scholarly journals Performance of Plunge Depth Control Methods During Friction Stir Welding

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 283 ◽  
Author(s):  
Jinyoung Yoon ◽  
Cheolhee Kim ◽  
Sehun Rhee
Keyword(s):  
Friction Stir Welding ◽  
Position Control ◽  
Longitudinal Direction ◽  
Control Methods ◽  
Friction Stir Lap Welding ◽  
Plunge Depth ◽  
Friction Stir ◽  
Compensation Control ◽  
Depth Control ◽  
Lap Welding

Friction stir welding is a preferred solid state welding process for Al/Fe joints, and in friction stir lap welding, the plunge depth is the most critical parameter for joint strength. We compared three plunge depth control methods, namely conventional position control, offset position control, and deflection compensation control in the friction stir lap welding of 3 mm-thick Al 5083-O alloy over 1.2 mm-thick DP 590 steel. The desired plunge depth was 0.2 mm into the steel sheet. However, the pin did not reach the steel surface under conventional position control due to deflection of the vertical axis of the welding system. In offset position control, an additional offset of 0.35 mm could achieve the desired plunge depth with considerable accuracy. Nevertheless, a gradual increase of the plunge depth along the longitudinal direction was unavoidable, due to an in-situ decrease of the material yield strengths. In deflection compensation control, the deflection is estimated by the coaxially measured plunging force and the force-deflection relationship, and then corrected by feedback control. Thus, the plunge depth is stabilized along the longitudinal direction and is precisely controlled with a 3.3-μm standard deviation of error during the tool traverse phase. There is also a consistent bias of 32 μm caused by the resolution of the measuring system, and it can be easily calibrated in the feedback control system.

Friction Stir Lap Welding of Aluminum to Steel Using Refractory Metal Pin Tools

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
M. Shamsujjoha ◽  
Bharat K. Jasthi ◽  
Michael West ◽  
Christian Widener
Keyword(s):  
Mechanical Properties ◽  
Refractory Metal ◽  
Joint Strength ◽  
Joint Interface ◽  
Friction Stir Lap Welding ◽  
Plunge Depth ◽  
Friction Stir ◽  
Joint Efficiency ◽  
Bonding Area ◽  
Lap Welding

Steel and Al were friction stir lap welded using two different W-25% Re-4% HfC pin tools, having two different pin diameters and pin lengths. The effects of plunge depth, bonding area, and top sheet positions on the microstructure and mechanical properties were investigated. Morphology of the joint interface showed severe steel flash on the retreating side, which controlled the joint strength when the top sheet was placed on the retreating side. A joint efficiency of 58% was achieved when right-handed lap welds were made using the pin tool with longer pin length.

Friction Stir Lap Welding of Aluminium Alloys

2014 ◽  
Vol 611-612 ◽  
pp. 1421-1428
Author(s):  
Carlo Bruni ◽  
Giovanni Quercetti ◽  
Massimiliano Pieralisi
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Tensile Shear ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Tool Geometries ◽  
Lap Welding ◽  
Welding Properties ◽  
Transverse Area ◽  
Tool Rotation

The friction stir welding of lap sheets can be performed considering different variables in terms of process parameters, tool configuration, welding typology and so on. The proposed investigation deals with the friction stir welding of blanks, with the same thickness, performed under lap configuration with the sheets welded, in one-side and in both sides as well, with different tool geometries and tool rotation-wise. The double side allows to extend the weld through the whole thickness leading to better mechanical welding properties at the blank to blank interface. The weld morphology has been investigated through microstructure observations performed on the transverse area, with respect to the welding velocity, of each joint. The tensile shear strength of the joint in one-side weld is generally lower than that detected in two side weld.

scholarly journals Effect of Process Factors on Tensile Shear Load Using the Definitive Screening Design in Friction Stir Lap Welding of Aluminum–Steel with a Pipe Shape

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5787
Author(s):  
Leejon Choy ◽  
Seungkyung Kim ◽  
Jeonghun Park ◽  
Myungchang Kang ◽  
Dongwon Jung
Keyword(s):  
Friction Stir Welding ◽  
Penetration Depth ◽  
Shear Load ◽  
Cast Aluminum ◽  
Tensile Shear ◽  
Plunge Depth ◽  
Friction Stir ◽  
Screening Design ◽  
Definitive Screening ◽  
Lap Welding

Recently, friction stir welding of dissimilar materials has emerged as one of the most significant issues in lightweight, eco-friendly bonding technology. In this study, we welded the torsion beam shaft—an automobile chassis component—with cast aluminum to lighten it. The study rapidly and economically investigated the effects of friction stir welding and process parameters for A357 cast aluminum and FB590 high-strength steel; 14 decomposition experiments were conducted using a definitive screening design that could simultaneously determine the effects of multiple factors. Friction stir welding experiments were conducted using an optical microscope to investigate the tensile shear load behavior in the welding zone. In addition to understanding the interactions between tool penetration depth and plunge speed and tool penetration depth and dwell time, we investigated and found that tool penetration depth positively affected the size of the hooking area and contributed to the stabilization and size reduction of the cavity. The experimental results showed that the plunge depth and tool penetration depth effects were most important; in this case, the plunge depth negatively affected the magnitude of tensile shear load, whereas the tool penetration depth had a positive effect. Therefore, when selecting a tool, it is important to consider the plunge depth and tool penetration depth in lap welding.

Micro friction stir lap welding of AISI 430 ferritic stainless steel: a study on the mechanical properties, microstructure, texture and magnetic properties

2018 ◽  
Vol 115 (3) ◽  
pp. 307
Author(s):  
Hossein Mostaan ◽  
Mehdi Safari ◽  
Arash Bakhtiari
Keyword(s):  
Stainless Steel ◽  
Magnetic Properties ◽  
Friction Stir Welding ◽  
Ferritic Stainless Steel ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Change Mechanism ◽  
Lap Welding ◽  
Field Emission Electron Microscopy ◽  
Aisi 430

In this study, the effect of friction stir welding of AISI 430 (X6Cr17, material number 1.4016) ferritic stainless steel is examined. Two thin sheets with dimensions of 0.4 × 50 × 200 mm3 are joined in lap configuration. Optical microscopy and field emission electron microscopy were used in order to microstructural evaluations and fracture analysis, respectively. Tensile test and microhardness measurements are employed in order to study the mechanical behaviors of welds. Also, vibrational sample magnetometry (VSM) is employed for characterizing magnetic properties of welded samples. Texture analysis is carried out in order to clarify the change mechanism of magnetic properties in the welded area. The results show that AISI 430 sheets are successfully joined considering both, the appearance of the welding bead and the strength of the welded joint. It is found that by friction stir welding of AISI 430 sheets, texture components with easy axes magnetization have been replaced by texture components with harder magnetization axes. VSM analysis showed that friction stir welding leads to increase in residual induction (Br) and coercivity (Hc). This increase is attributed to the grain refining due the friction stir welding and formation of texture components with harder axes of magnetizations.

Equal-load-bearing joining of alclad AA2024-T4 alloy stringers and skins in aviation via friction stir lap welding

2021 ◽  
Vol 68 ◽  
pp. 1295-1302
Author(s):  
Xiangchen Meng ◽  
Bingqi Cao ◽  
Yang Qiu ◽  
Huizi Chen ◽  
Yuming Xie ◽  
...  
Keyword(s):  
Friction Stir Lap Welding ◽  
Load Bearing ◽  
Friction Stir ◽  
Lap Welding
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