scholarly journals Effects of Shoulder Geometry on Microstructures and Mechanical Properties of Probeless Friction Stir Spot Welded Aluminum 7075-T651 Sheets

Metals ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1605
Author(s):  
Xingrong Chu ◽  
Meng Yin ◽  
Jun Gao ◽  
Xiaowei Wang ◽  
Yangang Wang
Keyword(s):  
Shear Fracture ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Joint Fracture ◽  
Dominant Process ◽  
Metallurgical Bond ◽  
Shoulder Geometry ◽  
Aluminum 7075 ◽  
Flat Tool

In this work, three types of probeless tools (archimedes, involute, and concave tools) were designed. A 7075-T651 sheet of 1.0 mm thickness was welded using the designed probeless tools. It was found that the stir zone and hook defect varied a lot for different joints. Plunge depth was the dominant process parameter for joint property. The joint’s maximum failure load (5.73 kN) was obtained with the concave tool when the target plunge depth was 0.55 mm. Two typical joint fracture modes (shear fracture and plug fracture) were found using three designed tools with different plunge depths, rotation speeds, and dwell times. Shoulder geometry presented little influence on heat generation. Compared with involute grooves, archimedes grooves showed to be more effective on the material flow. The properties of the joints with the archimedes tool were more sensitive to welding parameters. Compared with the flat tool, the concave tool decreased the escape of plasticized material, improved the forge force, and optimized the metallurgical bond at the interface.

Effect of Welding Conditions on Sheets’ Interface Properties in Friction Stir Spot Welding of Copper

2019 ◽  
Author(s):  
Ahmed Mahgoub ◽  
Neçar Merah ◽  
Abdelaziz Bazoune
Keyword(s):  
Surface Morphology ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Tensile Failure ◽  
Welding Parameters ◽  
Welding Condition ◽  
Friction Stir ◽  
Joint Fracture

Abstract Friction Stir Spot Welding (FSSW) is a solid-state joining technique widely applied to high conductive metals. In this paper, the effects of FSSW parameters, namely, rotational speed (N), plunging rate (V) and dwell time (DT) on the joint fracture mode and fractured surface morphology were investigated using scanning electron microscopy (SEM). The effect of the abovementioned welding parameters on the microhardness profile along the sheets’ interface was also investigated to gain insight into the strength of the joint and the width of the bonding ligament. Two conditions were considered for each parameter 1200 rpm and 900 rpm for N, 60 mm/min and 20 mm/min for V, 4 and 2 seconds for DT. The welding condition 1200 rpm rotational speed, 20 mm/min plunging rate and 2 seconds dwell time showed a wider bonding ligament, relatively higher elongation, higher tensile failure load, and greater microhardness on the sheets’ interface. Dimple surface morphology (DSM) with regular dimples along the stir zone was also observed at the abovementioned set of process parameters.

Friction stir lap welding thin aluminum alloy sheets

2020 ◽  
Vol 39 (1) ◽  
pp. 663-670
Author(s):  
Tao Wang ◽  
Xue Gong ◽  
Shude Ji ◽  
Gang Xue ◽  
Zan Lv
Keyword(s):  
Aluminum Alloy ◽  
Failure Load ◽  
Tensile Fracture ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Lap Shear ◽  
Thin Aluminum ◽  
Wide Range ◽  
Good Material

AbstractIn this work, thin aluminum alloy sheets with thickness of 0.8 mm were friction stir lap welded using small shoulder plunge depths of 0 and 0.1 mm. The joint formation, microstructure and mechanical properties were investigated. Results show that voids appear inside the stir zone when the small plunge depth of 0 mm is used because the tool shoulder cannot exert a good material-collecting effect at such low plunge depth. A plunge depth of 0.1 mm causes tight contact between the shoulder and the material and thus results in good material-collecting effect, which is helpful to eliminate the void. Sound joints are attained at a wide range of welding parameters when using the shoulder plunge depth of 0.1 mm. No crack is observed inside the bonding ligament. The joints own higher failure loads when the retreating side (RS) of the joint bares the main load during the lap shear tests. The shear failure load first increases and then decreases with increasing the rotating and welding speeds, and the maximum failure load of 6419 N is obtained at 600 rpm and 150 mm/min. The hardness of the joint presents a “W” morphology and the minimum hardness is obtained at the heat affected zone. The joints present tensile fracture and shear fracture when the advancing side and RS bare the main loads, respectively.

scholarly journals Simulation of Friction Stir Spot Welding of Copper and Aluminium During Plunging Phase

2021 ◽  
Vol 2129 (1) ◽  
pp. 012002
Author(s):  
N N S M Shobri ◽  
S R Pedapati ◽  
M Awang
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
Regression Line ◽  
Friction Stir Spot Welding ◽  
Peak Temperature ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Explicit Analysis ◽  
Residual Plots

Abstract Simulation is limited and remains briefly addressed in the literature of friction stir spot welding (FSSW) process in joining dissimilar copper and aluminium. Thus, this study simulated the FSSW process of copper and aluminium to investigate the peak temperature during the plunging phase produced by all possible combinations of levels for tool rotational speed, plunge rate, and plunge depth according to the full factorial design. The modeling was established by Coupled Eulerian-Lagrangian (CEL) model and ‘dynamic, temperature-displacement, explicit’ analysis. The highest peak temperature of 994.4 oC was produced by 2400 rpm rotational speed, 100 mm/min plunge rate, and 1.6 mm plunge depth. The combination was suggested to be the optimum welding parameters in joining copper to aluminium as sufficient heat input was essential to soften the area around the welding tool and adequately plasticize the material. Three sets of confirmation tests presented consistent responses with a mean peak temperature of 994.4 °C, which validated that the response produced by the suggested optimum welding parameters was reliable. The statistical result reported that the variability in the factors could explain 84.12% of the variability in the response. However, only the rotational speed and plunge depth were statistically significant. The residual plots showed that the regression line model was valid.

Optimization Analysis of Process Parameters of Friction Stir Welded Dissimilar Joints of Aluminium Alloys

2017 ◽  
Vol 867 ◽  
pp. 112-118
Author(s):  
Subburaj Rajesh Kannan ◽  
J. Lakshmipathy ◽  
M. Vignesh Kumar ◽  
K. Manisekar ◽  
N. Murugan
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Rotational Speed ◽  
Welding Process ◽  
Welding Parameters ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Optimum Parameters ◽  
Aluminum Plates ◽  
Aluminum 7075

Friction stir welding (FSW) is one of the new technique for welding materials in solid state welding process. In this proposed work we are using FSW to join the two dissimilar alloys of aluminium. The 6mm thick aluminum plates of aluminium 5086 and aluminum 7075 plates are considered for welding. These have been considered due to their application in various fields. In this experimental process Taguchi’s L9 orthogonal array method is used for optimizing the three process parameters namely rotational speed, axial force and welding speed. To produce a better joint the tensile strength is predicted for the optimum welding parameters and also their percentage of contribution is calculated, by applying the effect of analysis of variance. Depends upon the experimental study, the rotational speed is found better over the other process parameters, which enhances the quality of the weld. The tensile strength has been found for the optimum parameters and the result found during the experiment was 290Mpa which was higher than the base metal strength of aluminium 5086 alloy. The SEM fractograph analysis was done on the optimum parameters welded joints to show the fracture behaviour of tensile test which justifies the visual inspection results of brittle and ductile failures.

scholarly journals Pinless friction stir spot welding of aluminium alloy with copper interlayer

2020 ◽  
Vol 10 (1) ◽  
pp. 804-813
Author(s):  
Balsam H. Abed ◽  
Omar S. Salih ◽  
Khalid M. Sowoud
Keyword(s):  
Diffusion Process ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Tensile Shear ◽  
Plunge Depth ◽  
Friction Stir ◽  
Copper Interlayer ◽  
Cu Interlayer

AbstractSpot welding joints of Al-Mg-Si alloy (AA6061-T6) were produced with and without the addition of copper interlayer using pinless friction stir spot welding (P-FSSW). To investigate the effects of welding parameters on the metallurgical and mechanical properties of the weldment, various tool plunge depth and dwell time were used. Optical microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy (EDS) have been used for microstructural characterisation.Meanwhile, the mechanical characterisation of the welded joints was evaluated by tensile-shear test. The experimental results showed that a larger bonding area and sound joint were achieved with the addition of Cu interlayer due to the improvement in thermal distribution. Also, an alloying reaction took place between the aluminium substrate and Cu interlayer during P-FSSW, forming intermetallic compounds layer in the interface through the diffusion process. The increasing of dwell time and plunge depth to some extent were beneficial to the formation of the joint and diffusion process, and thus increasing the tensile-shear load of the joints. The observed fracture mode of the joint was either completely shear off in the interface or complete nugget pullout.

scholarly journals Spot Welding of 6061 Aluminum Alloy by Friction Stir Spot Welding Process

2017 ◽  
Vol 7 (3) ◽  
pp. 1629-1632 ◽  
Author(s):  
M. A. Tashkandi ◽  
J. A. Al-jarrah ◽  
M. Ibrahim
Keyword(s):  
Welded Joints ◽  
Spot Welding ◽  
Shear Fracture ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Fracture Load ◽  
Welding Parameters ◽  
Friction Stir ◽  
Pull Out ◽  
Lap Shear

This study was focused on the effect of welding parameters on the lap-shear fracture load of the welded joints prepared by friction stir spot welding. Four different weld parameters were analyzed: rotational speed, dwell time, pin length and shoulder size of the welding tool. It was found that the lap-shear fracture load increases with an increase of the welding parameters to a limited value and decreases with further increase. The strong welded joints failed under nugget-pull out fracture.

scholarly journals Refill Friction Stir Spot Welding of Dissimilar 6061/7075 Aluminum Alloy

2019 ◽  
Vol 38 (2019) ◽  
pp. 69-75 ◽  
Author(s):  
Zhenlei Liu ◽  
Kang Yang ◽  
Dejun Yan
Keyword(s):  
Aluminum Alloy ◽  
Spot Welding ◽  
Joint Strength ◽  
Shear Failure ◽  
Failure Load ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Lap Shear

AbstractRefill friction stir spot welding (RFSSW) was used to join 6061-T6 and 7075-T6 aluminum alloys in this work. Different sheet configurations and welding parameters were used to optimize joint strength. The effect of sleeve plunge depth on the microstructure and mechanical properties of the joints were investigated. The results showed that no defects were obtained when 6061-T6 aluminum alloy was placed as the upper sheet. The lap shear failure load of the joint using 6061-T6 aluminum alloy as the upper sheet was higher than that using 7075-T6 as the upper sheet. The maximum failure load of 12,892 N was attained when using the sleeve plunge depth of 3.6 mm. The joint failed at the upward flowing 7075 near the hook.

scholarly journals Multi objective prediction and optimization of control parameters of Friction stir welding on Casted AlSi10Mg plates with Taguchi – Gray Relational Analysis

2021 ◽  
Vol 8 (1) ◽  
pp. 001-009
Author(s):  
Balakrishna G ◽  
B Raghukumar ◽  
B Balakrishna
Keyword(s):  
Friction Stir Welding ◽  
Axial Load ◽  
Welding Process ◽  
Hardness Test ◽  
Gray Relational Analysis ◽  
Welding Parameters ◽  
Friction Stir ◽  
Relational Analysis ◽  
Dominant Process ◽  
Three Stages

In this study, a 3 mm thickness of AlSi10Mg Casted alloy plates was used in the friction stir welding process. The experimentations were conducted Using design of experiment to shorten the number of experiments and to get optimal friction stir welding parameters by utilizing Gray relational analysis based on the ultimate tensile and hardness test results. Orthogonal array of L9 (33) was used based on three main parameters and three stages for each parameter, where tool velocity of three stages are 800, 900 and 1000 Rpm, tool feed of 30,40,50 mm/min, plus axial load of 300,400 and 500 Kg. Using Minitab 17 software. Gray Relational analysis is used to explore the optimal set of process variables and their effects on the ultimate tensile strength and hardness of weld plates. The plates are effectively welded, tensile test and hardness is measured at room temperature. The end result shows that the tool velocity 1000 rpm, feed 50 mm / min, then axial load of 400 kg are dominant process parameters to join AlSi10Mg Casted alloy plates.

scholarly journals Modeling and Optimization of Friction Stir Welding Parameters for Joining Dissimilar Aluminum Alloys

2018 ◽  
Vol 4 (1) ◽  
pp. 1-14 ◽  
Author(s):  
Mohamed Mohamed Abd Elnabi ◽  
Tarek Abd Elsadek Osman ◽  
Alaa Eldeen El Mokadem ◽  
Abou Bakr Elshalakany 
Keyword(s):  
Friction Stir Welding ◽  
Base Metal ◽  
Tilt Angle ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Confidence Levels ◽  
Tool Tilt Angle

The objectives of this work are to optimize the process parameters on the mechanical properties (ultimate tensile strength (UTS) and ductility) of dissimilar joints between AA5454 and AA7075 produced by friction stir welding and to determine which of them is significant by using Taguchi L16 optimization method. Seven parameters at two levels were selected in this study. The selected parameters are tool rotational speed, traverse speed, pin profile (based on taper angle), D/d ratio, tool tilt angle, plunge depth, and base metal location. Then, mathematical models are built as function of significant parameters/ interactions using Response Surface Methodology. The results of this work showed that the rotational speed, traverse speed, D/d ratio and plunge depth are significant parameters in determining UTS (Mean, Signal to noise ratio (S/N)) at different confidence levels, but pin profile, location of base metal and tool tilt angle are insignificant parameters at any confidence levels. The traverse speed has the highest contribution to the process for UTS about 18.577 % and 16.943 % for S/N ratio and mean, respectively. The accuracy of the models according to the UTS is 97.678 % and 99.56 %for mean and S/N ratio, respectively. The maximum joint efficiency, compared to the strength of the AA5454, is 85.3%.

scholarly journals Assessment of Corrosive Behaviour and Microstructure Characterization of Hybrid Friction Stir Welded Martensitic Stainless Steel

2021 ◽  
Vol 21 (4) ◽  
pp. 67-78
Author(s):  
Dhanesh G. Mohan ◽  
S. Gopi ◽  
Jacek Tomków ◽  
Shabbir Memon
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Spindle Speed ◽  
Grain Structure ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Fine Grain ◽  
Weight Loss Method

Abstract This study examined the effect of induction heating on the microstructure and corrosion characteristics of hybrid friction stir welded AISI 410 stainless steel. Five joints have been produced with different friction stir welding parameters like welding speed, spindle speed, plunge depth, and induction power. Their microstructures were evaluated using a scanning electron microscope, and chemical composition was examined using energy-dispersive X-ray spectroscopy (EDX). The rate of corrosion was found out via the weight loss method in a 1 M HCL solution. The hybrid friction stir welding method used for this work is induction assisted friction stir welding; the results show that this method could produce sound AISI 410 stainless steel Joints. The experiment results show that the joint made at a spindle speed of 1150 rpm, welding speed 40 mm/min, plunge depth 0.5 mm, and in-situ heat by induction 480°C show a better corrosion resistance property with a fine grain structure.

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