Fundamental Aspects, Mechanical Behaviour and Mathematical Understanding of Friction Spot Stir Welds: A Review

2021 ◽  
Vol 39 (11) ◽  
Author(s):  
Arash Fattahi ◽  
E.E. Supeni ◽  
M.K.A. Ariffïn ◽  
M.R. Ishak ◽  
Sahar Zolfaghari ◽  
...  
Keyword(s):  
Spot Welding ◽  
Mechanical Performance ◽  
Processing Parameters ◽  
Friction Stir Spot Welding ◽  
Mathematical Understanding ◽  
Environmental Conservation ◽  
Service Industries ◽  
Effective Control ◽  
Friction Stir ◽  
Welding Processes

The energy-saving and environmental conservation are increasingly important issues in manufacturing and service industries worldwide that have received considerable attention in recent years. Most importantly, this process eliminates the grain solidification errors generated by the standard fusion process. Thus, in this papers types and methods of stir welding will be explained and discussed accordingly .   Friction stir spot welding is a tunable method as it allows an effective control and amendment of processing parameters using refill and powder-assisted schemes that can solve the problem of the keyhole and mechanical weaknesses in the joining of light metals processed by conventional Friction stir spot welding. This comprehensive review mainly focuses on the fundamental aspects of Friction stir spot welding processes and their impacts on the microstructural features and mechanical performance and mathematical understanding of various similar and dissimilar systems. To conclude, the challenges in further modification of Friction stir spot welding and future outlooks in different engineering applications are presented.

Effects of High Speed Tool Rotation in Micro Friction Stir Spot Welding of Aluminum A1100

2014 ◽  
Vol 493 ◽  
pp. 739-742 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
Suwarsono ◽  
Gandjar Kiswanto ◽  
Winarto
Keyword(s):  
Shear Strength ◽  
Spot Welding ◽  
High Speed ◽  
Tool Material ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Processes ◽  
Tool Rotation

Technology of Friction Stir Welding (FSW) is a relatively new technique for joining metal. In some cases on Aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and less distortion. The purpose of this study is to analyze the parameters effect of high speed tool rotation onmicro Friction Stir Spot Welding(μFSSW) to theshear strengthof welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. The spindle speed was fixed at 30000 rpm. Tool shoulder diameter was 3 mm, and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of pin diameter (1.5 mm, 2.0 mm, and 2.5 mm), a variable ofplunge speed(2 mm/min, 4 mm/min, 6 mm/min), and the variable ofdwell time(2 seconds, 4 seconds, 6 seconds). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was theshear strength.Response Surface Methods(RSM) was used to analyze μFSSW parameters with theshear strengthof welds. From the result of experiment and analysis, it is shown that the important welding parameters in high speed μFSSW process are pin diameter and plunge speed.

scholarly journals d EFFECT OF CYLINDRICAL PIN DEPTH ON THE TEMPERATURE DISTRIBUTION OF DISSIMILAR FRICTION STIR SPOT WELDING (FSSW)

2019 ◽  
Vol 19 (4) ◽  
pp. 357-368
Author(s):  
Kayser Aziz Ameen
Keyword(s):  
Spot Welding ◽  
Element Model ◽  
Friction Stir Spot Welding ◽  
Maximum Temperature ◽  
Thick Sheet ◽  
Nugget Zone ◽  
Friction Stir ◽  
Ansys Apdl ◽  
New Development ◽  
Welding Processes

Friction stir spot welding (FSSW) is provided a premium difference to resistance spot welding and rivet process for making the structures of aluminum sheet and it is a new development. ANSYS works is done which conducted on dissimilar material sheets of a1.1mm thick sheet of aluminum alloy (AA2024-T3) and a 0.8mm thick sheet of carbon steel (1006-AISI). A 3-D finite element model was built using ANSYS APDL to simulate the thermal and mechanical model during FSSW. The welding processes are performed using cylindrical pin with a 10mm diameter. Three tool rotational speeds are used during FSSW processes (900rpm, 1400rpm, 1800rpm). Results showed that the maximum temperature was 242.57ºC in nugget zone of dissimilar spot weld, at 15sec with a 0.4mm depth and 135.752°C at 10sec with a depth of 0.2mm.  

Towards Tool Path Numerical Simulation in Modified Friction Stir Spot Welding Processes

2009 ◽  
Vol 83-86 ◽  
pp. 1220-1227
Author(s):  
Gianluca Buffa ◽  
Livan Fratini
Keyword(s):  
Spot Welding ◽  
Tool Path ◽  
Base Material ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Lap Joints ◽  
Hollomon Parameter ◽  
Friction Stir ◽  
Strain And Strain Rate ◽  
Welding Processes

Spot welding can be considered a very common joining technique in automotive and transportation industries as it permits to obtain effective lap-joints with short process times and what is more it is easily developed through robots and automated systems. Recently the Friction Stir Spot Welding (FSSW) process has been proposed as a natural evolution of the already known Friction Stir Welding (FSW) process, allowing to obtain sound spot joints that do not suffer from the insurgence of typical welding defects due to the fusion of the base material. In the paper, a modified Friction Stir Spot Welding (FSSW) process, with a spiral circular movement given to the tool after the sinking stage, is proposed. A continuum based numerical model for Friction Stir Spot Welding process is developed, that is 2D Lagrangian implicit, coupled, rigid-viscoplastic. This model is used to investigate the distribution of the main field variables, namely temperature, strain and strain rate, as well as the Zener-Hollomon parameter which, in turn, strongly affects the Continuous Dynamic Recrystallization (CDRX) process that takes place in the weld nugget. Numerical and experimental results are presented showing the effects of the process parameters on the joint performances and the mechanical effectiveness of the modified process.

scholarly journals A COMPARATIVE STUDY ON SINGLE AND DOUBLE JOINTED CU-AL BIMETALLIC STRIPS USING FRICTION STIR SPOT WELDING PROCESS

2020 ◽  
Vol 15 (3) ◽  
Author(s):  
Karunakaran D ◽  
Venkatachalapathy VSK
Keyword(s):  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Lap Joint ◽  
H13 Steel ◽  
Friction Stir ◽  
Hazardous Gases ◽  
Friction Weld ◽  
Mechanical Bonding ◽  
Welding Processes

Welding is one of the best and quick process to join metals. In modern times, we concern more about environmental hazards due to hazardous gases liberated during conventional welding processes. Fiction Stir welding is a simple process in which a solid metal joint is produced by the heat of friction. In a similar technique, we can make spot welds of similar or dissimilar metallic joints by using Friction Stir Spot Welding. Since there is an absence of any liberation of poisonous gases, this method is safe to the environment and user. In this study, we made a dissimilar lap joint of Copper and Aluminium strips using an H13 steel tool. The pin profile of the tool is based on the thickness of the plate/weld. Weld based process parameters such as tool rotational speed, Dwell time and plunge depth. A lap joint with a desirable overlapping length between friction weld spots is compared and analyzed for mechanical bonding strength for both single and double joints. The results show a considerable increase in tensile strength for double-jointed specimen compared to a single-joint.

scholarly journals Parametric Study Of Friction Stir Spot Welding (FSSW) For Polymer Materials Case Of High Density Polyethylene Sheets: Experimental And Numerical Study

2020 ◽  
Vol 15 (55) ◽  
Author(s):  
Djilali Benyerou ◽  
El Bahri Ould Chikh ◽  
Habib Khellafi ◽  
Hadj Miloud Meddah ◽  
Ali Benhamena ◽  
...  
Keyword(s):  
Finite Element ◽  
Numerical Modeling ◽  
High Density Polyethylene ◽  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
High Density ◽  
Polymer Materials ◽  
Friction Stir ◽  
Welding Processes

Friction stir spot welding (FSSW) is a very important part of conventional friction stir welding (FSW) which can be a replacement for riveted assemblies and resistance spot welding. This technique provides high quality joints compared to conventional welding processes. Friction stir spot welding (FSSW) is a new technology adopted to join various types of metals such as titanium, aluminum, magnesium. It is also used for welding polymer materials which are difficult to weld by the conventional welding process. In various industrial applications, high density polyethylene (HDPE) becomes the most used material. The parameters and mechanical properties of the welds are the major problems in the welding processes. In this paper, we have presented a contribution in finite element modeling of the friction stir spot welding process (FSSW) using Abaqus as a finite element solver. The objective of this paper is to study the HDPE plates resistance of stir spot welding joints (FSSW). First, we show the experimental tests results of high-density polyethylene (HDPE) plates assembled by friction stir spot welding (FSSW). Three-dimensional numerical modeling by the finite element method makes it possible to determine the best representation of the weld joint for a good prediction of its behavior. Comparison of the results shows that there is a good agreement between the numerical modeling predictions and the experimental results.

Mechanical performance optimization of similar thin AA 7075‐T6 sheets produced by refill friction stir spot welding

2020 ◽  
Vol 51 (6) ◽  
pp. 830-835
Author(s):  
M.F. Yamin ◽  
M. Awang ◽  
U.F.H. Suhuddin ◽  
N. Sallih ◽  
B. Klusemann ◽  
...  
Keyword(s):  
Performance Optimization ◽  
Spot Welding ◽  
Mechanical Performance ◽  
Friction Stir Spot Welding ◽  
Friction Stir ◽  
Aa 7075

scholarly journals Effects of Dwell-Time and Plunge Speed during Micro Friction Stir Spot Welding on Mechanical Properties of Thin Aluminum A1100 Welds

2015 ◽  
Vol 758 ◽  
pp. 29-34 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
Suwarsono ◽  
M.Dz. Habibullah ◽  
Z. Arvay ◽  
G. Kiswanto ◽  
...  
Keyword(s):  
Spot Welding ◽  
High Speed ◽  
Dwell Time ◽  
Shear Fracture ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Welding Parameter ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Processes

Friction Stir Welding is a relatively new technique for joining metal. In some cases on aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and produces less distortion. The purpose of this study is to analyze the effect of high speed tool rotation on micro Friction Stir Spot Welding (μFSSW) to the shear fracture load of the welds. Response Surface Methods was used to analyze μFSSW parameters with the response. The welding material was Aluminum A1100, with thickness of 0.4 mm. The tool was made of HSS material which was shaped by micro grinding process. Tool shoulder diameter is 4 mm, and the pin diameter 1.5 mm with length of pin is 0.6 mm. The spindle speed is fixed at 33,000 rpm. The parameters that varied were the plunge speed (2 mm/min, 3 mm/min, 4 mm/min), and dwell time-1 (0 s, 2 s, 4 s) and variable of dwell time-2 (0 s, 2 s, 4 s). From the results of experiment and analysis, it is shown that the important welding parameter in high speed μFSSW process is dwell time-2.

AA5052 sheets welded by protrusion friction stir spot welding: High mechanical performance with considering sheets thickness at low dwelling time and tool rotation speed

2019 ◽  
Vol 233 (16) ◽  
pp. 5836-5847 ◽  
Author(s):  
N Farmanbar ◽  
SM Mousavizade ◽  
M Elsa ◽  
HR Ezatpour
Keyword(s):  
Mechanical Properties ◽  
Spot Welding ◽  
Dwell Time ◽  
Mechanical Performance ◽  
Rotation Speed ◽  
Peak Load ◽  
Friction Stir Spot Welding ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

In the present work, AA5052 sheets with thickness of 1 mm were successfully welded by protrusion friction stir spot welding as a low cost single-step method with a simple design that produces the no-keyhole joints with special mechanical properties at short dwell time and low tool rotation speed. By using suitable process parameters, the process is able to produce welds with superior mechanical performance in items of peak load and energy absorption compared to other techniques. The plunging depth and dwell time in this method were set as 0.2 mm and 6 s, respectively. The tool rotation speed was changed as 500, 800, 1250, and 1600 r/min to determine the optimum condition based on the microstructural and mechanical properties. Welds strength produced by the protrusion friction stir spot welding was directly related to the joint thickness, and the effective thickness of the upper sheet was maximum at 500 r/min. Protrusion friction stir spot welding joints presented circumferential failure mode after tensile shear testing. Regarding the sheets thickness used in this study, the joints produced by the current work presented high load bearing ability at dwell time of 6 s and tool rotation speed of 500 r/min compared to other techniques.

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