scholarly journals ANALYTICAL AND NUMERICAL THERMAL ANALYSIS ON FRICTION STIR WELDING USING POLYGONAL TOOL PIN

2021 ◽  
Vol 22 (2) ◽  
pp. 352-363
Author(s):  
Stephen Leon Joseph Leon ◽  
Alfred Franklin Varghese ◽  
Joseph Michel ◽  
Gopinath Gunasekaran
Keyword(s):  
Friction Stir Welding ◽  
Weld Line ◽  
Peak Temperature ◽  
Frictional Heat ◽  
Friction Stir ◽  
Proposed Model ◽  
Pin Geometry ◽  
Transient Thermal ◽  
Tool Pin ◽  
Solid State Joining

Frictional heat generation in the tool/matrix interface followed by the stirring of material along the weld line causes plasticized solid state joining in friction stir welding. In this paper, the existing torque based thermo-mechanical model for the tools with cylindrical pins is remodified for the polygonal tool pin profile by introducing novel multiplication factors with respect to the number of sides in the tool pin geometry. The variation in the effective heat supply with respect to the chosen pin geometry was analyzed. A comparative analysis of the proposed analytical model with the existing model was also carried out to understand the accuracy of the proposed model.  Furthermore, a transient thermal numerical modelling was carried out in the view of understanding the change in process peak temperature in the stir zone and change in temperature gradient along the heat affected zone with respect to the change in pin geometry for the opted set of process input parameters. An analytically estimated heat-input-based numerical model was adopted in the present study. It was observed that the process peak temperature was directly proportional to the number of sides in the tool pin. ABSTRAK: Penjanaan haba geseran antara muka pada alat/matrik diikuti dengan pengacauan material sepanjang garis kimpalan menyebabkan keadaan plastik pepejal melekat bersama geseran kimpalan pengacau. Kajian ini berkaitan tork sedia ada berdasarkan model mekanikal-terma bagi alat pin silinder yang terubah suai bagi profil pin alat poligon dengan memperkenalkan faktor gandaan berdasarkan bilangan sisi geometri alat pin. Perubahan pada bekalan haba efektif berdasarkan geometri pin pilihan telah dikaji. Analisis bandingan pada model analitik yang dicadang bersama model sedia ada, telah dilakukan bagi memahami ketepatan model cadangan. Tambahan, model transien numerikal terma telah dibuat bagi memahami proses perubahan suhu puncak ketika zon pengacauan dan perubahan gradien suhu sepanjang zon terkena haba perubahan geometri pin pada set proses parameter input terpilih. Kajian ini mengaplikasi model numerik berdasarkan input anggaran haba secara analitik. Dapatan kajian menunjukkan suhu puncak proses adalah berkadar langsung dengan bilangan sisi pin alat.

scholarly journals Experimental analysis on friction stir welding using flat-faced pins in AA2024-T3 plate

2021 ◽  
Vol 49 (1) ◽  
pp. 78-86
Author(s):  
Stephen Leon ◽  
G. Bharathiraja ◽  
V. Jayakumar
Keyword(s):  
Friction Stir Welding ◽  
Tool Life ◽  
Thermal Environment ◽  
Softening Temperature ◽  
Peak Temperature ◽  
Friction Stir ◽  
Pin Geometry ◽  
Tool Pin ◽  
The Impact ◽  
Dwell Period

In friction stir welding, lesser tool life restricts the usage of non-circular pin in friction stir welding tool eventhough it delivers comparatively better weld joints than circular pin. Process peak temperature during the process affects the shear strength of the flowing material around the tool pin. Maintaining the process peak temperature as low as possible improves the properties in heat affected zone but on the other hand it increases the stress on the tool pin.Especially on the usage of non-circular pin, the pin surface experiences uneven stress distribution and causes premature tool failure. In this paper, optimum thermal environment through proper selection of process parameters and dwell period with respect to the pin geometry are analysed. A comparative analysis is also made to understand the impact of increase in flat surfaces in the pin surface on weld quality in the view of developing a suitable thermal environment that can improve tool life without compromising joint strength. Apart from this, optimum dwell period for the chosen tool pin geometry is analysed based on the empirical softening temperature of the material.

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.

scholarly journals Influence of Mx-Trivex, A-Skew, Three Flat Threaded and Concave Shouldered Mx-Triflute Tool Pin Profiles on Tensile Properties and Fractural Behaviour of Aa 6082-T6 Weldments During Friction Stir Welding

2020 ◽  
Vol 9 (4) ◽  
pp. 1376-1384
Keyword(s):  
Friction Stir Welding ◽  
Tensile Test ◽  
Weld Zone ◽  
Base Material ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Pin ◽  
Solid State Joining ◽  
Joining Process ◽  
Brass Wire

Friction Stir Welding (FSW) is a topical and propitious solid-state joining process producing economical and strengthened joints of age-hardened and heat-treatable Aluminium Alloy AA 6082-T6. Mechanical and fractural behaviour of weldments were investigated in order to find crack initiation and necking on the weld zone thereby perceiving the complete behaviour of fracture occurred near the weld zone. Weldments are fabricated by employing four tool pin profiles namely MX-TRIVEX, A-SKEW, Three flat threaded and Concave shouldered MX-TRIFLUTE tools at various rotational speeds 1000 rpm, 1200 rpm and 1400 rpm at single traverse speed 25 mm/min. EXCETEX-EX-40 CNC wire cut EDM with 0.25 mm brass wire diameter has been employed to perform the extraction of tensile test specimens from the weldments according to ASTM E8M-04 standard. Tensile test was performed on elctromechanically servo controlled TUE-C-200 (UTM machine) according to ASTM B557-16 standards Maximum Ultimate Tensile Strength (UTS) of 172.33 MPa (55.5% of base material) and 0.2% Yield Stress (YS) of 134.10 MPa (51.5% of base material) were obtained by using A-SKEW at 1400 rpm, 25 mm/min and maximum % Elongation (%El) of 11.33 (113.3% of base material) was obtained at MX-TRIVEX at 1000 rpm, 25 mm/min. Minimum UTS of 131.16 MPa (42.30% of base material) and 0.2% YS of 105.207 MPa (40.46% of base material )were obtained by using Concave shouldered MX-TRIFLUTE at 1400 rpm, 25 mm/min. Minimum % El of 5.42 ( 54.2% of base material) was obtained by using A-SKEW at 1000 rpm, 25 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.

scholarly journals Experimental Investigation of Friction stir Welding Using Hybrid Alloys : A Review

2021 ◽  
pp. 308-313
Author(s):  
A. J Amroliya ◽  
Dr. D. B Jani ◽  
Dr. R. K Shukla
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Dissimilar Metals ◽  
Research Personnel ◽  
Friction Stir ◽  
Vertical Milling ◽  
Working Parameters ◽  
Fsw Parameters ◽  
Tool Pin ◽  
Solid State Joining

Friction stir welding is a solid state joining process which is used to join metals and alloys having low weldability .Study about the effect of FSW parameters like tool rpm, tool transverse speed and tool pin profile. A vertical milling head is used to produce FSW joints. In this study, solid state joining technology of friction stir welding (FSW) was carried out for Al and Mg butt joints and other dissimilar metals. This review article thoroughly highlights the influence of FSW working parameters on microstructure, mechanical properties. This effort not only sets eminent outcomes of the preceding research personnel but also proposes forthcoming guidelines for FSW of dissimilar metals.

Behaviour of Threaded Cylinder Tool in the Friction Stir Welding of Al–ZrB2 Composite

2019 ◽  
Vol 16 (2) ◽  
pp. 719-724 ◽  
Author(s):  
P. Jayaseelan ◽  
T. V. Christy ◽  
Prabhu G. Rubesh ◽  
R. Srinivasan
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Tool Material ◽  
Hardness Test ◽  
Material Base ◽  
Matrix Composites ◽  
Friction Stir ◽  
Tool Pin ◽  
Aluminum Metal Matrix Composites ◽  
Solid State Joining

Friction Stir welding is a solid state joining process with no filler material. In this work, we specifically investigated the Tool Pin Profile, Tool Material, Base Material and the process parameters in the Aluminum metal matrix composites especially reinforced with Zirconium diboride (Al–ZrB2 . Tools of Various Materials and the corresponding tensile strength of the weld specimen, microstructure analysis and Hardness test are evaluated. Threaded Cylinder made of various materials are OHNS, HCHCr, H13 tools are carried out in the process with D/d Ratio are used. The result will be stated with the Threaded Cylinder pin with which tool material provides highest strength to the Bas material.

scholarly journals Pin Angle Thermal Effects on Friction Stir Welding of AA5058 Aluminum Alloy: CFD Simulation and Experimental Validation

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7565
Author(s):  
Supat Chupradit ◽  
Dmitry Olegovich Bokov ◽  
Wanich Suksatan ◽  
Michał Landowski ◽  
Dariusz Fydrych ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Heat Generation ◽  
Cfd Simulation ◽  
Fluid Dynamic ◽  
Critical Role ◽  
Internal Heat ◽  
Mechanical Action ◽  
Friction Stir ◽  
Pin Geometry ◽  
Tool Pin

The friction stir welding (FSW) of tool pin geometry plays a critical role in the final properties of the produced joint. The tool pin geometry directly affects the generation of heat and the flow of internal materials during the FSW process. The effects of the FSW tool pin angle on heat generation and internal flow have not been quantitatively investigated in detail. In this manuscript, a validated Computational Fluid Dynamic (CFD) model was implemented to analyze the effects of pin angle on the thermo-mechanical action during the FSW process of AA5058 Al-Mg alloy. Experimental test results validate the thermal outcomes of the used model. The obtained results revealed that, when the pin angle is increased, the heat generation decreases while the mechanical action of the tool increases. The internal heat distribution at a higher pin angle is symmetrical. The higher mechanical action of the tool decreases the viscosity of the internal materials and increases stirring action (materials flow) around the pin. Furthermore, plastic flow near the tool increased stirring action and formed a larger stir zone in the joint area.

Numerical and experimental study of the heat transfer process in friction stir welding

2003 ◽  
Vol 217 (1) ◽  
pp. 73-85 ◽  
Author(s):  
M Song ◽  
R Kovacevic
Keyword(s):  
Heat Transfer ◽  
Friction Stir Welding ◽  
Transfer Process ◽  
Three Dimensional ◽  
Heat Transfer Process ◽  
Frictional Heat ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Pin ◽  
Good Agreement

A mathematical model to describe the detailed three-dimensional transient heat transfer process in friction stir welding (FSW) is presented. This work is both theoretical and experimental. An explicit central differential scheme is used in solving the control equations, the heat transfer phenomena during the tool penetrating, the welding and the tool-removing periods that are studied dynamically. The heat input from the tool shoulder is modelled as a frictional heat and the heat from the tool pin is modelled as a uniform volumetric heat generated by the plastic deformation near the pin. The temperature variation during the welding is also measured to validate the calculated results. The calculated results are in good agreement with the experimental data.

scholarly journals Influence of material velocity on heat generation during linear welding stage of friction stir welding

2016 ◽  
Vol 20 (5) ◽  
pp. 1693-1701
Author(s):  
Alin Murariu ◽  
Darko Veljic ◽  
Dragana Barjaktarevic ◽  
Marko Rakin ◽  
Nenad Radovic ◽  
...  
Keyword(s):  
Plastic Deformation ◽  
Friction Stir Welding ◽  
Heat Generation ◽  
Welding Process ◽  
Slip Rate ◽  
Frictional Heat ◽  
Al Alloy ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Pin

The heat generated during friction stir welding (FSW) process depends on plastic deformation of the material and friction between the tool and the material. In this work, heat generation is analysed with respect to the material velocity around the tool in Al alloy Al2024-T351 plate. The slip rate of the tool relative to the workpiece material is related to the frictional heat generated. The material velocity, on the other hand, is related to the heat generated by plastic deformation. During the welding process, the slippage is the most pronounced on the front part of the tool shoulder. Also, it is higher on the retreating side than on the advancing side. Slip rate in the zone around the tool pin has very low values, almost negligible. In this zone, the heat generation from friction is very low, because the material is in paste-like state and subjected to intensive plastic deformation. The material flow velocity around the pin is higher in the zone around the root of the pin. In the radial direction, this quantity increases from the pin to the periphery of the tool shoulder.

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