Ultrasonic Method for Rapid Detection of the Aluminum Friction Stir Welding Defects

2015 ◽  
Vol 51 (2) ◽  
pp. 7 ◽  
Author(s):  
Changxi WANG
Keyword(s):  
Friction Stir Welding ◽  
Rapid Detection ◽  
Ultrasonic Method ◽  
Friction Stir ◽  
Welding Defects

scholarly journals Study on residual stresses caused by underwater friction stir welding: FE modeling and ultrasonic measurement

2018 ◽  
Vol 233 (1) ◽  
pp. 118-137
Author(s):  
Solaleh Salimi ◽  
Pouya Bahemmat ◽  
Mohammad Haghpanahi
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Residual Stresses ◽  
Ultrasonic Method ◽  
Stress Fields ◽  
Optimum Process ◽  
Friction Stir ◽  
Mechanical Deformations ◽  
Underwater Friction Stir Welding ◽  
Precipitation Phenomena

Predicting residual stresses arising from the thermal and mechanical loading history during engineering processes including welding would be a viable tool to reach the optimum process parameters. In the present article, an elasto-thermo-visco-plastic model has been employed to estimate the residual stress caused by the underwater friction stir welding, which are resulted by large thermo-mechanical deformations on one hand and rapid cooling arising from the enormous non-uniform boiling heat convention of water on the other hand. Finally, the numerical results are compared with experimental data acquired by the ultrasonic method to evaluate the accuracy of the simulation process. Regarding the low temperature during underwater friction stir welding, the employed constitutive equations result in acceptable residual stress fields, while for in-air case, the amount of error increases significantly due to experience of high temperatures and intensification in hardening precipitation phenomena.

Metallurgical Studies on the Friction Stir Welding of Dissimilar A356 and A413 Alloys

2012 ◽  
Vol 488-489 ◽  
pp. 345-349
Author(s):  
G. Elatharasan ◽  
V.S. Senthil Kumar
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Structural Characteristics ◽  
Grain Structure ◽  
Cast Aluminum ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Cast Aluminum Alloys ◽  
Welding Defects

Friction stir welding is a technique useful for joining aluminum alloys that are difficult to weld. In recent years, however the focuses has been on welding dissimilar aluminum alloys, and analyze their mechanical properties and micro-structural characteristics. In the present study, the less investigated welding of cast aluminum alloys is considered. Cast aluminum alloys, A356 and A413, commonly used in automotive and aerospace industries, were friction-stir welded and their mechanical properties and micro-structural characteristics were analyzed. On testing their welded region, no welding defects were observed. The welded region exhibited a maximum tensile strength of 90 N/mm2 and Vickers micro-hardness of 56.8. The micro-structural observations at the nugget region revealed a refined grain structure.

Thermo-Mechanical Modelling of Jointing Process by Friction Stir Welding of Aluminium-Based Composite Materials

2012 ◽  
Vol 188 ◽  
pp. 144-149
Author(s):  
Marius Pop-Calimanu ◽  
Traian Fleșer
Keyword(s):  
Composite Materials ◽  
Friction Stir Welding ◽  
High Speed ◽  
Active Element ◽  
Three Dimensional ◽  
Maximum Temperature ◽  
Friction Stir ◽  
Thermal Fields ◽  
Welding Defects ◽  
Dimensional Distribution

Jointing with rotary active element gains field through technological facilities offered nowadays. Own research have developed a model for studying the thermal fields and the plastic deformations of jointing composite materials Al/20%SiC combined by friction stir welding (FSW). In this article we will present the three-dimensional distribution of investigated fields, correlated with input parameters in the process. The process is performed with solid state components. The numerical results indicate that the maximum temperature in the FSW process increases with increasing speed of rotational tools. For high speed welding joint, should be increased, at the same time, the rotational speed to avoid welding defects.

Evaluation of 7050 Aluminum Plates Joined by Friction Stir Welding Using Acoustoelastic

2017 ◽  
Author(s):  
Shirley Alexandra García Ruano ◽  
Felipe Bertelli ◽  
Auteliano Antunes dos Santos
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Residual Stresses ◽  
Ultrasonic Method ◽  
Welding Process ◽  
Longitudinal Direction ◽  
Structural Components ◽  
Friction Stir ◽  
Low Weight ◽  
Aluminum Plates

The 7050-T7451 aluminum alloy has been widely used in the aerospace industry. Due to its chemical composition, this alloy has high levels of mechanical properties that allow the production of low-weight aircraft structural components. However, these alloys are thermally treatable and are not able to bear manufacturing processes involving heat. Because of the importance of their applications, studies based on the development of solid state welding process would be desirable aiming to find an alternative to generate welded joints for this kind of components. In this work, an investigation concerning the behavior of the 7050-T7451 aluminum alloy during Friction Stir Welding (FSW) was carried out. The profile of longitudinal residual stresses of plates welded by the FSW process was obtained using the ultrasonic method through critically refracted longitudinal waves (LCR). Two different frequencies were employed, 3.5 MHz and 5 MHz. The measurements were performed in the longitudinal direction of the welded joint at different distances from the center line of the weld. The magnitude and distribution of residual stresses found with this method are consistent with literature review, reaching 150MPa on the center of the weld.

Investigation of the effects of welding variables on the welding defects of the friction stir welded high density polyethylene sheets

2021 ◽  
pp. 009524432110588
Author(s):  
Mustafa Kemal Bilici
Keyword(s):  
Friction Stir Welding ◽  
High Density Polyethylene ◽  
Welding Process ◽  
High Strength ◽  
High Density ◽  
Welding Parameters ◽  
Friction Stir ◽  
Wide Range ◽  
Welding Defects ◽  
Welding Processes

Modern thermoplastic materials are used in an expanding range of engineering applications, such as in the automotive industry, due to their enhanced stress-to-weight ratios, toughness, a very short time of solidification, and a low thermal conductivity. Recently, friction stir welding has started to be used in joining processes in these areas. There are many factors that affect weld performance and weld quality in friction stir welding (FSW). These factors must be compatible with each other. Due to the large number of welding variables in friction stir welding processes, it is very difficult to achieve high strength FSW joints, high welding performance, and control the welding process. Welding variables that form the basis of friction stir welding; machine parameters, tool variables, and material properties are divided into three main groups. Each welding variable has different effects on the weld joint. In this study, friction stir welds were made on high density polyethylene (HDPE) sheets with factors selected from machine parameters and welding tool variables. Although the welding performance, quality, and strength gave good results in some conditions, successful joints could not be realized in some conditions. In particular, welding defects occurring in the combination of HDPE material with FSW were investigated. Welding quality, defects, and performances were examined with macrostructure. In addition, the tensile strength values of some the joints were determined. The main purpose of this study is to determine the welding defects that occur at the joints. The causes of welding defects, prevention methods, and which weld variables caused were investigated. Welding parameters and welding defects caused by welding tools were examined in detail. In addition, the factors causing welding defects were changed in a wide range and the changes in the defects were observed.

Phased Array Ultrasonic Testing for Post-Weld and OnLine Detection of Friction Stir Welding Defects

2016 ◽  
Vol 28 (4) ◽  
pp. 187-210 ◽  
Author(s):  
D. J. Huggett ◽  
M. W. Dewan ◽  
M. A. Wahab ◽  
A. Okeil ◽  
T. W. Liao
Keyword(s):  
Friction Stir Welding ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Online Detection ◽  
Friction Stir ◽  
Welding Defects
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