scholarly journals Concomitant Outcomes due to the Alterations of Process Parameters During the Friction Stir Welding of T-Joint Between Dissimilar Aluminium Alloys

2020 ◽  
Vol 13 (2) ◽  
Author(s):  
Nadeem Fayaz Lone ◽  
Amanullah Mahmood ◽  
Arbaz Ashraf ◽  
Md Masroor Alam ◽  
Homi Hussain ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Aluminium Alloys ◽  
Dominant Factor ◽  
Welding Parameters ◽  
Engineering Structures ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Lower Tensile Strength

Dissimilar Friction Stir Welded T-joints gives auxiliary strength to engineering structures, keeping insignificantbody weight. Due to the stronger material being away from the heat source, the T-joint between AA8011 and AA5754 is very vulnerable to formation of defects which results in lower tensile strength along the skin and stringer. In this paper, two aluminium alloys, namely AA5754 and AA8011 were friction stir welded in the Tjoint configuration, and the roles of welding parameters such as the tool transverse speed, tool rotational speed, and tool shoulder diameter on the tensile strength along skin and stringer was analyzed and discussed. The relative importance of the three process parameters was also analyzed. The tool shoulder diameter is found to be the most dominant factor for the strength along the skin, whereas, tool transverse speed is found to be the most important for the strength along stringer.

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

Optimization of Welding Process Parameters in Novel Friction Stir Welding of Polyamide 66 Joints

2019 ◽  
Vol 969 ◽  
pp. 828-833 ◽  
Author(s):  
R. Nandhini ◽  
R. Dinesh Kumar ◽  
S. Muthukumaran ◽  
S. Kumaran
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Polyamide 66 ◽  
Friction Stir ◽  
Response Characteristics ◽  
Tool Shoulder ◽  
Stereo Microscope ◽  
Friction Plate

The friction stir welding of polyamide 66 with a specially modified tool is studied. A variation of the conventional friction stir welding is investigated by incorporating a friction plate for the purpose of heating the polymer in the course of welding process through the tool shoulder. This in turn, improves the efficiency of the weld. The association of the welding process parameters and the weld performance has been investigated by the grey relational analysis with multi response characteristics like weld tensile strength, percent elongation and hardness. Macrostructure of the weld joint cross section has been explored by Stereo microscope. The maximum weld tensile strength of 63 MPa and a Shore hardness of 60 D at the weld nugget are obtained. The hardness profiles of the welded samples have been analyzed in this investigation.

In-Plane Plane-Strain Formability Investigation of Friction Stir Welded Sheets Made of Dissimilar Aluminium Alloys

2013 ◽  
Vol 446-447 ◽  
pp. 301-305
Author(s):  
Mukesh Kumar ◽  
Satish V. Kailas ◽  
R. Ganesh Narayanan
Keyword(s):  
Plane Strain ◽  
Heat Input ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Traverse Speed ◽  
Al Alloys ◽  
Welding Parameters ◽  
Strain Hardening Exponent ◽  
Friction Stir ◽  
Shoulder Diameter

In the present work, the influence of shoulder diameter, traverse speed, and rotational speed on the formability of friction stir welded sheets made between sheets of AA6061T6 and AA5052H32 Al alloys has been studied. In-Plane Plane-Strain formability tests are conducted for this purpose. It is understood from the results that the formability of welded sheets can be improved by optimizing the welding and tool parameters. A larger shoulder diameter, higher traverse speed, and lower rotational speed are favorable for improved formability, and strain hardening exponent of weld region. This is due to the fact that the heat input and subsequent microstructure evolved depends on the heat input, which depends on the welding parameters.

Analysis of process parameters effects on underwater friction stir welding of aluminum alloy 6082-T6

2018 ◽  
Vol 233 (6) ◽  
pp. 1700-1710 ◽  
Author(s):  
Mohd Atif Wahid ◽  
Zahid A Khan ◽  
Arshad Noor Siddiquee ◽  
Rohit Shandley ◽  
Nidhi Sharma
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Underwater Friction Stir Welding ◽  
Optimal Setting

In friction stir welding of heat treatable aluminum alloys, the thermal cycles developed during the joining process result in softening of the joints which adversely affect their mechanical properties. Underwater friction stir welding can be a process of choice to overcome this problem due to low peak temperature and short dwell time involved during the process. Consequently, this article presents a study pertaining to the underwater friction stir welding of aluminum alloy 6082-T6 with an aim to develop a mathematical model to optimize the underwater friction stir welding process parameters for obtaining maximum tensile strength. The results of the study reveal that the tool shoulder diameter (d), tool rotational speed (ω), welding speed (v), and second-order term of rotational speed, that is, ω2, significantly affect the tensile strength of the joint. The maximum tensile strength of 241 MPa which is indeed 79% of the base metal strength and 10.7% higher than that of conventional (air) friction stir welding joint was achieved at an optimal setting of the underwater friction stir welding parameters, that is, tool rotational speed of 900 r/min, the welding speed of 80 mm/min, and a tool shoulder of 17 mm. The article also presents the results of temperature variation, the macrostructural and microstructural investigations, microhardness, and fractography of the joint obtained at the optimal setting for underwater friction stir welded (UFSWed) joint.

The Effect of Top Surface Lubrication on the Friction Stir Welding of Polycarbonate Sheets

2021 ◽  
Vol 36 (1) ◽  
pp. 94-102
Author(s):  
M. M. Z. Ahmed ◽  
A. Elnaml ◽  
M. Shazly ◽  
M. M. El-Sayed Seleman
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Transverse Cross Section ◽  
Joint Zone ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Fsw Parameters ◽  
Spherulitic Structure

Abstract In this work, top surface lubrication during friction stir welding of polycarbonate sheets was applied. A homogenous layer of Paraffin wax has been placed on the top surface of the joint area with a width that ensures to cover the shoulder diameter. Then FSW was applied using conventional FSW tool with rotating pin and shoulder at different FSW parameters (Rotation speeds of 1 000, 1500, 2 000 min–1 and welding speeds of 25, 50, 75,100 mm/min). The main objective of using the wax is to act as a lubricant that reduces the friction between the shoulder and the polycarbonate surface. The joints produced were investigated in terms of surface quality, internal defects, and mechanical properties. During FSW the wax is melted and played as lubricant between the tool shoulder and the polycarbonate surface and resulted in defect-free surface with no thickness reduction of the original plate. The transverse cross-section showed defect-free joints for the majority of the FSW parameters investigated. Tensile testing results showed a reduction of the tensile strength after FSW, and an enhancement in the tensile strength with the increase of welding speed or rotation speed. The fracture occurs at the joint zone and the fracture surface investigation using SEM showed the existence of spherulitic structure in the weld joint.

scholarly journals T-FSW of Dissimilar Aerospace Grade Aluminium Alloys: Influence of Second Pass on Weld Defects

Metals ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 525
Author(s):  
Mustufa Haider Abidi ◽  
Nabeel Ali ◽  
Hashmatullah Ibrahimi ◽  
Saquib Anjum ◽  
Dhruv Bajaj ◽  
...  
Keyword(s):  
Process Parameters ◽  
Aluminium Alloys ◽  
Detrimental Effect ◽  
Substantial Reduction ◽  
T Joints ◽  
Friction Stir ◽  
Weld Defects ◽  
Shoulder Diameter ◽  
Aerospace Sector

The restoration of numerous aircraft structures is achievable with effective repair of welded joints. T-joints are often utilized in these structures to provide structural stability, keeping minimal body weight. Multi-pass friction stir welding (FSW) has proved to be useful for improving the quality of aluminium alloy welds employed in the aerospace sector. However, FSW of these alloys in T-configuration has not been sufficiently addressed yet. Even rarer is the discussion of efficacy of second FSW pass, with altered process parameters for improving the weld quality in T-joints. Hence, two commonly used aerospace grade aluminium alloys, namely, AA2024 and AA7075, were friction stir welded in T-configuration, varying three process parameters, i.e., tool rotational speed, welding speed and shoulder diameter. The effect of second FSW pass, performed at an optimum set of parameters, on kissing bond and tunnelling defect was studied in detail. A substantial reduction in the detrimental effect of these weld defects was discussed via tensile testing, micro-hardness and micro-structural observations.

Study of the performance parameters of friction stir welded magnesium AZ31B alloy at optimized process parameters

2021 ◽  
pp. 095440622199240
Author(s):  
Pradeep K Yadav ◽  
Manoj K Khurana
Keyword(s):  
Process Parameters ◽  
Grey Relation Analysis ◽  
Percentage Elongation ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Analysis Technique ◽  
Shoulder Diameter ◽  
Optimum Response ◽  
Az31b Alloy ◽  
Grey Relation

The present study is aimed to analyze the effect of process parameters on the qualities of the Friction Stir Welded AZ31B Mg Alloy. Response Surface Methodology based Grey Relation Analysis technique was used to multi-optimization of the response parameters such as tensile strength (TS), percentage elongation (El), microhardness (MH), and impact strength (IMP). The mathematical models for response parameters were developed by considering tool rotational speed (RS), tool shoulder diameter (SD), and welding speed (WS) as process parameters. ANOVA (Analysis of Variance) was performed to check the adequacy of the formulated mathematical model and figure out the significant parameters. The results revealed that RS of 950 rpm, WS of 150 mm/min, and SD of 11 mm are the optimal process parameters for optimum response parameters (TS of 157.8700 MPa, IMP of 4.3001 Joule, MH of 84.1335 Hv, and El of 10.0071%). WS is the most significant factor, followed by RS and SD. The grain growth was observed in thermo-mechanically affected zone (TMAZ). The fracture analysis indicated that crack had initiated from the bottom of the centerline in the welded zone and propagated towards the advancing side.

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

2019 ◽  
Vol 234 (5) ◽  
pp. 1031-1043
Author(s):  
Arshad Noor Siddiquee ◽  
Sunil Pandey ◽  
Mustufa Haider Abidi ◽  
Abdulrahman Al-Ahmari ◽  
Noor Zaman Khan ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Traverse Speed ◽  
304 Stainless Steel ◽  
Welding Parameters ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter

Welding AISI 304 stainless steel is challenging, especially as fusion-based welding processes (such as arc welding) severely undermine the material's corrosion resistance due to sensitization. Solid-state friction stir welding is one of the most suitable alternatives. Friction stir welding of high-strength high-softening materials such as AISI 304 is difficult mainly because of the non-availability of affordable tools and tool life. In this study, AISI 304 stainless steel was successfully butt-welded by friction stir welding. The experiments were performed using Taguchi's L27 orthogonal array. Shoulder diameter, tool r/min, and traverse speed were selected as the most influential welding parameters. A Tungsten Carbide (WC) tool was employed with a tapered pin profile. Defect-free joints were fabricated successfully for all the welding conditions. Microstructural examinations using optical microscopy and scanning electron microscopy revealed significant grain refinement in the stir zone and the presence of distinct structural features such as stepped, dual, and ditch in various characteristics zones. The presence of precipitates was also observed in samples and was confirmed via energy-dispersive X-ray spectroscopy analysis. The in-process traverse force was measured by a special arrangement of force measuring units attached to the work fixture. The traverse force data were analyzed and optimized. The results of an analysis of variance reveal that the traverse speed was the most important parameter, followed by tool r/min, interaction between the tool shoulder diameter and traverse speed, interaction between the tool shoulder diameter and tool r/min, and, finally, the tool r/min.

Structural Properties of Similar and Dissimilar Aluminum Alloy Joints by FSW

2014 ◽  
Author(s):  
Ramgopal Varma Ramaraju ◽  
Abdullah Bin Ibrahim ◽  
Muhammed Arifpin Bin Mansor ◽  
Yaswanth Yattapu
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Process Parameters ◽  
Welded Joints ◽  
Aluminium Alloys ◽  
Traverse Speed ◽  
Micro Hardness ◽  
Taguchi Technique ◽  
Friction Stir ◽  
Micro Structures

The present study aims to predict the mechanical properties of similar and dissimilar aluminium alloy friction stir Welded joints. The present research also addresses the challenges in joining aluminium alloys Al5083 and Al6061 of 5mm thickness at varying process parameters. A total number of 24 joints have been fabricated with a set of eight joints each for Al6061 (similar), Al5083 (similar) and a combination of Al5083 × Al6061 (dissimilar alloy) as per the experimental plan by Taguchi technique using L8 orthogonal array. The dimensions of the plates are chosen in such a way that the weld length is fixed to 150 mm. The tensile strength and the micro hardness of the welded joints as well as micro structures have been examined. Taguchi technique has been utilized to study the optimized value of the process parameters. The process parameters for joining these have been identified as rotational speeds at 1000 and 1600 rpm, traverse speed 40 and 160mm/min and axial force of 2.5 and 3.5kn.

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