with/without conical shoulder, threaded square pin with conical shoulder) are used to fabricate the joints. The formation of FSP zones are analyzed macroscopically. Tensile properties of the joints are evaluated and correlated with the FSP zone formation. Consequently, it is obtained that welding creates a higher quality compared to other tool pin profiles using the square tool with curved shoulder and having threaded pin.

Friction Stir Welding on Corner Joint with New Surface Preparation Design

2016 ◽  
Vol 836 ◽  
pp. 208-213
Author(s):  
Widia Setiawan ◽  
Djarot B. Darmadi ◽  
Wahyono Suprapto ◽  
Rudy Sunoko
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tensile Test ◽  
Surface Preparation ◽  
Travel Speed ◽  
Welding Parameters ◽  
Micro Hardness ◽  
Micro Structure ◽  
Friction Stir ◽  
Preparation Design

Aluminium 6061 was joined by friction stir welding (FSW) with new surface preparation on corner design. The distribution micro structure in Corner-joints was tool welded rotation (rpm), and travel speed (mm/mnt) observed and analyzed. The welding parameters observing the tensile strength, micro structure and micro hardness it can be said. The result structure micro are homogen whilst from tensile test the strength joint is quilt good even better from preview publihsed papers. The obtained with the transverse speed 15 mm/menit, and 1500 rpm.

scholarly journals Process Optimization and Influence of Micro Structural Characterization by Friction Stir Welding of Various Materials

2019 ◽  
Vol 9 (2) ◽  
pp. 2105-2113
Keyword(s):  
Friction Stir Welding ◽  
Polymeric Materials ◽  
Industrial Sector ◽  
Industrial Applications ◽  
Critical Parameters ◽  
Experimental Investigations ◽  
Welding Parameters ◽  
Workpiece Material ◽  
Suitable Material ◽  
Friction Stir

Various advanced joining techniques are available now days to suit the process challenges and to connect the specific application areas of industrial sector. Several experimental investigations on mechanical characteristics of different materials along with process parameters are successfully joined and evaluated. Friction stir welding (FSW) defines a solid state bonding operation, which uses a non-consumable tool to join the workpiece material. Friction stir welding technique can be applied to weld the similar and dissimilar materials including ferrous, nonferrous and polymers to develop sustainable byproduct. Industrial applications in the fields of automobiles, aerospace are expecting the techniques to join various combinations of materials for lightweight and improved performance from engineering designs that ensures the fulfillment of current challenging desires. As the research intensifies into wider aspects like obtaining suitable material combinations to attain the objective of reduced weight and also to satisfy applications aspects, friction stir welding gave perfect platform to exhibit newer material integration. Objective of this paper is to research and analyze the influence of critical parameters through FSW. In this direction, review based on process based methodology of different materials combinations like ferrous materials, non-ferrous materials and dissimilar material has been focused. Welding parameters influencing the FSW operations and their effect on mechanical properties in the respective categories of material pooling has been indicated. Tensile test, hardness inspection, macro and microstructural evaluations of subjected materials have been highlighted in this section. This suggest with further recommendations that FSW can also be applied effectively in case of polymeric materials in continuance of research domain.

Influence of Friction Stir Welding Parameters on the Mechanical Properties of EN AW-7075 Weld Joints

2016 ◽  
Vol 835 ◽  
pp. 210-215
Author(s):  
Máté Nagy ◽  
Mária Behúlová
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Ultimate Strength ◽  
Base Material ◽  
High Strength ◽  
Welding Parameters ◽  
Micro Hardness ◽  
Friction Stir ◽  
Weld Joints ◽  
Welding Processes

The paper deals with the friction stir welding (FSW) of the high strength EN AW 7075-T651 aluminium alloy with the aim to analyze the influence of welding parameters on the mechanical properties of Al-weld joints. FSW represents relatively novel solid-state technology of material joining which can be successfully applied for welding of several metallic alloys including the high-strength aluminium alloys that are hard to weld by conventional fusion welding processes. In cooperation with VÚZ - PI SR Bratislava, nine experimental weld joints of samples with dimensions of 300 × 150 × 10 mm were prepared using the welding machine of the FSW-LM-060 type and different parameters of welding – the welding speed from 60 to 120 mm/min and the tool rotation rate from 600 to 1000 rpm in clockwise direction. The quality of weld joints was evaluated by static tensile tests and micro-hardness measurements. According to obtained results of tensile testing, the average values of ultimate strength of weld joints are by 32.2 % lower comparing with the ultimate strength of the base material. On the other hand, the ductility increased by 7.2 %. The highest micro-hardness of weld joints at the level of 129 HV was measured in thermo-mechanically affected zone on the retreating side.

Simplified Thermo-Elastoplastic Numerical Modelling Techniques Applied to Friction Stir Welding of Mild Steel

2013 ◽  
Author(s):  
Daniel Micallef ◽  
Duncan Camilleri ◽  
Pierluigi Mollicone
Keyword(s):  
Heat Flux ◽  
Friction Stir Welding ◽  
Residual Stresses ◽  
Boundary Conditions ◽  
Mild Steel ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Thermal Gradients ◽  
Friction Stir ◽  
Tool Shoulder

Friction stir welding is a relatively new advanced joining technique that requires minimal power input, ultimately leading to less inherent residual stresses and distortion. The process involves a spinning tool which first plunges into the surface of the, to be welded assembly and then traverses along the joint. Frictional heat is generated, softening the material at temperatures significantly below the melting temperature of the parent material. As the tool traverses along the joint at a predetermined speed, the assembly is joined by means of a plastic straining process. This advanced welding technology has been validated for various aluminium alloys but it is only recently, due to advances in tool technology, that the possibility of joining mild steel using friction stir welding has become a viable option. This study looks into friction stir welding of mild steel and develops simplified numerical methods for the prediction of thermal gradients, residual stresses and deformation. In principle the process modelling requires a multi-disciplinary approach involving coupled thermo-fluid, microstructural-structural modelling process. Much of the latest thermo-mechanical studies of friction stir welding rely on a number of over simplifications particularly related to the heat flux distribution across the tool shoulder, and also on the backing plate boundary conditions. The objective of this paper is to scrutinise the effects of modelling in more detail and establish the most important factors leading to accurate yet computationally efficient prediction of thermal gradients and inherent residual stresses. The results show that both the heat input and heat loss modelling, due to heat dissipation to the surroundings, are crucial for the determination of the final inherent welding residual stresses. The heat generated is modelled through a predefined linear heat flux variation across the tool shoulder. However if a more precise and localized residual stress information is sought, a full thermo-fluid-structural analysis is required. This is time consuming and probably does not give significant information on manufacturing optimization. On the other hand, simplified global solutions offer the possibility to optimise friction stir welding parameters and boundary conditions during the preliminary stages of the development of the fabrication procedures, at relatively minimal time and processing power. This work is financed under the European Commission in Call FP7-SST-2012-RTD-1 High Integrity Low Distortion Assembly (HILDA) project.

scholarly journals Optimization of process parameters on friction stir welding of 2014 aluminum alloy plates

2017 ◽  
Vol 7 (1.1) ◽  
pp. 9 ◽  
Author(s):  
V. Jaiganesh ◽  
D. Srinivasan ◽  
P. Sevvel
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
High Strength ◽  
Frictional Heat ◽  
Weld Strength ◽  
Electron Interaction ◽  
Welding Parameters ◽  
Work Piece ◽  
Friction Stir

Aluminum Alloy 2014 is a light weight high strength alloy used widely in the aerospace and also in other industries. 2014 is the second most popular of the 2000-series aluminium alloys, after 2024 aluminium alloy. However, it is difficult to weld, as it is subject to cracking. Joining of 2014 aluminium alloy in friction stir welding which is based on frictional heat generated through contact between a rotating tool and the work piece. Determination of the welding parameters such as spindle speed, transverse feed , tilt angle plays an important role in weld strength. The whole optimization process is carried out using Taguchi technique. The SEM analysis is done to check the micro structure of the material after welding by electron interaction with the atoms in the sample. Tensile test have been conducted and the s-n ratio curve is generated. The test is conducted and analysed on the basis of ASTM standards.

scholarly journals Effect of Copper Donor Material Assisted Friction Stir Welding of AA6061-T6 Alloy On Downward Force, Microstructure, And Mechanical Properties

2021 ◽  
Author(s):  
Srinivasa Bhukya ◽  
Zhenhua Wu ◽  
Joseph Maniscalco ◽  
Abdelmageed Elmustafa
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Tensile Failure ◽  
Welding Parameters ◽  
Micro Hardness ◽  
Friction Stir ◽  
Donor Material ◽  
Microstructure And Mechanical Properties ◽  
Effect Of Copper ◽  
Increase Tool Life

Abstract In this research, Copper (Cu) donor material assisted friction stir welding (FSW) of AA6061-T6 alloy was studied. Cu assisted FSW joints of AA6061-T6 alloy were prepared at a constant tool rotational rate of 1400 rpm and various welding speeds at 1 mm/s and 3 mm/s. The Cu donor material of different thickness (i.e., 20%, 40%, and 60%) with respect to the workpiece thickness was selected to assist the FSW joining at the plunge stage. It is observed that the downward force generated in the FSW process was gradually decreased after introducing Cu donor material with incremental thicknesses with respect to workpiece at the plunge stage. Post-weld analysis was characterized in terms of microstructure, and mechanical properties. The results of microstructure analysis at the stir zone (SZ) show the formation of finer grains due to dynamic recrystallization and plastic deformation. Micro-hardness tests reveal that the hardness decreased from the base metal (BM) to the SZ across the heat affected zone (HAZ) and thermo-mechanically affected zone (TMAZ). The lowest value of hardness appeared in the TMAZ and HAZ where tensile failure occurs. With increasing welding speed, the average hardness in the SZ decreased due to lower heat input and faster cooling rate. Tensile test plots show no significant change in ultimate tensile strength with or without Cu donor material. Fractography of tensile tested samples shows both ductile and brittle like structure for given welding parameters. This proposed work of FSW with Cu donor material is promising to increase tool life due to the decrement of the downforce during plunge and throughout the welding stage. Meanwhile, the inclusion of donor material did not compromise the weld quality in terms of the mechanical properties and micro-hardness.

Friction stir welding of aluminium alloys: An overview of experimental findings – Process, variables, development and applications

2017 ◽  
Vol 233 (6) ◽  
pp. 1191-1226 ◽  
Author(s):  
Pratik H Shah ◽  
Vishvesh J Badheka
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Copper Alloys ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Industrial Applications ◽  
Future Research ◽  
Welding Parameters ◽  
Friction Stir ◽  
Friction Stir Welding Process

The never ending appetite of the mankind to produce more and more competitive products results in continuous development of newer and newer manufacturing processes. One of such a kind, a solid state welding process highly appreciated for joining of a variety of aluminium and copper alloys, is friction stir welding. The process is also an accomplished method for joining dissimilar materials efficiently. The process finds its major application for joining hard-to-weld metals, especially the precipitation hardenable aluminium alloys and is widely adopted by industries for the welding of such aluminium alloys. However, the process has still not found an economical way for welding of steels and hence found limited applications in industries for welding steels. This paper aims at providing a comprehensive review of the work undertaken in the field of friction stir welding and provides an insight into the friction stir welding of aluminium alloys. The article pays critical attention and analytical evaluation of classification of aluminium alloys, friction stir welding process parameters, the mechanical testing and properties of the friction stir welding joints, macrostructure and microstructure evolution during friction stir welding, friction stir welding defects and industrial applications of the process. The friction stir welding process variants are discussed as well. Special accentuation has been given to (i) effect of friction stir welding parameters on the microstructure evolved and thus the ultimate mechanical properties (viz. tensile strength, hardness, fatigue strength, fracture toughness and residual stresses), (ii) the texture formation, microstructure refinement and the role of intermetallics. However, studies related to welding of dissimilar aluminium alloys, temperature, and heat transfer modeling and material flow are out of the scope of this paper. Finally, the directions of future research are examined.

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