scholarly journals Optimal FSW Process Parameters to Improve the Strength of Dissimilar AA6061-T6 to Cu Welds with Zn Interlayer

2019 ◽  
Vol 8 (4) ◽  
pp. 11688-11695
Keyword(s):  
Process Parameters ◽  
Empirical Relation ◽  
Travel Speed ◽  
Strength Properties ◽  
Dissimilar Welding ◽  
Test Results ◽  
Friction Stir ◽  
Taguchi Design Of Experiments ◽  
Potential Applications ◽  
Tool Pin

Dissimilar welding of Al-Cu has many potential applications in electric power, electronic and piping industries due to high corrosion resistance, heat and conducting properties. Weld joints through friction stir welding (FSW) process are free from melting- and solidification-related defects. Compared to the recently used Box–Behnken design of response surface methodology, a simple and reliable modified Taguchi design of experiments is utilized for the dissimilar welding of AA6061-T6 to Cu with Zn interlayer to obtain the optimal FSW process parameters and the expected range of strength properties. Empirical relation for the tensile strength is developed in terms of FSW process parameters (viz., tool rotation speed, tool travel speed and tool pin offset) and validated through test results. Most of the test data are within the expected range.

Investigation of the microstructural, mechanical, and thermal evolution of dissimilar aluminium alloys during friction stir welding

2020 ◽  
Vol 44 (1) ◽  
pp. 38-48
Author(s):  
T. Kasirajan ◽  
R. Ravindran ◽  
T. Ramkumar ◽  
M. Selvakumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Thermal Evolution ◽  
Travel Speed ◽  
Influence Of Process Parameters ◽  
Friction Stir ◽  
Joint Efficiency ◽  
Electron Microscopes ◽  
Tool Pin

This work deals with the joining of 6 mm thick dissimilar aluminium plates (AA5083-H111 and AA6082-T6) using a friction stir welding method and by varying the process parameters. Test experiments were performed to identify the influence of process parameters on the joint efficiency of the weldments. The process parameters such as tool rotation speed and tool pin profile were varied; whereas, tool travel speed, tilt angle, and axial force were kept constant for all weldments. Microstructure evaluation was carried out using light optical and scanning electron microscopes, which exposed the grain refinement in the nugget zone (NZ) and thermo-mechanical affected zone (TMAZ). Mechanical property tests for tensile strength, hardness, and bending were performed to understand the influence of the parameters over the weldments. Heat development between the tool shoulder and workpiece was analyzed by calculating the heat flow and heat flux. The thermal diffusivity of AA5083-H111 and AA6082-T6 were calculated to understand the influence of heat distribution in the joint efficiency of the weldments. It is inferred from the current study that the threaded cylinder tool at a rotational speed of 900 rpm achieved the highest tensile strength, hardness, and bend strength over the combination of other parameters.

scholarly journals Friction Stir Welding with Low-Medium-High Tool Travel Speed of 0.95 Mg-Al-Alloy and Pure Copper: Electrochemical and Surface Studies

2018 ◽  
Author(s):  
Neetesh Soni ◽  
Ambrish Singh
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Pure Copper ◽  
Travel Speed ◽  
Localized Corrosion ◽  
Al Alloy ◽  
Kelvin Probe ◽  
Friction Stir ◽  
Surface Optical ◽  
Joining Process

The aim of this work is to assess the influence of Friction Stir Welding (FSW), process parameters, optimized tool traveling speed, and corrosion resistance of the 0.95 Mg-Al-alloy and pure copper weldment. Samples of aluminum-copper with and without deformation were characterized to investigate the metallurgical effects created during the welding deformation process. Effect of process parameters on microstructure and corrosion rate have been investigated for all the samples. All the electrochemical and polarization tests were done in 3.5 wt.% NaCl solution. Scanning Kelvin Probe (SKP) was done to detect the localized corrosion on the surface. Optical micrography observation indicated that the primary α-Al phase, which was formed during solidification can effectively limit the growth of Cu9Al4 phase. Finer acicular α-Al precipitates were observed in CuAl matrix during joining process that tends to coarser with the increase in tools travel speed. The electrochemical and polarization results showed that among all the tool travelling speed the specimen joined at tool travelling speed of 40 mm/min shows the best non-corrosive property.

The Influence of Cu/Ti Overlapping Region Microstructures on the Mechanical Tensile Properties of the Joint via Friction Stir Lap Welding

2017 ◽  
Vol 1142 ◽  
pp. 260-264 ◽  
Author(s):  
Bo Li ◽  
Yi Fu Shen ◽  
Lei Yao
Keyword(s):  
Tensile Properties ◽  
Travel Speed ◽  
Lap Joints ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Lap Welding ◽  
Mechanical Tensile ◽  
Tool Pin ◽  
Solid State Joining ◽  
Locking Effect

The investigation on friction stir lap welding (FSLW) of dissimilar Cu and Ti is reported in this research, aiming to achieve a reliable solid-state joining and effectively control the intermetellic (IMC) formation at the lapping Cu/Ti dissimilar welded interfaces. Following the previous process optimization of the FSLW tool rotation speed and downward plunge value of the tool pin into the lower Ti sheet, the tool travel speed was further tailored for a defect-free joint. No significant Ti-Cu IMC was founded in the generated joints. After the analyses of tensile properties of the FSLW joints, the so-called mechanical locking effect of the Cu/Ti alternate band structure was further elucidated. The composite-like structure played a so-called mechanical locking effect on the Cu/Ti lap joints. The fracture resistant strength of the joint reached 95% of that of the used parent copper.

Parameters optimization in FSW of polypropylene based on RSM

2015 ◽  
Vol 11 (1) ◽  
pp. 32-42 ◽  
Author(s):  
K Panneerselvam ◽  
Kasirajan Lenin
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Optimization Techniques ◽  
Parameters Optimization ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Output Characteristics ◽  
Tool Pin

Purpose – The purpose of this paper is to weld polypropylene (PP) material by friction stir welding (FSW) process. The input process parameters considered were: tool pin profile, feed rate and tool rotational speed and the process output characteristics were tensile strength, Shore-D hardness, Rockwell hardness, Izod strength, Charpy strength and nugget area. Design/methodology/approach – Optimization of process parameters were carried out based on response surface methodology (RSM) and significant parameters were obtained by performing analysis of variance (ANOVA). Findings – The optimized results were the threaded pin profile for feed of 60 mm/min and tool rotational speed of 1,500 rpm. A confirmation test was carried out to verify the optimized results. Originality/value – In this paper, the process parameters were optimized based on RSM. This is newly adopted optimization techniques in the FSW process of PP materials and also it gives better results.

Multi Response Optimization of Submerged Friction Stir Welding Process Parameters Using TOPSIS Approach

2015 ◽  
Author(s):  
Senthil Kumar Velukkudi Santhanam ◽  
Lokesh Rathinaraj ◽  
Rathinasuriyan Chandran ◽  
Shankar Ramaiyan
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Response Characteristics ◽  
Response Optimization ◽  
Topsis Approach ◽  
Tool Pin

Friction stir welding (FSW) is a solid-state welding process which is used to join high-strength aircraft aluminum alloys and other metallic alloys which are difficult to weld by conventional fusion welding. In this paper, AA6063-O alloy of 6mm thickness was taken and friction stir welded under the water in order to improve the joint properties. The process parameters considered as rotational speed, welding speed and tool pin profiles (cylindrical, threaded and tapered) are optimized with multi response characteristics including hardness, tensile strength and % elongation. In order to solve a multi response optimization problem, the traditional Taguchi approach is insufficient. To overcome this constraint, a multi criteria decision making approach, namely, techniques for order preference by similarity to ideal solution (TOPSIS) is applied in the present study [13]. The optimal result indicates that the multi response characteristics of the AA6063-O during the submerged friction stir welding process can be enhanced through the TOPSIS approach. The Analysis of Variance (ANOVA) was carried out to investigate the significant parameter for the submerged friction stir welding process. The mechanical properties of the submerged FSW are compared with normal FSW joints.

Optimization of process parameters for friction stir welding of joining A6061 and A6082 alloys by Taguchi method

2012 ◽  
Vol 227 (6) ◽  
pp. 1150-1163 ◽  
Author(s):  
Sanjay Kumar ◽  
Sudhir Kumar ◽  
Ajay Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Experimental Tests ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Optimization Of Process Parameters ◽  
Tool Pin

The friction stir welding is a pioneering solid-state metal joining technique for producing high-quality joints in materials. In this article, Taguchi approach is applied to analyze the optimal process parameters for optimum tensile strength and hardness of welded dissimilar A6061 and A6082 alloys. An orthogonal array of L9 is implemented and the analysis of variance is employed to investigate the importance of parameters on responses. The experimental tests, conducted according to combination of rotational speed, tool tilt and types of tool pin profile parameters. The results indicate that the rotational speed is most significant process parameter that has the highest influence on tensile strength and hardness, followed by tool pin profile and tool tilt. The optimum results verified by conducting confirmation experiments. The predicted optimal value of tensile strength and hardness of dissimilar joints produced by friction stir welding are 267.74 MPa and 80.55 HRB, respectively.

Role of Mg2Si particles on mechanical, wear, and corrosion behaviors of friction stir welding of AA6061-T6 and Al-Mg2Si composite

2020 ◽  
Vol 54 (26) ◽  
pp. 4035-4057 ◽  
Author(s):  
A Moharami ◽  
A Razaghian ◽  
B Babaei ◽  
OO Ojo ◽  
M Šlapáková
Keyword(s):  
Material Flow ◽  
Travel Speed ◽  
Friction Stir ◽  
Base Materials ◽  
Al Composite ◽  
Wear And Corrosion ◽  
Corrosion Behaviors ◽  
Si Joint ◽  
Tool Pin

This paper investigates the effect of different tool pin morphologies on the inter-mixing capability, microstructure, mechanical properties, corrosion, fracture, and wear behaviors of the dissimilar friction stir welded AA6061-T6 alloy--Al 20wt% Mg2Si composite. Grooved shoulder tools with varying pin profiles such as tapered cylindrical, threaded tapered cylindrical, and triangular tapered pins were used for joining the base materials. The parameter combination of 80 mm/min travel speed and 1000 r/min rotation speed (at which no visible flow-induced defect was obtained) was used for this study. Among the pin profiles, the triangular tapered pin produced significantly improved intermingling/inter-material flow, fragmentation, and dispersion of the primary Mg2Si particles in the AA6061-T6/Al-Mg2Si joint. The triangular tapered tool reduced the average grain sizes of the AA6061 alloy and the Mg2Si particles from 18.4 to 4.6 µm and from 115 to 7.5 µm, respectively. Intermetallic phases of Mg2Si, AlFe, Al3.21Si0.47, and Al0.7Fe3Si0.3 are formed in the weld nugget of all the AA6061/Al-Mg2Si joints. The tensile strengths of the joints fabricated with tapered cylindrical, threaded tapered cylindrical, and triangular tapered tools are 108, 139, and 141 MPa, respectively. Abrasive wear is promoted in the joints fabricated with triangular tapered tool due to the homogeneous dispersion and fragmentation of the inherent hard Mg2Si particles. The corrosion attack is dependent on the fragmentation level of the Mg2Si phase. Triangular tapered pin tool is recommended for dissimilar Al/composite welding due to favorable tool-induced material flow, dispersion, and fragmentation of reinforcement.

scholarly journals Failure of En19 Taper Thread Tool On Welding Ms Plate

2019 ◽  
Vol 8 (11) ◽  
pp. 3237-3240
Keyword(s):  
Aerospace Industry ◽  
Research Work ◽  
Test Results ◽  
Tool Rotational Speed ◽  
Tensile Shear ◽  
Flat Plates ◽  
Friction Stir ◽  
Specimen Width ◽  
Tool Pin ◽  
Better Than

FSSW is used a lot of vicinity which are from marine to aerospace industry. FSSW is effected with tool rotational speed, tool transverse speed, dwell time and tool plunge depth. One of them is weight. With the reference to the research work In this paper two flat plates of similar metals of MS of 1.2 mm thickness & 30.25mm specimen width are subjected to a solid state welding at 900rpm using the EN19 taper thread tool. The tensile-shear test results showed that the FSSW specimens are better than the specimens welded by the conventional FSSW process at 900-1300 tool rotational speeds with using taper thread tool pin profiles. By doing tensile test following ASTM B 557:2006 procedure the ultimate shear load obtained from the conventional friction stir spot welds is 1.960KN.

Optimization of Corrosion Behavior in Submerged Friction Stir Processed Magnesium AZ31B Alloy

2017 ◽  
Author(s):  
Sankar Ramaiyan ◽  
Udayakumar Mani ◽  
Rathinasuriyan Chandran ◽  
Senthil Kumar Velukkudi Santhanam
Keyword(s):  
Corrosion Rate ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Optimization Technique ◽  
Traverse Speed ◽  
Immersion Test ◽  
Friction Stir ◽  
Response Optimization ◽  
Az31b Alloy ◽  
Tool Pin

In this research, friction stir processing of AZ31B magnesium alloy of 6 mm thickness was done in submerged conditions. The process parameters, i.e. tool pin profile (simple cylindrical, stepped cylindrical, stepped square), rotational speed ranging from 800 to 1200 rpm and traverse speed ranging from 0.5 to 1.5 mm/sec were optimized using the multi response optimization technique. The experiment was conducted with L27 orthogonal arrays. The Immersion test and hardness have been considered as output response. From the view of an application, it would be more significant to optimize the Immersion Corrosion rate and Hardness of Submerged Friction Stir Processed AZ31B alloy. Thus, this study aims at optimizing the process parameters, including various tool pin profiles, feed rates and rotational speeds with corrosion rate and micro hardness using TOPSIS. Using analysis of variance (ANOVA), the most significant parameter effect of the submerged friction stir processing was determined.

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