Effect of Operational Parameters on AA2014 Friction Stir Weldments Using Plain Cylindrical Tool

2014 ◽  
Vol 592-594 ◽  
pp. 216-223
Author(s):  
Nallavelli Ramesh ◽  
K. Palaksha Reddy
Keyword(s):  
Aluminum Alloy ◽  
Solid State ◽  
Fusion Welding ◽  
Basic Material ◽  
Welding Parameters ◽  
Zone Formation ◽  
Friction Stir ◽  
Structural Applications ◽  
Tool Pin ◽  
Joining Process

Aluminum alloys are mostly used for high strength structural applications utilized in aircraft structure, trucks body, military vehicles, bridges and weapons manufacture. Conventional fusion welding of aluminum alloy produces porosity and hot cracks in the welded joint due to incorrect selection of consumables and parameters, which may lead to lower weld toughness and defects in the mechanical properties. The mostly adopted method for welding AA 2014-T6 is solid state joining process. Friction stir welding (FSW) is an emerging solid state of joining process which avoids bulk melting of the basic material, hot cracking and porosity. The welding parameters and tool pin profile play a major role in deciding weld quality. In this investigation, an attempt has been made to understand the various influences of tool rotational speed, welding speed and pin profile of the tool on friction stir processed (FSP) zone formation in joining of AA2014 aluminum alloy. High Carbon High Chromium steel tool of plain cylindrical pin profile is used to fabricate the joints. The average grey relation grade for each level of each factor are calculated and it was found that the optimal settings of the levels of factors Tool rotation speed (A), Weld speed (B) and Tilt angle (C) are A1-B3-C3. The findings from these investigations will be presented and discussed.

scholarly journals Additive Friction Stir-Enabled Solid-State Additive Manufacturing for the Repair of 7075 Aluminum Alloy

2019 ◽  
Vol 9 (17) ◽  
pp. 3486 ◽  
Author(s):  
R. Joey Griffiths ◽  
Dylan T. Petersen ◽  
David Garcia ◽  
Hang Z. Yu
Keyword(s):  
Aluminum Alloy ◽  
Additive Manufacturing ◽  
Solid State ◽  
Side Wall ◽  
Fusion Welding ◽  
7075 Aluminum Alloy ◽  
Hole Filling ◽  
Friction Stir ◽  
Advantages And Disadvantages ◽  
Through Hole

The repair of high strength, high performance 7075 aluminum alloy is essential for a broad range of aerospace and defense applications. However, it is challenging to implement it using traditional fusion welding-based approaches, owing to hot cracking and void formation during solidification. Here, the use of an emerging solid-state additive manufacturing technology, additive friction stir deposition, is explored for the repair of volume damages such as through -holes and grooves in 7075 aluminum alloy. Three repair experiments have been conducted: double through-hole filling, single through-hole filling, and long, wide-groove filling. In all experiments, additive friction stir deposition proves to be effective at filling the entire volume. Additionally, sufficient mixing between the deposited material and the side wall of the feature is always observed in the upper portions of the repair. Poor mixing and inadequate repair quality have been observed in deeper portions of the filling in some scenarios. Based on these observations, the advantages and disadvantages of using additive friction stir deposition for repairing volume damages are discussed. High quality and highly flexible repairs are expected with systematic optimization work on process control and repair strategy development in the future.

Characterization o Solid-State Vortices Associated with the Friction-Stir Welding of Copper to Aluminum

1998 ◽  
Vol 4 (S2) ◽  
pp. 530-531
Author(s):  
R. D. Flores ◽  
L. E. Murr ◽  
E. A. Trillo
Keyword(s):  
Plastic Deformation ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Weld Zone ◽  
Thick Plates ◽  
6061 Aluminum Alloy ◽  
Friction Stir ◽  
The Past ◽  
Joining Process

Although friction-stir welding has been developing as a viable industrial joining process over the past decade, only little attention has been given to the elucidation of associated microstructures. We have recently produced welds of copper to 6061 aluminum alloy using the technique illustrated in Fig. 1. In this process, a steel tool rod (0.6 cm diameter) or head-pin (HP) traverses the seam of 0.64 cm thick plates of copper butted against 6061-T6 aluminum at a rate (T in Fig. 1) of 1 mm/s; and rotating at a speed (R in Fig. 1) of 650 rpm (Fig. 1). A rather remarkable welding of these two materials results at temperatures measured to be around 400°C for 6061-T6 aluminum welded to itself. Consequently, the metals are stirred into one another by extreme plastic deformation which universally seems to involve dynamic recrystallization in the actual weld zone. There is no melting.

Influences of Tool pin Profile and Tool Shoulder Curvature on the Formation of Friction Stir Welding Zone in AA6061 Aluminium Alloy

2012 ◽  
Vol 445 ◽  
pp. 789-794 ◽  
Author(s):  
Vahid Moosabeiki ◽  
Ghasem Azimi ◽  
Mostafa Ghayoor
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Zone Formation ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Shoulder ◽  
Aa6061 Aluminium Alloy ◽  
Tool Pin

Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the weld quality. Friction stir tool plays a major role in friction stir welding process. In this investigation, it is tried to evaluate the effect of tool pin thread and tool shoulder curvature on FSW zone formation in AA6061 aluminium alloy. In this regard, six different tool pin geometries (threadless triangular pin with/without conical shoulder, threaded triangular pin with conical shoulder, threadless square pin with/without conical shoulder, threaded square pin with conical shoulder) are used to fabricate the joints. The formation of FSP zones are analyzed macroscopically. Tensile properties of the joints are evaluated and correlated with the FSP zone formation. Consequently, it is obtained that welding creates a higher quality compared to other tool pin profiles using the square tool with curved shoulder and having threaded pin.

Researching on hybrid friction stir welding between two differential materials as steel and aluminium

2020 ◽  
Vol 3 (SI1) ◽  
pp. First
Author(s):  
Truong Minh Nhat ◽  
Truong Quoc Thanh ◽  
Tran Trong Quyet ◽  
Luu Phuong Minh
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Welding Process ◽  
Welding Parameters ◽  
Thermal Imager ◽  
Friction Stir ◽  
Hybrid Techniques ◽  
State Process

Friction stir welding exploits its solid-state process behavior to join aluminum to steel, which differs in thermal and mechanical properties, and where a combination of these metallic alloys by fusion welding prompts a deleterious reaction as a result of the melting and resolidification phases. Recently, hybrid techniques have been employed in FSW for several materials and alloys, particularly for steel–steel joining. These methods are generally aimed to pre-heat the steel plate materials. This study presents conducted heat simulations and experimental jointing flat-plate of aluminum alloy 6061 and SUS 304. Temperature is simulated by the COMSOL software in three states: (1) Preheat the Friction Stir Welding (FSW) by TIG welding, (2) Thermal contact resistance between aluminum and steel, and (3) The welding process using stirring friction is simulated. The simulations intended to predict the temperature, which is used for the preheating and welding process to ensuring the required solid-state welding. The temperature is also determined and checked by a thermal imager comparing with simulation results. Besides, the results of tensile strength are carried out. The Box - Behnken method is used to identify the relationship between the welding parameters (rotation, speed, and offset), temperature, and tensile strength. The maximum tensile strength is 77% compared to the strength of the aluminum alloy. The optimal set of parameters for the process is n = 676 rpm, v = 46 mm / min and x = 0.6 mm. The optimizing welding parameters to achieving a good quality of the welding process are described. SEM images to determine some properties of welding materials. This is also the basis for initial research to identify some defects in the welding of two different materials (IMC thickness and interconnected pores) and the cause of these defects.

Effect of Rotating Tool Geometry on Mechanical Properties of Friction Stir Welded Aluminum Alloy 2195

2018 ◽  
Vol 783 ◽  
pp. 132-136
Author(s):  
Ho Sung Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Fusion Welding ◽  
Frictional Heat ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Space Vehicles ◽  
Friction Stir ◽  
Size And Shape ◽  
Welding Processes

It is known that Al-Li alloys show high specific strength and have been used in space vehicles with Friction stir welding (FSW). FSW has many advantages including the absence of porosity, low distortion and reduced residual stresses which are typical defects of the fusion welding processes. The process uses a rotating tool with a profiled pin that penetrates the parts to be welded. The tool starts to travel along the welding line and the softened material due to the frictional heat is stirred and mechanically mixed together by the rotating pin forming a weld in solid state without melting. Welding parameters such as tool rotational speed, travelling speed, and tool geometry are the main parameters which affect the material flow and the heat generation rate. The important tool geometry includes pin size and shape, pin tread and pitch, tool materials, and shoulder size and shape. The present work is to study the effect of tool geometry on the microstructure and mechanical properties of friction stir welded aluminum alloy 2195. Five different tool profiles have been used to investigate the effects of tool geometry on mechanical properties. The experimental results show that aluminum alloy 2195-T8 can be welded using FSW process with maximum welding efficiency of 75% using threaded cylindrical with concave shoulder at rotation speed, 600 RPM and welding speed, 300 mm/min.

Application of Solid State Joining Technologies in Aerospace Parts

2020 ◽  
Vol 837 ◽  
pp. 69-73
Author(s):  
Ho Sung Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo
Keyword(s):  
Solid State ◽  
Diffusion Bonding ◽  
Plastic Material ◽  
Welding Process ◽  
Bonding Process ◽  
Fusion Welding ◽  
Frictional Heat ◽  
Friction Stir ◽  
Solid State Joining ◽  
Joining Process

This study presents manufacturing lightweight aerospace components by solid state joining technologies. The advantages of solid state joining are due to the lack of hot cracking from solidification, since there is no liquid phase involved in joining process. This produces a high quality joint as compared to that from conventional fusion welding process. In diffusion bonding process, two different surfaces are matched together at elevated temperature under a low pressure without macroscopic plastic deformation in the interface. In friction stir welding process, the rotating shoulder of the tool generates frictional heat on the surface. As the pin rotates it forces the plastic material to mix mechanically in the vicinity of the pin and produces a heavily deformed microstructure around the pin. In this study, solid state joining processes of diffusion bonding and friction welding, are applied to manufacture several launcher components with lightweight, efficient and cost saving.

Effect of Process Parameters on Mechanical Characterization of Dissimilar Friction Stir Welded Aluminium Alloys

2015 ◽  
Vol 766-767 ◽  
pp. 701-704
Author(s):  
R. Ramesh ◽  
S. Suresh Kumar ◽  
R.V. Srinivasan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Weight Ratio ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Axial Forces ◽  
Tool Pin

Aluminum alloys exhibit poor weldability by conventional fusion welding process. The heat treatable aluminum alloy AA2014 is extensively used in the aircraft industry because it has good ductility and high strength to weight ratio. In this paper the effects of welding parameters and tool profile on the mechanical properties of friction stir welded butt joints of dissimilar aluminum alloy sheets AA6082 and AA2014. The process parameters such as rotational speed, transverse speed and axial forces were considered. The effect of parameters on weld quality was analyzed. Hardness and tensile tests are carried out at room temperature to examine the mechanical properties of the welded joints. The joints produced with straight square tool pin profile have higher ultimate tensile strength, whereas the straight cylindrical tool pin profile results in lower tensile strength.

scholarly journals Analysis of Welding Behaviour of Friction Stir Welded UHMW-PE Plate

2021 ◽  
pp. 1-13
Author(s):  
M. Azhagar ◽  
S. Kamalakannan ◽  
N. Kesavavannan ◽  
S. Mohamed Riyaz ◽  
Mr. R. Vijayaragavan
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Polymer Processing ◽  
Polymer Materials ◽  
Welding Parameters ◽  
Engineering Applications ◽  
Friction Stir ◽  
State Process ◽  
Materials Used ◽  
Tool Pin

Polypropylene is one of the thermoplastic materials used in the lot of engineering applications such as marine, aerospace, automotive, toys and etc. Friction Stir Welding (FSW) is a solid-state method of used for joining metals. FSW process was successfully extended to join thermoplastic materials. Friction Stir Welding (FSW) is a solid-state process in joining thermoplastic materials. Polymers are engineering materials used for future technological development as the polymer processing and fabrication techniques have developed novel plastic products and components in major industries. Particularly UHMWPE is one of the polymer materials with a lot of engineering applications and a study on the behavior of the joining properties of polyethylene by FSW is necessary at this stage. In this investigation, FSW process has to be applied to join a polyethylene plate of 8 mm thickness with specially designed threaded tool pin profile. The research will be applied Taguchi Method on UHMWPE specimen of dimensions 100 × 100 × 8 mm, which have following parameters: various RPM, Feed and Axial Load. The experiments will be done in following aspects: Ultimate tensile strength and other mechanical properties. The main objective of the experimental of factors affecting to mechanical property of UHMWPE with FSW at different welding parameters and it has to be followed by L4 arrays.

scholarly journals Effect of Skewness during Friction Stir Welding of Dissimilar Aluminium Alloys EN AA 5083-H116 and EN AA 6082-T6 Including Fracture Observations

2020 ◽  
Vol 9 (4) ◽  
pp. 1896-1900
Keyword(s):  
Aluminium Alloys ◽  
Research Work ◽  
Traverse Speed ◽  
Fusion Welding ◽  
Friction Stir ◽  
Structural Applications ◽  
Radiographic Inspection ◽  
Tool Pin ◽  
Welding Processes ◽  
Solid State Joining

The corrosive resistant aluminium-magnesium alloy AA 5083-H116 and aluminium-silicon alloy AA 6082-T6 is widely used in ship building, marine and various structural applications. FSW is an emerging solid state joining process suitable for joining the aluminium alloys with minimized formation of weld defects like cracks, porosity etc. compared to other fusion welding processes. This research work presents FSW of EN AA 5083-H116 and EN AA 6082-T6 using skew tool pin profile with the consideration of influential process parameters like tool rotational speed of 710 and 900 rpm at constant traverse speed of 16 mm/min. Radiographic inspection has been performed for evaluating the weldments soundness. From the radiographic results it has been found that at higher rpm i.e at 900 rpm the occurrence of lack of fusion is more compared to the weldment fabricated at 710 rpm. Tensile properties and fractural observations were carried out on the weldments. It has been noted that good mechanical properties were observed with the weldment fabricated at 710 rpm with high tensile strength of 160 MPa. From the fractural observations it has been observed that all the specimens are prone to ductile fracture, besides shear lips were observed at specimens fabricated at 900 rpm.

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