scholarly journals The influence of friction stir welding tool shape on quality of AZ31 Magnesium welding product

2021 ◽  
Vol 10 (2) ◽  
Author(s):  
Irza Sukmana ◽  
Fauzi Ibrahim ◽  
Ahmad Yudi Eka Risano
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Base Metal ◽  
Welding Speed ◽  
Welding Process ◽  
Base Metals ◽  
Friction Stir ◽  
Tool Shape ◽  
Spiral Shape ◽  
Tool Rotation

Magnesium is one type of material that can be used as a base metal in welding. Magnesium has superior properties, including low density, good ductility, medium strength and excellent corrosion resistance. Because of its properties, the metal is widely used, ranging from household goods to aircraft components. These base metals are categorised as mild when viewed from the specific gravity of magnesium (1.74 g/cm3 and 1.83 g/cm3). Welding is the process of merging two or more base metals which are merged at the contact surface with or without additives or fillers. Welding is divided into two main categories, Liquid and Solid-State Welding. Friction Stir Welding (FSW) is an example of Solid-State Welding (Non-Fusion Welding). FSW is a friction welding process that twists the tool by utilising heat energy and pressing without additives or fillers until the base metal is in a phase change.  The welding process in this study used the cone and spiral shape with a tool rotation at 2000 rpm and a welding speed of 16 mm/min. The tests carried out are tensile and hardness testing. This study found that the tool shape, tool rotation, and welding speed significantly affect the mechanical properties of the welded AZ31 magnesium. The spiral shape will make the welding area wider. Although the cone shape will have a small area, the weld will look perfect with good tensile strength, while the hardness values for the two tool shapes are almost the same, but the cone shape is better.

Friction Stir Welding of Oxygen Free Copper and 60%Cu-40%Zn Copper Alloy

2008 ◽  
Vol 580-582 ◽  
pp. 447-450
Author(s):  
Hwa Soon Park ◽  
Byung Woo Lee ◽  
Taichi Murakami ◽  
Kazuhiro Nakata ◽  
Masao Ushio
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Base Metal ◽  
Welding Speed ◽  
Copper Alloy ◽  
Rotation Speed ◽  
Friction Stir ◽  
Wide Range ◽  
Hardness Values ◽  
Tool Rotation

The mechanical properties of the friction stir welds of the oxygen free copper (OFC) and 60%Cu-40%Zn copper alloy(60/40 brass) were investigated. The defect-free welds were obtained in a relatively wide range of welding conditions; the tool rotation speed had rpm of 1000 to 2000 in the OFC and 1000 to 1500 in the 60/40 brass, with the welding speed of 500 to 2000 mm/min. The SZ hardness values of the OFC welds were almost the same or slightly lower than those of the base metal. However, the SZ hardness values of the 60/40 brass in all welding conditions were much higher than those of the base metal. The SZ hardness values of both metals increase with a decrease in heat input. The tensile properties of the all-SZ showed relative correspondence to the variation of the SZ hardness values.

scholarly journals Investigations on force generation and joint properties of dissimilar thickness friction stir corner welded AA 5086 alloy

2020 ◽  
Vol 40 (1) ◽  
pp. 67-74
Author(s):  
Manigandan Krishnan ◽  
Senthilkumar Subramaniam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Welding Process ◽  
Spindle Motor ◽  
Parent Material ◽  
Force Generation ◽  
Friction Stir ◽  
Current Consumption ◽  
Spindle Motor Current

The force generation, joint mechanical and metallurgical properties of friction stir corner welded non-heat treatable AA 5086 aluminum alloy are investigated in this paper. The friction stir welding process is carried out with the plate thicknesses of 6 mm and 4 mm. The welding speed, tool rotational speed and tool plunge depth were considered as the process parameters to conduct the welding experiments. The machine spindle motor current consumption and tool down force generation during friction stir welding were analyzed. The microstructures of various joint regions were observed. The tensile samples revealed the tensile strength of 197 MPa with tool rotational and welding speeds of 1,000 rev/min and 150 mm/min respectively, which is 78 % of parent material tensile strength. A maximum micro hardness of 98 HV was observed at thermomechanically joint affected zone, which was welded with tool rotation of 1,000 rev/min and welding speed of 190 mm/min.

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

Probeless Tool Aided Friction Stir Welding as a Fabrication Technique for Tungsten Embedded Mechanical Composite of Copper

2014 ◽  
Author(s):  
Yogita Ahuja ◽  
Raafat Ibrahim ◽  
Anna Paradowska ◽  
Daniel Riley
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Base Metal ◽  
Parametric Study ◽  
Effective Parameter ◽  
Frictional Heat ◽  
Fabrication Technique ◽  
Shear Testing ◽  
Friction Stir ◽  
Parameter Combination

Friction stir welding (FSW) is a relatively new solid state metallurgical joining technique. It flourishes on the simple principle of utilising frictional heat by the stirring motion of a non-consumable rotating tool to create the seam. Feasibility of FSW aided by a newly designed probeless tool was investigated for fabricating copper-tungsten mechanical composite. The most effective parameter combination was determined by conducting a parametric study of the probeless tool aided FSW copper. Strength of the mechanical composite fabricated at this condition was evaluated through punch shear testing. Punch shear testing established that the friction stir welded interface of the copper-tungsten composite was 87% as strong as the base metal (i.e. copper). Advantages of the designed technique have been summarised.

A Study on the Thermal Deformation of Fillet Joint Friction Stir Welding

2020 ◽  
Author(s):  
Sungwook Kang ◽  
Jaewoong Kim ◽  
Donghyun Kim ◽  
Kwangjin Lee ◽  
Yoonchul Jung
Keyword(s):  
Friction Stir Welding ◽  
Heat Source ◽  
Welding Process ◽  
Frictional Heat ◽  
Process Conditions ◽  
Joint Friction ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Shape ◽  
Fillet Joint

Abstract In this study, experiments and simulations were performed for fillet joint friction stir welding according to tool shape and welding conditions. Conventional butt friction stir welding has good weldability because heat is generated by friction with the bottom of the tool shoulder. However, in the case of fillet friction stir welding, the frictional heat is not sufficiently generated at the bottom of the tool shoulder due to the shape of the tool and the shape of the joint. Therefore, it is important to sufficiently generate frictional heat by slowing the welding speed as compared to butt welding. In this study, experiments and simulations were carried out on an aluminum battery housing made by friction stir welding an extruded material with a fillet joint. The temperature of the structure was measured using thermocouple during welding, and the heat source was calculated through correlation analysis. Thermal elasto-plastic analysis of the structure was carried out using the calculated heat source and geometric boundary conditions. It is confirmed that the experimental results and the simulation results are well matched. Based on the results of the study, the deformation of the structure can be calculated through simulation even if the tool shape and welding process conditions change.

Studies on Friction Stir Welding of AA2014, AA6082 and AA7075 Simillar and Dissimillar Joints

2020 ◽  
Vol 37 ◽  
pp. 15-24
Author(s):  
P. Gunasekaran ◽  
K.T. Thilagham ◽  
D. Noorullah
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotation Speed ◽  
Hardness Distribution ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Profile ◽  
Tool Rotation

The joining of similar and dissimilar AA2014, AA6068 and AA7075 aluminium plates of 6mm thickness was carried out by friction stir welding (FSW) technique. FSW of Aluminium to Aluminium has caught significant consideration from assembling industries, such as Shipbuilding, Automotive, Railway and Aircraft generation. Here, the chosen process parameters are tilt angle (2º), tool rotation speed (900rpm) and transverse feed of (80mm/min) at constant axial force 2kN. An attempt was made to join the similar and dissimilar aluminium plate of 6 mm thickness with a conical tapered tool profile. Then, the effect of welding speed on microstructures, hardness distribution and tensile properties of the welded similar and dissimilar joints AA2014, AA6068 and AA7075 were investigated.

Influence of Tool Rotational Speed on the Mechanical Properties of Friction Stir Welded Al-Cu-Li Alloy

2016 ◽  
Vol 857 ◽  
pp. 228-231
Author(s):  
Ho Sung Lee ◽  
Ye Rim Lee ◽  
Kyung Ju Min
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Space Shuttle ◽  
Welding Process ◽  
High Strength ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Mechanical And Microstructural Properties ◽  
Tool Rotation

Aluminum-Lithium alloys have been found to exhibit superior mechanical properties as compared to the conventional aerospace aluminum alloys in terms of high strength, high modulus, low density, good corrosion resistance and fracture toughness at cryogenic temperatures. Even though they do not form low-melting eutectics during fusion welding, there are still problems like porosity, solidification cracking, and loss of lithium. This is why solid state friction stir welding is important in this alloy. It is known that using Al-Cu-Li alloy and friction stir welding to super lightweight external tank for space shuttle, significant weight reduction has been achieved. The objective of this paper is to investigate the effect of friction stir tool rotation speed on mechanical and microstructural properties of Al-Cu-Li alloy. The plates were joined with friction stir welding process using different tool rotation speeds (300-800 rpm) and welding speeds (120-420 mm/min), which are the two prime welding parameters in this process.

Solid State Welding Process for Aerospace Components

2015 ◽  
Vol 1119 ◽  
pp. 597-600
Author(s):  
Hyun Ho Jung ◽  
Ye Rim Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo ◽  
Kyung Ju Min ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Structural Integrity ◽  
Welding Process ◽  
Diffusion Welding ◽  
Intimate Contact ◽  
Friction Stir ◽  
Base Materials ◽  
Welding Processes ◽  
And Diffusion

Since solid state welded joint is formed from an intimate contact between two metals at temperatures below the melting point of the base materials, the structural integrity of welding depends on time, temperature, and pressure. This paper provides some of examples of friction stir welding and diffusion welding process for aerospace components. Friction stir welding process of AA2195 was developed in order to study possible application for a large fuel tank. Massive diffusion welding of multiple titanium sheets was performed and successful results were obtained. Diffusion welding of dissimilar metals of copper and stainless steel was necessary to manufacture a scaled combustion chamber. Diffusion welding of copper and steel was performed and it is shown that the optimum condition of diffusion welding is 7MPa at 890°C, for one hour. It is shown that solid state welding processes can be successfully applied to fabricate lightweight aerospace parts.

Numerical Modeling of Thermal Field Distribution during Friction Stir Welding (FSW) of Dissimilar Materials

2016 ◽  
Vol 254 ◽  
pp. 261-266
Author(s):  
Bogdan Radu ◽  
Cosmin Codrean ◽  
Radu Cojocaru ◽  
Cristian Ciucă
Keyword(s):  
Numerical Modeling ◽  
Friction Stir Welding ◽  
Solid State ◽  
Thermal Field ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Dissimilar Joints ◽  
Element Analysis ◽  
Friction Stir ◽  
The Cost

Friction Stir Welding (FSW) is an innovative solid state welding process, relatively new in industry, which allow welding of two or more materials which have very different properties, particularly thermal properties as fusion temperature, thermal expansion coefficient, specific heat and thermal conduction and have a predisposition to form intermetallic brittle phases, neither one of the components to be weld reach to the melting point. Being a solid state welding process temperature field is very important for the quality of the welded joint, and a lot of researches focused on this topic. This paper presents some results in modeling and estimation of thermal field developed during FSW of dissimilar joints, using Finite Element Analysis. Numerical modeling of thermal field allows engineers to predict, in advance, the evolution of temperature and to estimate the behavior of the welded materials during the welding process. This will reduce significantly the time and number of experiments that have to be carried out, in the process of establishing a good FSW technology, as well as reducing significantly the cost of the tests.

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