scholarly journals A Research on Friction Stir Welding using M42 Tool on Aisi 1018 Steel Plates

2019 ◽  
Vol 8 (12S) ◽  
pp. 362-366
Keyword(s):  
Friction Stir Welding ◽  
High Speed ◽  
High Speed Steel ◽  
Steel Plates ◽  
Milling Machine ◽  
Friction Stir ◽  
High Melting Temperature ◽  
Ferrous Material ◽  
Vertical Milling ◽  
Vertical Milling Machine

Friction Stir Welding was mainly suitable for aluminum alloys due to low softening temperatures. It is challenging to join the high melting temperature metals due to the lack of tool materials. The main focus of this work is to study the feasibility of joining the similar or dissimilar ferrous material. The molybdenum based high speed steel acts a rotating non consumable tool to weld the two ferrous plates. The friction stir welding was achieved using vertical milling machine. Welding samples were examined by destructive and nondestructive test. The welds were produced by 3 mm plate over a range of spindle speed from 500 to 1000 rpm. The results of FSW, stir zone of hardness varies from 139 to 145 HV executed on AISI 1018 plate steel.

scholarly journals Influence of Tool Pin Profile and Tool Rotating Speed on Mechanical Properties of Al6082 Alloy

2019 ◽  
Vol 8 (12) ◽  
pp. 3342-3345
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Automatic Process ◽  
Work Piece ◽  
Milling Machine ◽  
Friction Stir ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Tool Pin

Friction stir welding is a solid state welding which uses non consumable welding tool. It is an automatic process which generally performs on the vertical milling machine. In this type of welding, the relative motion between the tools and work piece creates heat which uses the region of work piece to be welded get softened and to joint the two work pieces. Friction stir welding process is more reliable for the materials which are generally non heat treatable. In this present investigation it will observe that how the rotational speeds of the tool and different shapes of the tool pins effects the mechanical properties of the aluminium alloy 6082. For this purpose three tools with different profiles, i.e triangular, cylindrical and square was designed and fabricated. At three different rotational speeds of 560 rpm, 900 rpm, 1800 rpm work pieces are joined using vertical milling machine. Specimens are prepared and tested for mechanical properties, tensile, impact, and hardness tests are performed and to detect the defects and voids x-ray test performed on the weld joints. And it was observed that highest tensile strength was presented when the square pin tool used at 560 rpm. The rotational speed increased mechanical properties are reducing significantly.

Reconfiguration of a Milling Machine to Achieve Friction Stir Welds

2012 ◽  
Vol 232 ◽  
pp. 86-91 ◽  
Author(s):  
Akinlabi Esther Titilayo ◽  
Madyira Daniel Makundwaneyi ◽  
Akinlabi Stephen Akinwale
Keyword(s):  
Control System ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Friction Stir Processing ◽  
Joint Strength ◽  
Milling Machine ◽  
Friction Stir ◽  
Backing Plate ◽  
Vertical Milling ◽  
Vertical Milling Machine

This paper reports on the reconfiguration of a milling machine to produce friction stir welds of aluminium and copper and friction stir processing of 6086 aluminium alloy. Friction stir welding tools were designed and manufactured from tool steel. The tools were inserted into the chuck of the milling machine. A backing plate was also specially designed and manufacturedfrom mild steel to protect the milling machine table and was placed on the bed with the use of T-nuts. The plates were secured firmly on the backing plate with the use of specially designed clamping fixtures. The varied welding speeds and the rotational speeds were achieved using the control system on the vertical milling machine. The reconfigured milling machine was successfully employed to produce friction stir processing of aluminium and friction stir welds of aluminium and copper. An optimum joint strength of 74% was achieved.

scholarly journals Wear Inducing Phase Transformation of Plasma Transfer Arc Coated Tools during Friction Stir Welding with Al Alloy

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Kuan-Jen Chen ◽  
Fei-Yi Hung ◽  
Truan-Sheng Lui ◽  
Yong-Ren Shih
Keyword(s):  
Wear Resistance ◽  
Phase Transformation ◽  
Friction Stir Welding ◽  
High Speed ◽  
Phase Transfer ◽  
Welding Process ◽  
High Speed Steel ◽  
Al Alloy ◽  
Transfer Layer ◽  
Friction Stir

The friction stir welding process (friction stir welding/processing, FSW/FSP) has wear problems related to stirring tools. In this study, the plasma transfer arc (PTA) method was used with stellite 1 powders (Co-based) to coat on the head of a SKD61 stirring tool (SKD61-ST1) in order to investigate the wear performance and phase transformation of SKD61-ST1 after FSW. Under the same experimental parameters, the wear data were compared with the high-speed steel SKH51 (tempering material SKH51-T and annealed material SKH51-A) and tungsten-carbide cobalt (TCC). Results showed the PTA coating was a γ-Co solidification matrix with M7C3 and M23C6 carbides. After FSW, the wear resistance of SKD61-ST1 was better than that of SKH51-A and SKH51-T and lower than that of TCC. The SKD61-ST1, SKH51-A, and SKH51-T stirring tools exhibited sliding wear after FSP, where the pin and shoulder of the stirring tool formed a phase transfer layer on the surface, and the peeling of the phase transfer layer caused wear weight loss. The main phase of the phase transfer layer of the SKD61-ST1 tool was Al9Co2. The affinity and adhesion energy of the Co-Al phase was lower than that of Fe-Al phase, and the phase transfer layer of the SKD61-ST1 tool was thinner and had lower coverage, thereby increasing the wear resistance of the SKD61-ST1 stirring tools during FSW.

Friction Stir Forming for Mechanical Interlocking of Ultra-Thin Stainless Steel Strands and Aluminum Alloys

2018 ◽  
Vol 382 ◽  
pp. 114-119 ◽  
Author(s):  
Hamed Mofidi Tabatabaei ◽  
Tadashi Nishihara
Keyword(s):  
Stainless Steel ◽  
Aluminum Alloys ◽  
Tensile Tests ◽  
Al Alloys ◽  
Milling Machine ◽  
Mechanical Interlocking ◽  
Friction Stir ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Novel Method

In this study, a novel method of mechanical interlocking of super-thin stainless steel strands with different aluminum alloys was conducted by using friction stir forming (FSF). The potential for the development of a multi-functional composite material was studied experimentally. It was concluded that FSF can successfully interlock stainless steel strands and different Al alloys and presents the possibility of improving the mechanical properties of the alloy. Trials of FSF were carried out on a modified vertical milling machine. The results are discussed in terms of microstructure observations, hardness distributions and tensile tests.

Microstructure and Mechanical Properties of Friction Stir Welding Joint of Pure Copper

2011 ◽  
Vol 418-420 ◽  
pp. 1520-1523
Author(s):  
Yong Zhao ◽  
You Li Ye ◽  
Keng Yan ◽  
Li Long Zhou
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
High Speed ◽  
Bonding Temperature ◽  
Pure Copper ◽  
High Speed Steel ◽  
Weld Nugget ◽  
Nugget Zone ◽  
Friction Stir ◽  
Welding Joint

Microstructures and mechanical properties of pure copper weld joints are discussed under different parameters of friction stir welding. The results reveal that it is conducive to the formation of compact joint in friction stir welding by applying high speed steel tool with high anti-bonding temperature. The friction stir welding joint with compact and defect-free microstructure could be obtained when the tool rotation rate is 1250- 1650 r/min and the tool traverse speed is 20-50 mm/min. Intensively plastic deformation occurs in the soften materials of the weld nugget zone and numerous crystal particles are broken under the influence of tool stirring. The microstructure of weld nugget zone is composed of tiny isometric crystals, which is due to the dynamic recrystallization of broken crystal particles. The structure of thermo-mechanical affected zone on both sides is asymmetric. Obvious boundary of the thermo affected zone could be seen on the advancing side, and the plastic streamline is apparent.

GENETIC ALGORITHM-ASSISTED ARTIFICIAL NEURAL NETWORK FOR THE ESTIMATION OF DRILLING PARAMETERS OF MAGNESIUM AZ91 IN VERTICAL MILLING MACHINE

2020 ◽  
Vol 27 (10) ◽  
pp. 1950221
Author(s):  
M. VARATHARAJULU ◽  
G. JAYAPRAKASH ◽  
N. BASKAR ◽  
A. SARAVANAN
Keyword(s):  
Neural Network ◽  
Genetic Algorithm ◽  
Artificial Neural Network ◽  
High Speed Steel ◽  
Milling Machine ◽  
Ann Model ◽  
Drilling Parameters ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Artificial Neural

The selection of appropriate drilling parameters is essential for improving productivity and part quality, therefore, this work mainly concentrates on the investigation of drilling time, burr height, burr thickness, roundness and surface roughness. The drilling experiments were carried out on Magnesium (Mg) AZ91 with High Speed Steel (HSS) tool using the Vertical Milling Machine (VMM). The parameters reckoned are spindle speed and feed rate. Artificial Neural Network (ANN) was concerned with the building of the model that will be used to forecast the responses following the consideration of Response Surface Methodology (RSM). Conventional method of modeling (RSM) yields poorer results which redirected the study with ANN. The Genetic Algorithm (GA)-based ANN has been reckoned for developing the model. With two nodes in the parameter layer and seven nodes in the response layer, six different networks were constructed using variety of nodes in the hidden layers which are 2–6–7, 2–7–7, 2–8–7, 2–6–6–7, 2–7–6–7 and 2–8–6–7. It is observed that the 2–8–7 network offers the best ANN model in predicting the various responses. The prediction results ensure the reliability of the ANN model to analyze the effect of drilling parameters over the various responses.

Modeling of Friction Stir Welding of AL7075 Using Neural Networks

2012 ◽  
Vol 3 (1) ◽  
pp. 66-79 ◽  
Author(s):  
Sasidhar Muttineni ◽  
Pandu R. Vundavilli
Keyword(s):  
Neural Network ◽  
Mechanical Properties ◽  
Neural Networks ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
High Speed ◽  
Welding Process ◽  
High Speed Steel ◽  
Operating Conditions ◽  
Friction Stir

Friction stir welding (FSW) is a solid state welding process, which is used for the welding of aluminum alloys. It is important to note that the mechanical properties of the FSW process depends on various process parameters, such as spindle speed, feed rate and shoulder depth. Two different tool materials, such as High speed steel (HSS) and H13 are considered for the welding of Al 7075. The present paper deals with the modeling of FSW process using neural networks. A three layered feed forward neural network (NN) has been used to model the FSW of aluminum alloys. It is important to note that the connection weights and bias values of the NN are optimized with the help of a binary coded genetic algorithm (GA). The training of the NN with the help of GA is a time consuming process. Hence, offline training has been provided to optimize the connection weights and bias values of the neural network. Once, the training is over, the GA trained neural network will be used for online prediction of the mechanical properties of FSW process at different operating conditions.

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