scholarly journals Effect of dwelling time and plunge depth on the joint properties of the dissimilar friction stir spot welded aluminum and steel

2021 ◽  
Vol 9 ◽  
Author(s):  
Mohamed M. Z. Ahmed ◽  
◽  
Mahmoud A. Abdu Abdul-Maksoud ◽  
Mohamed M. El-Sayed Seleman ◽  
◽  
...  
Keyword(s):  
Rotational Speed ◽  
Shear Failure ◽  
Failure Load ◽  
Pure Aluminum ◽  
Dissimilar Materials ◽  
Welding Parameters ◽  
Microstructural Investigation ◽  
Plunge Depth ◽  
Friction Stir ◽  
Joint Properties

Sound joints of a far apart property, pure aluminum and mild steel, dissimilar materials were obtained by friction stir spot welding (FSSW) solid state joining process. Sheets of 2 mm thickness were overlapped and fixed with a fixture device then welded. Welding parameters that produced the sound joint were identified. Joints microstructure and mechanical properties were investigated. A microstructural investigation has revealed a creation of mechanical interlocking and discontinuous formation of the intermetallic compounds found at the interface. The intermetallic compound (IMC) layer thickness ranged from 6 μm to 17 μm with the optimum condition specimen, 800 rpm and 5 Sec dwell time. Tensile–shear test showed that failure load has increased with increasing tool plunge depth and rotational speed. After the optimum value of rotational speed, the shear failure load decreased. The maximum shear failure load of 2.15 KN attained at 800 rpm and 2.4 mm plunge depth.

Multi-Objective Optimization of Friction Stir Spot Welds of Aluminum Alloy Using Entropy Measurement

2019 ◽  
Vol 45 ◽  
pp. 28-41
Author(s):  
Olatunji Oladimeji Ojo
Keyword(s):  
Rotational Speed ◽  
Dwell Time ◽  
Shear Failure ◽  
Failure Load ◽  
Multi Objective Optimization ◽  
Plunge Depth ◽  
Friction Stir ◽  
Multi Objective ◽  
Entropy Measurement ◽  
Grey Relational

Surface finish accrued extra-production cost, reduced effective sheet thickness, stir zone galling, undesirable flash-root stress concentration and fatigue cracks are consequences of bulk expulsion of flash during friction stir spot welding of aluminum alloys. This paper attempts to cutback the abovementioned challenges and improves the weld strength (shear failure load) of friction stir spot welded joints of an Al alloy by adopting an integrated Grey relational analysis-entropy measurement method as a multi-objective optimization tool. Shear failure load, and expelled flash properties (pushed out length and thickness) are the three examined quality characteristics of the joint while tool rotational speed (600-1400 rpm), dwell time (3-6 s) and plunge depth (1.5-1.7 mm) are the studied process parameters. The experiment was planned via the use of Taguchi method whereas the entropy measurement method facilitated the identification of the precise weighting values required for the estimation of the unified grey relational grade. The failure load of the joint was maximized while both flash height and pushed-out length were minimized. The optimized shear failure load and flash properties were attained at a parameter setting of 1400 rpm rotational speed, 6 s dwell time and 1.5 mm plunge depth. The tool rotational speed was found to have the most significant effect and percentage contribution on the combined responses with 67.75%, followed by plunge depth (12.88 %) and dwell time (11.94 %) respectively. The validation results confirm the robustness of the entropy measurement-based multi-objective optimization as a tool for improving the quality responses of friction stir spot welds.

scholarly journals Refill Friction Stir Spot Welding of Dissimilar 6061/7075 Aluminum Alloy

2019 ◽  
Vol 38 (2019) ◽  
pp. 69-75 ◽  
Author(s):  
Zhenlei Liu ◽  
Kang Yang ◽  
Dejun Yan
Keyword(s):  
Aluminum Alloy ◽  
Spot Welding ◽  
Joint Strength ◽  
Shear Failure ◽  
Failure Load ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Lap Shear

AbstractRefill friction stir spot welding (RFSSW) was used to join 6061-T6 and 7075-T6 aluminum alloys in this work. Different sheet configurations and welding parameters were used to optimize joint strength. The effect of sleeve plunge depth on the microstructure and mechanical properties of the joints were investigated. The results showed that no defects were obtained when 6061-T6 aluminum alloy was placed as the upper sheet. The lap shear failure load of the joint using 6061-T6 aluminum alloy as the upper sheet was higher than that using 7075-T6 as the upper sheet. The maximum failure load of 12,892 N was attained when using the sleeve plunge depth of 3.6 mm. The joint failed at the upward flowing 7075 near the hook.

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.

Friction stir lap welding thin aluminum alloy sheets

2020 ◽  
Vol 39 (1) ◽  
pp. 663-670
Author(s):  
Tao Wang ◽  
Xue Gong ◽  
Shude Ji ◽  
Gang Xue ◽  
Zan Lv
Keyword(s):  
Aluminum Alloy ◽  
Failure Load ◽  
Tensile Fracture ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Lap Shear ◽  
Thin Aluminum ◽  
Wide Range ◽  
Good Material

AbstractIn this work, thin aluminum alloy sheets with thickness of 0.8 mm were friction stir lap welded using small shoulder plunge depths of 0 and 0.1 mm. The joint formation, microstructure and mechanical properties were investigated. Results show that voids appear inside the stir zone when the small plunge depth of 0 mm is used because the tool shoulder cannot exert a good material-collecting effect at such low plunge depth. A plunge depth of 0.1 mm causes tight contact between the shoulder and the material and thus results in good material-collecting effect, which is helpful to eliminate the void. Sound joints are attained at a wide range of welding parameters when using the shoulder plunge depth of 0.1 mm. No crack is observed inside the bonding ligament. The joints own higher failure loads when the retreating side (RS) of the joint bares the main load during the lap shear tests. The shear failure load first increases and then decreases with increasing the rotating and welding speeds, and the maximum failure load of 6419 N is obtained at 600 rpm and 150 mm/min. The hardness of the joint presents a “W” morphology and the minimum hardness is obtained at the heat affected zone. The joints present tensile fracture and shear fracture when the advancing side and RS bare the main loads, respectively.

scholarly journals Simulation of Friction Stir Spot Welding of Copper and Aluminium During Plunging Phase

2021 ◽  
Vol 2129 (1) ◽  
pp. 012002
Author(s):  
N N S M Shobri ◽  
S R Pedapati ◽  
M Awang
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
Regression Line ◽  
Friction Stir Spot Welding ◽  
Peak Temperature ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Explicit Analysis ◽  
Residual Plots

Abstract Simulation is limited and remains briefly addressed in the literature of friction stir spot welding (FSSW) process in joining dissimilar copper and aluminium. Thus, this study simulated the FSSW process of copper and aluminium to investigate the peak temperature during the plunging phase produced by all possible combinations of levels for tool rotational speed, plunge rate, and plunge depth according to the full factorial design. The modeling was established by Coupled Eulerian-Lagrangian (CEL) model and ‘dynamic, temperature-displacement, explicit’ analysis. The highest peak temperature of 994.4 oC was produced by 2400 rpm rotational speed, 100 mm/min plunge rate, and 1.6 mm plunge depth. The combination was suggested to be the optimum welding parameters in joining copper to aluminium as sufficient heat input was essential to soften the area around the welding tool and adequately plasticize the material. Three sets of confirmation tests presented consistent responses with a mean peak temperature of 994.4 °C, which validated that the response produced by the suggested optimum welding parameters was reliable. The statistical result reported that the variability in the factors could explain 84.12% of the variability in the response. However, only the rotational speed and plunge depth were statistically significant. The residual plots showed that the regression line model was valid.

scholarly journals Modeling and Optimization of Friction Stir Welding Parameters for Joining Dissimilar Aluminum Alloys

2018 ◽  
Vol 4 (1) ◽  
pp. 1-14 ◽  
Author(s):  
Mohamed Mohamed Abd Elnabi ◽  
Tarek Abd Elsadek Osman ◽  
Alaa Eldeen El Mokadem ◽  
Abou Bakr Elshalakany 
Keyword(s):  
Friction Stir Welding ◽  
Base Metal ◽  
Tilt Angle ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Welding Parameters ◽  
Plunge Depth ◽  
Friction Stir ◽  
Confidence Levels ◽  
Tool Tilt Angle

The objectives of this work are to optimize the process parameters on the mechanical properties (ultimate tensile strength (UTS) and ductility) of dissimilar joints between AA5454 and AA7075 produced by friction stir welding and to determine which of them is significant by using Taguchi L16 optimization method. Seven parameters at two levels were selected in this study. The selected parameters are tool rotational speed, traverse speed, pin profile (based on taper angle), D/d ratio, tool tilt angle, plunge depth, and base metal location. Then, mathematical models are built as function of significant parameters/ interactions using Response Surface Methodology. The results of this work showed that the rotational speed, traverse speed, D/d ratio and plunge depth are significant parameters in determining UTS (Mean, Signal to noise ratio (S/N)) at different confidence levels, but pin profile, location of base metal and tool tilt angle are insignificant parameters at any confidence levels. The traverse speed has the highest contribution to the process for UTS about 18.577 % and 16.943 % for S/N ratio and mean, respectively. The accuracy of the models according to the UTS is 97.678 % and 99.56 %for mean and S/N ratio, respectively. The maximum joint efficiency, compared to the strength of the AA5454, is 85.3%.

Mechanical Property of Friction Stir Welded Retardant Magnesium Alloy Joint

2011 ◽  
Vol 295-297 ◽  
pp. 1929-1932
Author(s):  
Yi Min Tu ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Xin Zhang ◽  
Ke Ke Zhang
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Welding Speed ◽  
Rotational Speed ◽  
Maximum Strength ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir

In order to obtain better understanding of the friction stir weldability of the magnesium alloy and provide some foundational information for improving mechanical properties of retardant magnesium alloy joints. A retardant magnesium alloy was weld using the method of friction stir welding. The influence of welding parameters on the strength of the joint was investigated. The maximum strength of 230 MPa was obtained from the joint welded at the tool rotational speed of 1000 r/min and welding speed of 750 mm/min.

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.

An investigation on the mechanical properties of friction stir welded polycarbonate/aluminium oxide nanocomposite sheets

2016 ◽  
Vol 49 (6) ◽  
pp. 498-512 ◽  
Author(s):  
Ali Doniavi ◽  
Saeedeh Babazadeh ◽  
Taher Azdast ◽  
Rezgar Hasanzadeh
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Rotational Speed ◽  
Signal To Noise Ratio ◽  
Base Material ◽  
Travel Speed ◽  
Effective Parameter ◽  
Welding Parameters ◽  
Effective Parameters ◽  
Friction Stir

Although considerable progress has been made in recent years in field of polymer welding, challenges still remain in using a friction stir welding method to join polycarbonate (PC) composites. This research provides an investigation on the effect of welding parameters (tool’s travel and rotational speeds) on mechanical properties of PC nanocomposite weld lines. PC nanocomposites were prepared with different percentages of Al2O3 nanofiller using a twin screw extruder and injection moulded as sheets in order to ease the welding. Considering various parameters and their levels, optimization of Taguchi experimental design was carried out, an L16 orthogonal standard array was selected and the effective parameter was calculated using analysis of variance of the results. The results indicated that nanoalumina percentage is the most effective parameter on the tensile strength of weld and tool’s travel speed and rotational speed are next effective parameters, respectively. According to signal-to-noise ratio, maximum weld tensile strength (89.5% of base material) is revealed when nanoalumina percentage, tool’s travel speed and tool’s rotational speed were chosen as 1 wt%, 12 mm/min and 1250 r/min, respectively.

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