Welding Performance of a Homemade Friction Stir Welding Tool

2013 ◽  
Vol 446-447 ◽  
pp. 660-664
Author(s):  
Irfan Hilmy ◽  
Erry Yulian T. Adesta
Keyword(s):  
Friction Stir Welding ◽  
Mild Steel ◽  
Tensile Test ◽  
Low Cost ◽  
Hardness Test ◽  
Milling Machine ◽  
Friction Stir ◽  
Mechanical Performances ◽  
Tensile Test Result ◽  
Test Result

Homemade Friction Stir Welding (FSW) Tool utilizing conventional milling machine has been developed. The FSW tool made from mild steel was designed and fabricated. Experimental investigation of FSW process of the Aluminum alloy specimens to observe its mechanical performances was performed. To evaluate its performance, hardness test, tensile test as well as visual inspections of the welding result were performed. Hardness number in the welding region was measured about 40-60% lower than the base metal, and heat affected zone region. The tensile test result varies with maximum 100 MPa. The imperfection of final form of metal due to the stirring mechanism was inspected. The presence of void/crack at cross-section of the welded specimen was observed. It was found that by applying suitable configuration, the use of mild steel as the FSW tool was reasonable for performing FSW process. It was concluded that, using a relatively low cost FSW tool, a quite satisfactory result of welding performance was achieved.

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.

Effect of Taper Pin Ratio on AA7075 Aluminium Alloy Friction Stir Welding

2016 ◽  
Vol 701 ◽  
pp. 154-158
Author(s):  
Nurul Hidayah Othman ◽  
Norsyahfiana Abdul Razak ◽  
Luqman Hakim Ahmad Shah ◽  
Mahadzir Ishak
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tensile Test ◽  
Optical Microscope ◽  
Milling Machine ◽  
Friction Stir ◽  
Microstructure Observation ◽  
Optimum Parameters ◽  
Shoulder Diameter

This study focuses on the effect of pin taper tool ratio on friction stir welding of aluminum AA7075. Two pieces of AA7075 alloy with thickness of 6 mm were friction stir welded by using conventional milling machine. The shoulder diameter used in this experiment is fix 18mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2,and 6:1. The rotational speeds that were used in this study were 1000 rpm, 1200 rpm and 1400 rpm, respectively. The welding speeds used are 60 mm/min, 80 mm/min and 100 mm/min. Microstructure observation of welded area was studied by using optical microscope. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:2 shows higher tensile strength compared to other taper pin ratio up to 197 MPa. Moreover, taper pin ratio 6:1 showed better tensile test compared to taper pin ratio above 6:3. The optimum parameters were found to be taper pin ratio 6:2 with 1000 rpm of rotational speed and 60mm/min welding speed.

scholarly journals Improving Astm A516 Grade 70 Mechanical Properties by Sandblasting Process

2018 ◽  
Vol 7 (4.35) ◽  
pp. 216
Author(s):  
Omar Suliman Zaroog ◽  
S.A.P. Sughanthy ◽  
Mohd Rashdan Isa ◽  
M.N.M. Ansari
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Tensile Test ◽  
Hardness Test ◽  
Time Duration ◽  
Before And After ◽  
Tensile Test Result ◽  
Test Result

Nowadays, sandblasting is commonly use in industries. The ability of sandblasting is to remove any stain, unwanted matter and many other functions making this process generally used worldwide. The effect of sandblasting on mechanical properties of ASTM A516 grade 70 was investigated in this study. Samples of the material have been sandblasted with different size of grits and times. Surface roughness, hardness and tensile was measured before and after sandblasting. The roughness test result showed that when the time duration of sandblasting increased, the roughness of the specimen also increased. Based on hardness test result, it showed that the hardness improved when the smallest size of grits was applied. However, the hardness decreased when the size of grits and time was increased. The tensile test result pattern showed quite similar to hardness test result. The size of grits and time duration for sandblasting need to set depending on application of the sandblasting process usage applied to the samples or materials.

Measurement and Comparison of Force Effort During Friction Stir Welding in a Parallel Kinematic 5-Axis Milling Machine

2012 ◽  
Author(s):  
Arun Prasath Manogaran ◽  
Guillaume Racineux ◽  
Jean-Yves Hascoet
Keyword(s):  
Friction Stir Welding ◽  
Low Cost ◽  
Milling Machine ◽  
Friction Stir ◽  
Advantages And Disadvantages ◽  
Measuring Devices ◽  
Wide Range ◽  
Dynamic Measuring ◽  
And Control

Friction stir welding (FSW) is so quite promising that leads it to one of the preferred joining process for a wide range of applications especially for Aluminum. FSW machines are very expensive. The objective is to develop a simple and low cost technique to measure and control the force during FSW in a milling machine. Measurement of forces during welding is a difficult task. Many dynamic measuring devices such as dynamometers are available but each have their own advantages and disadvantages. A new approach to measure force while performing weld is discussed. First, incorporation of FSW in PKM 5-axes milling machine is done. The head of the machine is modified to support higher force levels that are generated during FSW. With the help of the NC-Controller, the force values are retrieved from the axes of the machine while performing weld through actuators. Forces were also measured from load cell and compared to estimate the quality of measurement.

scholarly journals Post-Weld Heat Treatment Effects on Mechanical Properties and Microstructure of AA6061-T6 Butt Joints Made by Friction Stir Welding at Right Angle (RAFSW)

2019 ◽  
Vol 3 (2) ◽  
pp. 42 ◽  
Author(s):  
Mahboubeh Momeni ◽  
Michel Guillot
Keyword(s):  
Friction Stir Welding ◽  
Aging Process ◽  
Artificial Aging ◽  
Low Cost ◽  
Hardness Test ◽  
Industrial Sector ◽  
Fusion Welding ◽  
Butt Joints ◽  
Friction Stir ◽  
Weld Heat

Friction stir welding (FSW) provides users with many advantages over fusion welding techniques. Nevertheless, it is not widely employed in current industry mainly due to high equipment costs and royalties. To overcome these issues, a low-cost FSW technique operated at a right angle, called RAFSW, has recently been developed by our research team. To make the RAFSW technique reliable for potential users, we are going to analyze the effect of various post-weld heat treatments (PWHT) on the mechanical and physical properties of the RAFSW joints. To this end, optimized process parameters are used to weld butt joints of an AA6061-T6 alloy. The joints were characterized using a tensile test, a micro-hardness test, and metallography techniques. The most efficient aging time was obtained for various aging temperatures. Moreover, it was found that artificial aging at 220 °C for 30 min could be used as a fast and cost-effective artificial aging PWHT for the industrial sector. In addition, the repeatability of the PWHTs were demonstrated by studying the effect of waiting time prior to the artificial aging. Finally, it was revealed that a single fast artificial aging process is more beneficial than solubilizing followed by an artificial aging process in terms of tensile properties, consumed time, and cost.

Friction Stir Welding of Dissimilar Formed Mg Alloys (AZ31/AZ91)

2005 ◽  
Vol 486-487 ◽  
pp. 249-252 ◽  
Author(s):  
Chang Yong Lee ◽  
Won Bae Lee ◽  
Yun Mo Yeon ◽  
Seung Boo Jung
Keyword(s):  
Friction Stir Welding ◽  
Dynamic Recrystallization ◽  
Tensile Test ◽  
Intermetallic Compounds ◽  
Grain Growth ◽  
Weld Zone ◽  
Mg Alloys ◽  
Mg Alloy ◽  
Friction Stir ◽  
Az31 Mg Alloy

Friction stir welding of dissimilar formed Mg alloys(AZ31/AZ91) was successfully carried out at the limited welding conditions. In a sound joint, SZ was mainly consisted of AZ31 Mg alloy which was located the retreating side. Dynamic recrystallization and grain growth occurred and β intermetallic compounds of AZ 91 Mg alloy was not observed in SZ. BM had a higher hardness than that of the weld zone. The fracture location was not weld zone but BM of the AZ91 Mg alloy in tensile test.

scholarly journals Influence of Mx-Trivex, A-Skew, Three Flat Threaded and Concave Shouldered Mx-Triflute Tool Pin Profiles on Tensile Properties and Fractural Behaviour of Aa 6082-T6 Weldments During Friction Stir Welding

2020 ◽  
Vol 9 (4) ◽  
pp. 1376-1384
Keyword(s):  
Friction Stir Welding ◽  
Tensile Test ◽  
Weld Zone ◽  
Base Material ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Pin ◽  
Solid State Joining ◽  
Joining Process ◽  
Brass Wire

Friction Stir Welding (FSW) is a topical and propitious solid-state joining process producing economical and strengthened joints of age-hardened and heat-treatable Aluminium Alloy AA 6082-T6. Mechanical and fractural behaviour of weldments were investigated in order to find crack initiation and necking on the weld zone thereby perceiving the complete behaviour of fracture occurred near the weld zone. Weldments are fabricated by employing four tool pin profiles namely MX-TRIVEX, A-SKEW, Three flat threaded and Concave shouldered MX-TRIFLUTE tools at various rotational speeds 1000 rpm, 1200 rpm and 1400 rpm at single traverse speed 25 mm/min. EXCETEX-EX-40 CNC wire cut EDM with 0.25 mm brass wire diameter has been employed to perform the extraction of tensile test specimens from the weldments according to ASTM E8M-04 standard. Tensile test was performed on elctromechanically servo controlled TUE-C-200 (UTM machine) according to ASTM B557-16 standards Maximum Ultimate Tensile Strength (UTS) of 172.33 MPa (55.5% of base material) and 0.2% Yield Stress (YS) of 134.10 MPa (51.5% of base material) were obtained by using A-SKEW at 1400 rpm, 25 mm/min and maximum % Elongation (%El) of 11.33 (113.3% of base material) was obtained at MX-TRIVEX at 1000 rpm, 25 mm/min. Minimum UTS of 131.16 MPa (42.30% of base material) and 0.2% YS of 105.207 MPa (40.46% of base material )were obtained by using Concave shouldered MX-TRIFLUTE at 1400 rpm, 25 mm/min. Minimum % El of 5.42 ( 54.2% of base material) was obtained by using A-SKEW at 1000 rpm, 25 mm/min.

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

Control of Material Flow During Friction Stir Welding Between Aluminum and Steel by Welding Tool Shape

2020 ◽  
Author(s):  
Toshiaki Yasui ◽  
Yuki Ogura ◽  
Xu Huilin ◽  
F. Farrah Najwa ◽  
Daichi Sugimoto ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Simulation Experiment ◽  
Low Cost ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
High Strength ◽  
Friction Stir ◽  
Tool Shape ◽  
Computational Fluid Dynamics Cfd

Abstract For the Friction stir welding (FSW) between aluminum and steel is important to fabricate vehicles with light weight and high strength for safety at low cost. For the fabrication of sound weld, it is necessary to control the material flow during FSW. In this study, the material flow during FSW was elucidated by numerical simulation by computational fluid dynamics (CFD) analysis and simulation experiment by transparent Poly-vinyle chloride (PVC) as simulant of aluminum and tracer material. Based on this material flow analysis, several shapes of welding tool were examined for control of material flow during FSW. Scroll shoulder is effective for enhancement of stirring zone by increasing material velocity around the probe. Flute and fine screw probe promote the material flow in depth and horizontal direction. The welding tool with scroll shoulder and flute and fine screw probe achieved sound weld with highest tensile strength of 120.4 MPa.

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