scholarly journals 3D-Printed Tool Shoulder Design for the Analogue Modelling of Bobbin Friction Stir Weld Joint Quality

2021 ◽  
Vol 21 (1) ◽  
pp. 27-42
Author(s):  
A. Tamadon ◽  
D. J. Pons ◽  
K. Chakradhar ◽  
J. Kamboj ◽  
D. Clucas
Keyword(s):  
Friction Stir Welding ◽  
Cross Sections ◽  
Weld Joint ◽  
Flow Patterns ◽  
Friction Stir Weld ◽  
Butt Weld ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Analogue Modelling ◽  
3D Printed

Abstract A variety of tool shoulder designs comprising three families i.e. blade, spiral and circular shaped scrolls, were produced to improve the material flow and restrictions to avoid the tunnel void. The bobbin tools were manufactured by 3D printing additive manufacturing technology using solid filament. The butt weld joint was produced by each tool using plasticine as the workpiece material. The apparent surface features and bi-colour cross-sections provided a physical flow comparison among the shoulder designs. For the bobbin friction stir welding (BFSW), the tool shoulder with a three-spiral design produced the most stability with the best combination of the flow patterns on surface and cross-sections. The circular family tools showed a suitable intermixing on the surface pattern, while the blade scrolls showed better flow features within the cross-sections. The flow-driven effect of the shoulder features of the bobbin-tool design (inscribed grooves) was replicated by the 3D-printed tools and the analogue modelling of the weld samples. Similar flow patterns were achieved by dissimilar aluminium-copper weld, validating the accuracy of the analogue plasticine for the flow visualization of the bobbin friction stir welding.

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%.

Studies of the characterization of weld joint created by using friction stir welding with stellite stir tool

2020 ◽  
Author(s):  
G. Britto Joseph ◽  
T. N. Valarmathi ◽  
A. John Rajan ◽  
K. Pawana Sudeer Kumar ◽  
S. Prasath
Keyword(s):  
Friction Stir Welding ◽  
Weld Joint ◽  
Friction Stir

A Thermo-Fluid Analysis of the Friction Stir Welding Process

2007 ◽  
Vol 539-543 ◽  
pp. 3832-3837 ◽  
Author(s):  
D. Jacquin ◽  
Christophe Desrayaud ◽  
Frank Montheillet
Keyword(s):  
Friction Stir Welding ◽  
Bulk Material ◽  
Welding Process ◽  
Vertical Motion ◽  
Velocity Fields ◽  
Fluid Simulation ◽  
Metal Sheet ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Fluid Analysis

The thermo-mechanical simulation of Friction Stir Welding focuses the interest of the welding scientific and technical community. However, literature reporting material flow modeling is rather poor. The present work is based on the model developed by Heurtier [2004] and aims at improving this thermo-fluid simulation developed by means of fluid mechanics numerical and analytical velocity fields combined together. These various velocity fields are investigated separately and especially according to the power dissipated during the flow. Boundary conditions are considered through a new approach based on the kinematic analysis of the thread of the pin. An equilibrium is established between the vertical motion of the bulk material dragged in the depth of the metal sheet, and its partial circulation around the pin. The analyses of the obtained velocity fields enable the understanding of the welded zone asymmetry and highlights the bulk material mixing between the welded coupons in the depth of the sheet. A regression is performed on the relative sliding velocity of the aluminium according to the surface of the tool: shoulder and pin. Two dimension flow lines in the depth of the metal sheet are then obtained and successfully compared with the results obtained by Colegrove (2004) [1].

Effects of Tool Pin Profile and Tool Shoulder Diameter on the Tensile Behaviour of Friction Stir Welded Joints of Aluminium Alloys

2014 ◽  
Vol 984-985 ◽  
pp. 586-591 ◽  
Author(s):  
R. Ashok Kumar ◽  
M.R. Thansekhar
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Tensile Properties ◽  
Welded Joints ◽  
Tensile Behaviour ◽  
Light Weight ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Weight Structures

— For fabricating light weight structures, it requires high strength-to weight ratio. AA6061 aluminium alloy is widely used in the fabrication of light weight structures. A356 aluminium alloy has wide spread application in aerospace industries. Friction stir welding is solid state joining process which is conducting for joining similar and dissimilar materials. The friction stir welding parameters play an important role for deciding the strength of welded joints. In this investigation, A356 and AA6061 alloys were friction stir welded by varying triangular, square, hexagonal pin profiles of tool keeping the remaining parameters same and AA6061 alloys were friction stir welded by varying tool shoulder diameter as 12mm,15mm,18mm without changing other parameters. Tensile properties of each joint have been analyzed microscopically. From the experimental results, it is observed that hexagonal pin profiled tool and 15mm shoulder diameter tool provides higher tensile properties when compared to other tools.

Friction Stir Welding of Aluminum 6061-T6 and Multi-Purpose Copper 11000 Alloy

2017 ◽  
Author(s):  
Lewis N. Payton
Keyword(s):  
Friction Stir Welding ◽  
Copper Alloy ◽  
Tangential Velocity ◽  
Nuclear Industry ◽  
Fusion Welding ◽  
Alternative Methods ◽  
Friction Stir Weld ◽  
Tool Geometry ◽  
Work Piece ◽  
Friction Stir

Friction Stir Welding (FSW) is a solid-state joining process invented by The Welding Institute (TWI, United Kingdom) in 1991 in partnership with the National Aeronautics Space Agency. The process is emerging as one of the preferred alternative methods to permanently join materials that are difficult to join with traditional fusion methods (e.g., MIG, TIG, etc.). The welding of various copper alloys to various aluminum alloys is of great interest to the nuclear industry and the electrical distribution industry. The very different melting points of these two alloys preclude traditional fusion welding. Since the pin tool is simultaneously rotating and traversing through the work piece, flow around the tool is asymmetrical. This has led to designating one side of the tool as advancing and the opposite side as retreating. On the advancing side of the weld, the tool has a tangential velocity in the same direction as the weld is being created. The retreating side of the weld tool is the opposite. It can be can expected that asymmetric heating and deformation will occur in the weld due to this advancing/retreating nature of the FSW pin tool. Although previous studies have been performed that have observed this asymmetric behavior in both similar and dissimilar materials, the resulting welds have been of a poor quality. Large statistical experiments were conducted locally to study the effects of tool geometry, process parameters, and material composition have upon the friction stir butt welding of aluminum alloy 6061-T6 to copper alloy 11000 using a modern conventional 3-axis CNC vertical mill. The research seeks to determine (1) which direction a dissimilar metal friction stir weld between aluminum and copper should be executed, (2) the optimal shoulder diameter to be used when friction stir welding aluminum and copper on a CNC mill, and (3) the addition of a third material to act as an aide. The extensive statistical interactions between these parameters is also documented. A weld schedule was developed that resulted in an ultimate tensile strength (UTS) surpassing (greater than 90% of the weaker, more ductile copper alloy UTS strength) what has been documented in the current literature despite the machine limitations of the CNC vertical mill. Proper optimization of the welding schedule developed may approach 100 percent of the basic copper 11000 properties across the welded zone into the aluminum 6061-T6 alloy.

On the problem of tool destruction when obtaining fixed joints of thick-walled aluminum alloy blanks by friction welding with mixing

2021 ◽  
Vol 23 (3) ◽  
pp. 72-83
Author(s):  
Kirill Kalashnikov ◽  
◽  
Andrey Chumaevskii ◽  
Tatiana Kalashnikova ◽  
Aleksey Ivanov ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Friction Welding ◽  
Welding Process ◽  
High Strength ◽  
Heterogeneous Structure ◽  
Adhesive Interaction ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Electric Erosion

Introduction. Among the technologies for manufacturing rocket and aircraft bodies, marine vessels, and vehicles, currently, more and more attention is paid to the technology of friction stir welding (FSW). First of all, the use of this technology is necessary where it is required to produce fixed joints of high-strength aluminum alloys. In this case, special attention should be paid to welding thick-walled blanks, as fixed joints with a thickness of 30.0 mm or more are the target products in the rocket-space and aviation industries. At the same time, it is most prone to the formation of defects due to uneven heat distribution throughout the height of the blank. It can lead to a violation of the adhesive interaction between the weld metal and the tool and can even lead to a destruction of the welding tool. The purpose of this work is to reveal regularities of welding tool destruction depending on parameters of friction stir welding process of aluminum alloy AA5056 fixed joints with a thickness of 35.0 mm. Following research methods were used in the work: the obtaining of fixed joints was carried out by friction welding with mixing, the production of samples for research was carried out by electric erosion cutting, the study of samples was carried out using optical metallography methods. Results and discussion. As a result of performed studies, it is revealed that samples of aluminum alloy with a thickness of 35.0 mm have a heterogeneous structure through the height of weld. There are the tool shoulder effect zone and the pin effect zone, in which certain whirling of weld material caused by the presence of grooves on tool surface is distinctly distinguished. It is shown that the zone of shoulders effect is the most exposed to the formation of tunnel-type defects because of low loading force and high welding speeds. It is revealed that tool destruction occurs tangentially to the surface of the tool grooves due to the high tool load and high welding speeds.

Multi-Performance Optimization in Friction Stir Welding of Aluminum Alloy Using Response Surface Methodology

2018 ◽  
pp. 240-263
Author(s):  
Rajat Gupta ◽  
Kamal Kumar ◽  
Neeraj Sharma
Keyword(s):  
Response Surface Methodology ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Response Surface ◽  
Process Parameters ◽  
Performance Optimization ◽  
Desirability Function ◽  
High Carbon Steel ◽  
Friction Stir ◽  
Tool Shoulder

This chapter presents the friction stir welding (FSW) of aluminum alloy AA-5083-O using vertical milling machine. In present FSW experimentation, effects of different process parameter namely tool rotation speed, welding speed, tool geometry, and tool shoulder diameter have been determined on welding quality of two pieces of AA-5083-O using response surface methodology (RSM). The optimal sets of process parameters have been determined for weld quality characteristics namely tensile strength (UTS) and percentage elongation (%EL). In present experimentations, a specially designed tool made of high carbon steel with different shoulder diameters (15mm, 17.5mm, and 20 mm) having constant pin length (6 mm) were used for FSW of two pieces of aluminum alloy. The ANOVA and pooled ANOVA were used to study the effect of FSW parameters on UTS and %EL. Multi response optimization has been carried out using desirability function in conjunction with RSM to obtain the optimal setting of process parameters for higher UTS and lower %EL.

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