Effect of Friction Stir Welding pin Shape on Mechanical Properties of AA6061 Alloy Weldment

2013 ◽  
Vol 465-466 ◽  
pp. 1309-1313
Author(s):  
Mohd Hasbullah Idris ◽  
Mohd Shamsul Husin
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Material Flow ◽  
Weld Line ◽  
Butt Joint ◽  
Hardness Distribution ◽  
Plunge Depth ◽  
Friction Stir ◽  
Joint Properties

The present study is aimed to determine the effect of friction stir welding pin; square and diamond shape on mechanical properties of butt joint AA6061 weldment. Welding was carried out at different plunge depths of 0.0, 0.2, 0.3 and 0.4 mm together with rotation and transverse speeds of 500 rpm and 40 mm/min, respectively. Material flow, tensile strength and hardness of the weldment were evaluated. The results indicated that joint properties were significantly affected by tool design. It was found that material flow was higher for diamond pin tool compared to that of square pin resulting in considerable increased in tensile strength of the joint. In addition, the highest tensile strength was obtained on the samples welded with square shape pin at 0.4 mm plunge depth whilst the lowest was by diamond shape at the plunge depth of 0.0 mm. Regardless of pin shape and plunge depth; asymmetrical hardness distribution was observed for all weldments. The highest hardness was found to be close to the weld line produced by the diamond shaped pin at 0.0 mm plunge depth.

Effect of friction stir welding parameters on the material flow, mechanical properties and corrosion behavior of dissimilar AA5083-AA6061 joints

2021 ◽  
pp. 095440622110361
Author(s):  
Kethavath Kranthi Kumar ◽  
Adepu Kumar ◽  
MVNV Satyanarayana
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Corrosion Behavior ◽  
Process Parameters ◽  
Material Flow ◽  
Stir Zone ◽  
Friction Stir ◽  
Notch Tensile Strength ◽  
Mechanical Properties And Corrosion

Material flow has a significant impact on the joint properties and is one of the most challenging aspects to be understood in dissimilar friction stir welding. The present study emphasizes the role of process parameters on material flow, mechanical properties and corrosion behavior of dissimilar friction stir welds of AA5083-AA6061. Microstructural analysis revealed that the onion ring sub-layer width observed at the stir zone was substantially changed by varying process parameters. It was understood that the higher rotational speeds promote better intermixing and enhanced mechanical properties. The notch tensile strength values were in correlation with the intermixing of materials at the stir zone and the highest notch tensile strength value was obtained at 1400 rpm and 60 mm/min. A remarkable degree of material intermixing and fragmentation of intermetallics at higher rotational speeds resulted in better corrosion resistance.

Effect of Process Parameters during Friction Stir Welding of Al 6063 Alloy

2014 ◽  
Vol 984-985 ◽  
pp. 604-607 ◽  
Author(s):  
V. Jaiganesh ◽  
P. Sevvel
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Yield Strength ◽  
Processing Condition ◽  
Butt Joint ◽  
Dominant Factor ◽  
Optimum Result ◽  
Friction Stir ◽  
Shoulder Diameter

In the Present paper, the effects of axial force, rotational speed of the FSW tool, welding speed and shoulder penetration on various mechanical properties of Aluminium alloy 6063 butt joint produced by Friction Stir Welding have been analyzed. The mechanical properties like tensile strength, Yield strength and % Elongation have been tested using 6 mm thickness plate. The tool used for conducting the experiment was Hot Die Steel (HDS). The welding quality can be improved by enhancing the mechanical properties and minimizing the defects. Hence, analysing & examining the mechanical or physical properties and other relevant significant factors would help to enhance the weld reliability. Tensile Strength (TS), Percentage of Elongation & Yield Strength (YS) of FSW Al 6063 alloy has been carried out under different processing condition using Taguchi’s experimental design. An optimum result has been obtained using main effects plot using S/N ratio values. The rotation speed of the FSW tool has been found dominant factor for TS followed by feed and shoulder penetration. Shoulder diameter shows the least effect on TS compared to parameters like Percentage of Elongation & Yield Strength (YS).

scholarly journals Effect of weld line shape on material flow during friction stir welding of aluminum and steel

2014 ◽  
Vol 61 ◽  
pp. 012009 ◽  
Author(s):  
Toshiaki Yasui ◽  
Naoyuki Ando ◽  
Shinpei Morinaka ◽  
Hiroki Mizushima ◽  
Masahiro Fukumoto
Keyword(s):  
Friction Stir Welding ◽  
Line Shape ◽  
Material Flow ◽  
Weld Line ◽  
Friction Stir

Stir zone material flow patterns during friction stir welding of heavy gauge AA5056 workpieces and stability of its mechanical properties

2021 ◽  
Vol 23 (4) ◽  
pp. 140-154
Author(s):  
Tatiana Kalashnikova ◽  
◽  
Vladimir Beloborodov ◽  
Kseniya Osipovich ◽  
Andrey Vorontsov ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Elevated Temperatures ◽  
Thin Sheet ◽  
Stir Zone ◽  
Clear Correlation ◽  
Material Structure ◽  
Friction Stir ◽  
Significant Difference

Introduction. Friction stir welding and processing are almost identical processes of severe plastic deformation at elevated temperatures. These technologies differ mainly in the purpose of its use: the formation of a hardened surface layer or producing a welded joint. However, it is known that both during welding and during processing of heavy gauge workpieces temperature gradients occur. As a result, the conditions of adhesive interaction, material plastic flow, and the formation of the stir zone change as compared to thin-sheet workpieces with fundamentally different heat dissipation rates. In this connection, the purpose of the work is to determine the regularities of the structure formation and stability of the mechanical properties in different directions in the material of 35-mm-thick aluminum-magnesium alloy samples produced by friction stir welding/processing. Research Methodology. The technique and modes of friction stir welding and processing of AA5056 alloy workpieces with a thickness of 35 mm are described. Data on the equipment used for mechanical tests and structural research are given. Results and discussion. The data obtained show the excess mechanical properties of the processing zone material over the base metal ones in all studied directions. Material structure heterogeneities after friction stir welding/processing of heavy gauge workpieces have no determining effect on the stir zone properties. At the same time, there is no clear correlation between the tensile strength values and the load application direction, nor is there any significant difference in mechanical properties depending on the location of the samples inside the stir zone. The average ultimate tensile strength values in the vertical, transverse, and longitudinal directions are 302, 295 and 303 MPa, respectively, with the yield strength values of 155, 153 and 152 MPa, and the relative elongation of 27.2, 27.5, 28.7 %.

Evaluating the Strength of the Friction Stir Welded Joints at Various Rotational Speeds

2013 ◽  
Vol 446-447 ◽  
pp. 312-315
Author(s):  
Ramaraju Ramgopal Varma ◽  
Abdullah Bin Ibrahim ◽  
B. Ravinder Reddy
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Yield Strength ◽  
Welded Joints ◽  
Rotational Speed ◽  
Testing Machine ◽  
Friction Stir ◽  
Universal Testing ◽  
Welding Technique

The present research paper aims in evaluating the strength of the welded AA6351 alloy plates of 6 mm thick by using friction stir welding technique at different rotational speeds The applied welding technique is capable of achieving the mechanical properties of the alloy close to that of the original alloy. In the present investigation, the speeds of the spindle were varied from 1100 rpm to 1500 rpm with a constant transverse speed of 20 mm/min. The tensile strength of the joints is determined by an universal testing machine. The results from the present investigation show that the values of the yield strength were very much closer to the values of the AA6351Alloy prior to welding. It has been found from the experiments that the strength of the joints increases with the increase in the rotational speed; however, the same is decreasing after achieving certain speed.

Prediction and optimization of the mechanical properties of dissimilar friction stir welding of aluminum alloys using design of experiments

2016 ◽  
Vol 232 (8) ◽  
pp. 1384-1394 ◽  
Author(s):  
R Palanivel ◽  
RF Laubscher ◽  
S Vigneshwaran ◽  
I Dinaharan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Ultimate Tensile Strength ◽  
Design Of Experiments ◽  
Process Parameters ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process

Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face–centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351–AA5083. Three weld parameters that influence weld quality were considered, namely, tool shoulder profile (flat grooved, partial impeller and full impeller), rotational speed and welding speed. Experimental results detailing the variation of the ultimate tensile strength as a function of the friction stir welding process parameters are presented and analyzed. An empirical model that relates the friction stir welding process parameters and the ultimate tensile strength was obtained by utilizing a design of experiments technique. The models developed were validated by an analysis of variance. In general, the full impeller shoulder profile displayed the best mechanical properties when compared to the other profiles. Electron backscatter diffraction maps were used to correlate the metallurgical properties of the dissimilar joints with the joint mechanical properties as obtained experimentally and subsequently modeled. The optimal friction stir welding process parameters, to maximize ultimate tensile strength, are identified and reported.

A Numerical and Experimental Analysis of Microstructural Aspects in AA2024-T3 Friction Stir Welding

2013 ◽  
Vol 554-557 ◽  
pp. 1022-1030 ◽  
Author(s):  
Pierpaolo Carlone ◽  
Gaetano S. Palazzo
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Heat Generation ◽  
Process Parameters ◽  
Fluid Dynamic ◽  
Weld Line ◽  
Work Piece ◽  
Viscoplastic Material ◽  
Influence Of Process Parameters ◽  
Friction Stir

In recent years, remarkable interest has been focused on the Friction Stir Welding (FSW) process, by academic as well as industrial research groups. Conceptually, the FSW process is quite simple: a non-consumable rotating tool is plunged between the adjoining edges of the parts to be welded and moved along the desired weld line. Frictional and viscous heat generation increases the work piece temperature, softening the processing material and forcing it to flow around the pin. Although FSW has been effectively applied in welding of several materials, such as copper, steel, magnesium, and titanium, considerable attention is still focused on aluminum welding, in particular for transport applications. Recent literature clearly evidenced microstructural variations in the stir zone, imputable to continuous dynamic recrystallization phenomena, leading to the formation of a finer equiaxed grains. Moreover, depending on the specific alloy, thermal cycles can induce coarsening or dissolution of precipitates in the thermo-mechanically affected zone (TMAZ) and in the heat affected zone (HAZ). The influence of the aforementioned microstructural aspects on mechanical properties and formability of FSWed assemblies is also well recognized. The aim of this paper is to numerically and experimentally investigate the influence of process parameters, namely rotating speed and welding speed, on microstructural aspects in AA2024-T3 friction stir butt welds. A three-dimensional Computational Fluid Dynamic (CFD) model has been implemented to simulate the process. A viscoplastic material model, based on Wright and Sheppard modification of the constitutive model initially proposed by Sellars and Tegart has been implemented in the commercial package ANSYS CFX, considering an Eulerian framework. Tool-workpiece interaction has been modeled assuming partial sticking/sliding condition, and incorporating both frictional and viscous contributions to the heat generation. Microstructural aspects have been numerically predicted using the Zenner-Holloman parameter and experimentally measured by means of conventional metallographic techniques. Satisfactory agreement has been found between simulated and experimental results. The influence of process parameters on mechanical properties has also been highlighted.

scholarly journals Influence of tool rotational speed on the evolution of microstructure and mechanical properties of precipitation-hardened Aluminium 6061 butt joint during friction stir welding

2022 ◽  
Author(s):  
Biplab Ghosh ◽  
Hrishikesh Das ◽  
Asis Samanta ◽  
Jyotsna Dutta Majumdar ◽  
Manojit Ghosh
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotational Speed ◽  
Butt Joint ◽  
Tool Rotational Speed ◽  
Nugget Zone ◽  
Friction Stir ◽  
Transmission Electron ◽  
Free Region ◽  
Evolution Of Microstructure

Abstract The present investigation intends to interpret the effect of tool rotational speed on the mechanical properties and microstructural evolution in Aluminium 6061-T6 alloy during friction stir welding. A higher value of tool rotation produces more hardness at the nugget zone, which is attributed to the higher intensity of reprecipitation at higher rpm, revealed by transmission electron microscopy. The nugget zone is revealed as a nearly precipitate-free region, while the thermo-mechanically affected zone contains coarse precipitates, deformed and dynamically recovered grains with a few recrystallized grains. Significant reduction in grain size in the stirred zone is also a key finding. The observations depict the dependence of microstructure, and thus mechanical behaviour on tool rotational speed. A specific combination of process parameters has been determined from experiments, which corresponds to the maximum joint efficiency.

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