scholarly journals Experimental Review on Friction Stir Welding of Aluminium Alloys with Nanoparticles

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 390
Author(s):  
Cyril Vimalraj ◽  
Paul Kah
Keyword(s):  
Friction Stir Welding ◽  
Dissimilar Materials ◽  
Strengthening Mechanism ◽  
High Heat ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Joint Properties ◽  
Weld Properties ◽  
Welding Processes

To reduce environmental impacts and ensure competitiveness, the fabrication and construction sectors focus on minimizing energy and material usage, which leads to design requirements for complex structures by joining of similar and dissimilar materials. Meeting these industrial demands requires compatible materials with improved properties such as good weight-to-strength ratios, where aluminum (Al) and its alloys are competing candidates for various complex applications. However, joining Al with fusion welding processes leads to joint deterioration. Friction stir welding (FSW) produces joints at temperatures below the melting temperature, thus avoiding flaws associated with high heat input, yet requires improvement in the resultant joint properties. Recent studies have shown that nanoparticle reinforcement in FSW joints can improve weld properties. The main focus of this study is to critically review similar and dissimilar friction stir welding of AA5083 and AA6082 with carbide and oxide nanoparticle reinforcement. The study also discusses the effect of welding parameters on reinforcement particles and the effect of nanoparticle reinforcement on weld microstructure and properties, as well as development trends using nanoparticles in FSW. Analysis shows that friction stir welding parameters have a significant influence on the dispersion of the reinforcement nanoparticles, which contributes to determining the joint properties. Moreover, the distributed nanoparticles aid in grain refinement and improve joint properties. The type, amount and size of reinforcement nanoparticles together with the welding parameters significantly influence the joint properties and microstructures in similar and dissimilar Al welds. However, research is still required to determine the strengthening mechanism used by nanoparticles and to assess other nanoparticle additions in FSW of Al alloys.

scholarly journals Design and Fabrication of Friction Stir Welding End-Effector for an ABB IRB1410 Robot

2016 ◽  
Vol 5 (2) ◽  
pp. 98
Author(s):  
Santosh Vanama
Keyword(s):  
Friction Stir Welding ◽  
High Strength ◽  
Fusion Welding ◽  
Fusion Temperature ◽  
End Effector ◽  
Friction Stir ◽  
Aluminum Sheets ◽  
Operation Pressure ◽  
Welding Processes ◽  
Tool Rotation

<p>The paper propose modelling and fabrication of friction stir welding end-effector for ABB IRB1410 robot. A dynamically developing version of pressure welding processes, join material without reaching the fusion temperature called friction stir welding. As friction stir welding occurs in solid state, no solidification structures are created thereby eliminating the brittle and eutectic phase’s common to fusion welding of high strength aluminium alloys. In this paper, Friction stir welding is applied to aluminum sheets of 2 mm thickness. A prototype setup is developed to monitor the evolution of main forces and tool temperature during the operation. Pressure of a gripper plays a major role for tool rotation and developing torque.  Fabrication of the tool has done. Force calculations are done by placing the sensors on the outer surface of gripper. Methods of evaluating weld quality are surveyed as well.</p>

Effect of double-sided friction stir welding on the mechanical and microstructural characteristics of AA5754 aluminium alloy

2021 ◽  
Vol 63 (9) ◽  
pp. 829-835
Author(s):  
Sare Çelik ◽  
Fatmagül Tolun
Keyword(s):  
Friction Stir Welding ◽  
Al Alloys ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Al Alloy ◽  
Test Results ◽  
Feeding Rates ◽  
Microstructural Characteristics ◽  
Friction Stir ◽  
Tool Tilt Angle

Abstract AA5754Al alloy is widely used in industry. However, as in the case of all Al alloys, the 5xxx series Al alloys cannot be easily joined through fusion welding techniques. To address this problem, in this study, the effect of double-sided friction stir welding at various tool rotational speeds (450, 710, and 900 rpm), feeding rates (40, 50, and 80 mm × min-1), and tool tilt angles (0°, 1°, 2°) on the welding parameters and mechanical and microstructural characteristics of AA5754 Al alloy was determined. Tensile strength tests and microhardness tests were performed to examine the mechanical properties of the welded specimens. The microstructures of the welded zone were examined by obtaining optical microscopy and scanning electron microscopy images. The tensile test results indicated that the specimens exhibited the highest welding performance of 95.17 % at a tool rotational speed, feed rate, and tool tilt angle of 450 rpm, 50 mm × min-1 and 1°, respectively.

Establishing the Dependence of Output Parameters Depending on Local Process Conditions for Friction Stir Welding of Pure Copper Plates

2018 ◽  
Vol 1146 ◽  
pp. 32-37 ◽  
Author(s):  
Marius Adrian Constantin ◽  
Ana Boşneag ◽  
Eduard Niţu ◽  
Lia Nicoleta Boţilă
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Speed ◽  
Frictional Heating ◽  
Pure Copper ◽  
Fusion Welding ◽  
Process Conditions ◽  
Friction Stir ◽  
Local Process ◽  
Welding Processes

Welding copper and its alloys is usually difficult to achieve by conventional fusion welding processes because of high thermal diffusivity of the copper, which is at least 10 times higher than most steel alloys, in addition to this, there are the well-known disadvantages of conventional fusion welding represented by necessity of using alloying elements, a shielding gas and a clean surface. To overcome these inconveniences, Friction Stir Welding (FSW), a solid state joining process that relies on frictional heating and plastic deformation, is being explored as a feasible welding process. In order to achieve an increased welding speed and a reduction in tool wear, this process is assisted by another one (TIG) which generates and adds heat to the process. The research includes two experiments for the FSW process and one experiment for tungsten inert gas assisted FSW process. The process parameters that varied were the rotational speed of the tool [rpm] and the welding speed [mm/min] while the compressive force remained constant. The purpose of this paper is to correlate the evolution of temperature, tensile strength, elongation and microscopic aspect with the linear position on the joint (local process parameters) for each experimental case and then make comparisons between them, and to identify and present the set of process parameters that has the best mechanical properties for this material.

scholarly journals Investigation of Nondestructive Testing Methods for Friction Stir Welding

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 624 ◽  
Author(s):  
Hossein Taheri ◽  
Margaret Kilpatrick ◽  
Matthew Norvalls ◽  
Warren J. Harper ◽  
Lucas W. Koester ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Nondestructive Testing ◽  
Dissimilar Materials ◽  
Ex Situ ◽  
Testing Methods ◽  
Friction Stir ◽  
Weld Properties ◽  
Unique Approach ◽  
Nondestructive Testing Methods

Friction stir welding is a method of materials processing that enables the joining of similar and dissimilar materials. The process, as originally designed by The Welding Institute (TWI), provides a unique approach to manufacturing—where materials can be joined in many designs and still retain mechanical properties that are similar to, or greater than, other forms of welding. This process is not free of defects that can alter, limit, and occasionally render the resulting weld unusable. Most common amongst these defects are kissing bonds, wormholes and cracks that are often hidden from visual inspection. To identify these defects, various nondestructive testing methods are being used. This paper presents background to the process of friction stir welding and identifies major process parameters that affect the weld properties, the origin, and types of defects that can occur, and potential nondestructive methods for ex-situ detection and in-situ identification of these potential defects, which can then allow for corrective action to be taken.

Influence of Tool Rotational Speed on the Mechanical Properties of Friction Stir Welded Al-Cu-Li Alloy

2016 ◽  
Vol 857 ◽  
pp. 228-231
Author(s):  
Ho Sung Lee ◽  
Ye Rim Lee ◽  
Kyung Ju Min
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Space Shuttle ◽  
Welding Process ◽  
High Strength ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Mechanical And Microstructural Properties ◽  
Tool Rotation

Aluminum-Lithium alloys have been found to exhibit superior mechanical properties as compared to the conventional aerospace aluminum alloys in terms of high strength, high modulus, low density, good corrosion resistance and fracture toughness at cryogenic temperatures. Even though they do not form low-melting eutectics during fusion welding, there are still problems like porosity, solidification cracking, and loss of lithium. This is why solid state friction stir welding is important in this alloy. It is known that using Al-Cu-Li alloy and friction stir welding to super lightweight external tank for space shuttle, significant weight reduction has been achieved. The objective of this paper is to investigate the effect of friction stir tool rotation speed on mechanical and microstructural properties of Al-Cu-Li alloy. The plates were joined with friction stir welding process using different tool rotation speeds (300-800 rpm) and welding speeds (120-420 mm/min), which are the two prime welding parameters in this process.

Optimization of Friction Stir Welding Process Parameters to Join Al 5052 and Al 6061 Alloy Plates Using Grey-Taguchi Technique

2017 ◽  
Author(s):  
R. Sandeep ◽  
D. Sudhakara ◽  
G. Prasanthi
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Fusion Welding ◽  
Optimum Process ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Grey Analysis ◽  
Grey Taguchi

Friction stir welding (FSW) is a solid state welding process used for welding similar and dissimilar materials. The process is widely used because it does not have common problems such as solidification and liquefaction cracking associated with the fusion welding techniques. The objective of the present research is to find the best combination of friction stir welding process parameters to join aluminium 5052 and 6061 alloy materials. The combination of process parameters is helpful to improve ultimate tensile strength, yield strength, percentage of elongation and hardness of welded joint. To achieve the research objective taguchi based grey analysis was used. The optimum process parameters were found be at rotational speed is 1400 rpm, transverse speed of 100 mm/min and axial force is at 11 KN.

Influence of Friction Stir Processing Parameters on the Fabrication of SiC/316L Surface Composite

2010 ◽  
Vol 297-301 ◽  
pp. 221-226 ◽  
Author(s):  
R. Salekrostam ◽  
M.K. Besharati Givi ◽  
P. Asadi ◽  
P. Bahemmat
Keyword(s):  
Stainless Steel ◽  
Friction Stir Processing ◽  
Traverse Speed ◽  
Processing Parameters ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Stainless Steel 316L ◽  
Friction Stir ◽  
The Many ◽  
Welding Processes

Compared to the many fusion welding processes that are routinely used for joining stainless steel 316L, the friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and is being recast. The welding parameters play a major role in deciding the weld quality. In this investigation an attempt has been made to understand the influences of rotational speed and traverse speed of the tool on the microstructure of the friction stir processing zone in stainless steel 316L. Five different tool rotational speeds have been used to fabricate the joints at four different traverse speeds from this investigation which is the optimum for the tool speed and higher or lower amounts of these parameters are not useful for the process.

Friction Stir Welding of Mg and Al Alloys

2014 ◽  
Vol 875-877 ◽  
pp. 1477-1482
Author(s):  
Tomáš Kupec ◽  
Ivana Hlaváčová ◽  
Milan Turňa
Keyword(s):  
Friction Stir Welding ◽  
Slovak Republic ◽  
Welding Process ◽  
Hardness Measurement ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Power Sources ◽  
Friction Stir ◽  
Alloy Type ◽  
Equipment Type

The work deals with welding of aluminium alloy typeAlMg4,5Mn and magnesium alloy type AZ 31 in solid state by FSW (Friction Stir Welding) process. Experiments were performed in cooperation with VÚZ PI SR (Welding Research Institute Industrial Institute of Slovak Republic) Bratislava, which has available a new installed equipment type FSW LM 060 manufactured in China. Welding parameters and conditions were proposed and approved. Quality of fabricated joints was assessed by optical microscopy, micro hardness measurement and radiographic test - RT. It was supposed that optimisation of welding parameters would allow to fabricate the joints of acceptable quality that might compete to technologies of fusion welding, including welding with concentrated power sources.

Friction Stir Welding of Composite Materials with Metallic Matrix: A Brief Review

2015 ◽  
Vol 809-810 ◽  
pp. 449-454 ◽  
Author(s):  
Ana Boşneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Monica Iordache ◽  
Alin Rizea
Keyword(s):  
Composite Materials ◽  
Friction Stir Welding ◽  
Welded Joint ◽  
Metallic Matrix ◽  
Welding Process ◽  
Fusion Welding ◽  
Industrial Environment ◽  
Friction Stir ◽  
Current State ◽  
Welding Processes

Composite materials with metallic matrix are increasingly require more than traditional materials metallic, being lighter, more reliable and with their superior properties like: rigidity, tensile strength, flexural strength, fatigue strength, modulus of elasticity, hardness, etc. Due to these advantages, above mentioned, this process has largely penetrated industrial environment. Despite these advantages, there are restrictions on their combination through traditional fusion welding methods so that was passed at the solid-state welding processes, respectively at Friction Stir Welding (FSW). Our researches presents in this brief review: some general ideas about composite materials with metallic matrix and Friction Stir Welding process, appearance and benefits, basic information about the process and composite materials welded by this process, shows the current state of the research with respect to behaviour macrostructure, microstructure, microhardness, tensile properties and defects of the welded joint between composite materials with metallic matrix.

scholarly journals Optimization of Process Parameters for Friction Stir Welding of Dissimilar Aluminium Alloy AA6061 to AA5183 using TOPSIS Technique

2019 ◽  
Vol 8 (9S3) ◽  
pp. 1315-1319
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Rotational Speed ◽  
Transverse Velocity ◽  
Welding Process ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Friction Stir

Friction stir welding has proven to be the most promising solid state joining process. It can be used to get high weldability in joining of high strength aerospace aluminium alloys and other metallic alloys which used to be low with traditional fusion welding process. This paper emphasises on finding the optimum process parameter for friction stir welding of dissimilar aluminium alloy AA6061 to AA5183 using multi criteria decision making method (MCDM). Friction stir welding was done at different tool rotational speed and transverse velocity and mechanical properties such as tensile strength, percentage elongation and hardness were studied for each weld specimen. Finally optimization was done using TOPSIS (Techniqueof Ordered Preference by Similarity to Ideal Solution). The result revealed that the tool rotational speed of 1200 rpm and welding speed of 80mm/min are the optimum welding parameters.

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