scholarly journals A Comparative Study of Tool-Pin Profile on Process Response of Friction Stir Welding of AA6082-T6 Aluminium Alloy

2017 ◽  
Vol 61 (4) ◽  
pp. 296 ◽  
Author(s):  
Kayode Oyedemi ◽  
Patrick McGrath ◽  
Hannalie Lombard ◽  
Balázs Varbai
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Dwell Time ◽  
Research Work ◽  
Welding Process ◽  
Nugget Zone ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Pin ◽  
Welding Direction

This paper presents research work conducted to experimentally establish the process response of two diverse shaped tool-pin profiles for friction stir welding (FSW) AA6082-T6 aluminium. The dwell time was optimised by plunging each tool-pin into a plate sample until the spindle torque stabilised thus ensuring sufficient plasticised material in contact with tool shoulder and the tool-pins. The welds were conducted by employing the optimised dwell time, which in turn revealed a minimised process response time and distance to reach weld stability with respect to (1) the force exerted on the tool-pin in the welding direction, Fx , and (2) the spindle torque, T, during the welding process. Both Fx and T stabilised well within the set (pre-determined) ramp-up distance of 20 mm, indicating that the effective (useful) weld length is maximised. The macrographs also revealed good dynamic material flow within the nugget zone regions and more evident in the nugget zone of the flared tool.

scholarly journals Temperature Monitoring and Material Flow Characteristics of Friction Stir Welded 2A14-t6 Aerospace Aluminum Alloy

Materials ◽  
2019 ◽  
Vol 12 (20) ◽  
pp. 3387 ◽  
Author(s):  
Tingke Wu ◽  
Fengqun Zhao ◽  
Haitao Luo ◽  
Haonan Wang ◽  
Yuxin Li
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Flow Model ◽  
Welding Process ◽  
Temperature Monitoring ◽  
Measuring System ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Pin

Aiming at the problems that the temperature in the welding area of friction stir welding (FSW) is difficult to measure and the joints are prone to defects. Hence, it is particularly important to study the material flow in the welding area and improve the welding quality. The temperature of the tool shoulder and the tool pin was monitored by the wireless temperature measuring system. The finite element model of friction stir welding was established and the welding conditions were numerically simulated. The flow law of material of the friction stir welding process was studied by numerical simulation. The material flow model was established by combining the microstructure analysis results, and the forming mechanism of the defects was analyzed. The results show that the temperature in the welding zone is the highest at 1300 rpm, and the temperature at the tool shoulder is significantly higher than that at the tool pin in the welding stage. When high-rotation speeds (HRS) are chosen, the material beneath the tool shoulder tends to be extruded into the pin stirred zone (PSZ) after flowing back to the advancing side. This will cause turbulence phenomenon in the advancing side of the joint, which will easily lead to the formation of welding defects. In the future, temperature monitoring methods and the flow model of material can be used to optimize the welding parameters.

Numerical Study of the Tool Rake Angle Effect on the Material Flow in Friction Stir Welding Process

2007 ◽  
Author(s):  
Hosein Atharifar ◽  
Radovan Kovacevic
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Numerical Study ◽  
Welding Process ◽  
Rake Angle ◽  
Heat Transfer Analysis ◽  
Tool Geometry ◽  
Friction Stir ◽  
Tool Pin ◽  
Welding Processes

Minimizing consumed energy in friction stir welding (FSW) is one of the prominent considerations in the process development. Modifications of the FSW tool geometry might be categorized as the initial attempt to achieve a minimum FSW effort. Advanced tool pin and shoulder features as well as a low-conductive backing plate, high-conductive FSW tools equipped with cooling fins, and single or multi-step welding processes are all carried out to achieve a flawless weld with reduced welding effort. The outcomes of these attempts are considerable, primarily when the tool pin traditional designs are replaced with threaded, Trifiute or Trivex geometries. Nevertheless, the problem remains as to how an inclined tool affects the material flow characteristics and the loads applied to the tool. It is experimentally proven that a positive rake angle facilitates the traverse motion of the FSW tool; however, few computational evidences were provided. In this study, numerical material flow and heat transfer analysis are carried out for the presumed tool rake angle ranging from −4° to 4°. Afterwards, the effects of the tool rake angle to the dynamic pressure distribution, strain-rates, and velocity profiles are numerically computed. Furthermore, coefficients of drag, lift, and side force and moment applied to the tool from the visco-plastic material region are computed for each of the tool rake angles. Eventually, this paper confirms that the rake angle dramatically affects the magnitude of the loads applied to the FSW tool, and the developed advanced numerical model might be used to find optimum tool rake angle for other aluminum alloys.

Experimental investigation and optimization of mechanical properties on combination of higher and lower strength of aluminum alloys

2021 ◽  
pp. 095440892110606
Author(s):  
C Ganesan ◽  
K Manonmani
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Axial Load ◽  
Welding Process ◽  
Process Parameter ◽  
Nugget Zone ◽  
Friction Stir ◽  
Tool Pin

Friction stir welding is a high potential technology for joining similar and dissimilar aluminum materials, utilized extensively in aerospace and automotive industrial applications to eradicate the problems like hot cracking, porosity, element loss, etc. due to the fusion welding process. This Research addresses the joining of two dissimilar materials of AA 5754 – H32 and AA 8090T6511 – Al-Li and their mechanical properties analysis with the effects of friction stir welding process parameters like tool rotational speed, welding speed and axial load on weld nugget zone formation quality. The significant roles of different tool pin profiles are also emphasized. A mathematical modeling equation was formed by using regression analysis to optimize the process parameter and found the best tool pin profile for defect-free weld nugget zone and higher tensile and hardness properties. This research also portrays the contribution of various pin profiles and each process parameter on the ultimate tensile strength by response surface methodology. The results indicate that the defect-free weld joints are observed with 1800 r/min of rotational speed, welding speed of 15 mm min−1 and 8.5 kN of axial load with hexagonal pin profile.

scholarly journals Numerical Simulation of Material Flow and Analysis of Welding Characteristics in Friction Stir Welding Process

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 621 ◽  
Author(s):  
Haitao Luo ◽  
Tingke Wu ◽  
Peng Wang ◽  
Fengqun Zhao ◽  
Haonan Wang ◽  
...  
Keyword(s):  
Finite Element ◽  
Friction Stir Welding ◽  
Finite Element Model ◽  
Material Flow ◽  
Welding Process ◽  
Element Model ◽  
Welding Seam ◽  
Friction Stir ◽  
Tool Pin ◽  
The Finite Element Model

Friction stir welding (FSW) material flow has an important influence on weld formation. The finite element model of the FSW process was established. The axial force and the spindle torque of the welding process were collected through experiments. The feasibility of the finite element model was verified by a data comparison. The temperature field of the welding process was analyzed hierarchically. It was found that the temperature on the advancing side is about 20 °C higher than that on the retreating side near the welding seam, but that the temperature difference between the two sides of the middle and lower layers was decreased. The particle tracking technique was used to study the material flow law in different areas of the weld seam. The results showed that part of the material inside the tool pin was squeezed to the bottom of the workpiece. The material on the upper surface tends to move downward under the influence of the shoulder extrusion, while the material on the lower part moves spirally upward under the influence of the tool pin. The material flow amount of the advancing side is higher than that of the retreating side. The law of material flow reveals the possible causes of the welding defects. It was found that the abnormal flow of materials at a low rotation speed and high welding speed is prone to holes and crack defects. The forming reasons and material flow differences in different regions are studied through the microstructure of the joint cross section. The feasibility of a finite element modeling and simulation analysis is further verified.

scholarly journals Analysis of Tools used in Friction Stir Welding process

2018 ◽  
Vol 8 (6) ◽  
Author(s):  
Akshansh Mishra ◽  
Adarsh Tiwari ◽  
Mayank Kumar Shukla ◽  
A. Razal Rose
Keyword(s):  
Friction Stir Welding ◽  
Critical Role ◽  
Base Material ◽  
Welding Process ◽  
Tool Geometry ◽  
Work Piece ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Pin ◽  
Joining Process

A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminium alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material. The tool geometry plays a critical role in material flow and governs the transverse rate at which FSW can be conducted. The tool serves three primary functions, i.e., (a) heating of the work piece, (b) movement of material to produce the joint, and (c) containment of the hot metal beneath the tool shoulder. Heating is created within the work piece by friction between both the rotating tool pin and shoulder and by severe plastic deformation of the work.

Analytical Modeling and Analysis of the Matter Flow during Friction Stir Welding

2019 ◽  
Vol 297 ◽  
pp. 1-16
Author(s):  
Zineelabidine Harchouche ◽  
Mokhtar Zemri ◽  
Abdelkader Lousdad
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Solid Phase ◽  
Welding Process ◽  
Computational Time ◽  
Modeling And Analysis ◽  
Friction Stir ◽  
Tool Pin ◽  
Welding Processes ◽  
Matter Flow

Friction stir welding is a solid-phase welding process based on the mixing of the pasty material in the stirred zone. The main advantage of this technique is the ability to weld metal alloys which are generally difficult to weld by conventional welding processes. In this paper an analytical model is proposed for the description in 2D the distribution of the material (fluid) flow in the vicinity of the tool pin during friction stir welding process "FSW". For this reason, the analytical solutions are built on the basis of traditional problem of mechanics of the fluids which is used to solve the equation associated with this problem. Furthermore, the aim is to make an analytical study of these aspects for a better understanding of this phenomenon. This method provides a reduction in computational time compared to those required for finite or differential elements methods. Moreover, it highlights on the effects of the different parameters on the material flow during welding.

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.

An analytical and experimental investigation considering the effect of material flow velocity on tensile strength of a steel alloy joint produced by friction stir welding process

2020 ◽  
pp. 095440622093631
Author(s):  
Behzad Hadi ◽  
ME Aalami-Aleagha ◽  
Saeed Feli
Keyword(s):  
Friction Stir Welding ◽  
Flow Velocity ◽  
Analytical Method ◽  
Rotational Speed ◽  
Material Flow ◽  
Welding Process ◽  
Linear Speed ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

In this paper, the effects of linear speed, rotational speed, and tool radius of the pin and shoulder are investigated on the material flow velocity in friction stir welds. To obtain the maximum material flow velocity by an analytical method, a suggested relation is introduced for the rotational speed and tool optimum radius. The derived relation is based on the assumption of a velocity field in the stirring region. Besides, the effect of the linear speed on material flow velocity is investigated based on continuity and momentum equations. Finally, by using the experimental method and checking the mechanical properties of the welded parts obtained with different rotational speed, linear speed, and tool dimensions, the proposed analytical model is validated. The results indicate that in the friction stir welding process, the significant component effect on the stirring process is generated through the tool pin radius size. Besides, increasing the material flow velocity in the boundary layer increases the yield and ultimate strength of welds. To achieve the high-quality welds, rotational speed and other tool dimensions must be selected considering the equation extracted from the analytical method. Also, to make the maximum life for the pin and its components in friction stir welding of high melting point metals such as steel alloys, the operation is adjusted at a lower linear speed to prevent the destruction of the tool and improve the quality of the joint.

scholarly journals Modeling and Simulation Based Analysis of the Matter Flow During Friction Stir Welding Process

2021 ◽  
Vol 54 (2) ◽  
pp. 363-369
Author(s):  
Zine El Abidine Harchouche ◽  
Abdelkader Lousdad ◽  
Mothtar Zemri ◽  
Nabila Dellal ◽  
Foudil Khelil
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Rapid Development ◽  
Thermal Power ◽  
Great Part ◽  
Welding Process ◽  
Industrial Applications ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Tool Pin

Friction Stir Welding (FSW) is a recent assembly process which has been developed at the British Welding Institute (TWI) at the beginning of the 90's. This welding process has gone a rapid development and an increasing success. Many remarkable industrial applications achieved mainly in spatial, aeronautical, automobile, railways, marine and naval industries.... The translation and the rotation of the tool during the FSW process generate the flow and plastic deformation of the material which had been often differently interpreted in contradictory manner. In this paper, an analytical model is proposed to describe the flow of matter in the vicinity of the FSW tool pin during the welding process. Analytical solutions are elaborated on the basis of conventional fluid mechanics theory which is used to solve the associated equation to the mentioned problem based on the Laurent's series (called also Laurent's development). The knowledge of the material flow around the tool pin can lead to a better understanding of the metallurgical phenomena which have a significant effect on the mechanical properties of the welded joint and allows a better description of the speed fields which is worth full for the thermal modelisation since the great part of the thermal power is generated by auto-heating energy. The results obtained on the effect of the speeds on the material flow are in good accordance with the experimental results found in the literature. The study highlights and gives a better understanding of the material flow phenomenon during the Friction Stir Welding process.

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.

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