Experimental Investigation on the Impact of the Tool Material & Geometry in Joining of Al 63400 Alloy Using Friction Stir Welding Process

2014 ◽  
Vol 592-594 ◽  
pp. 312-315 ◽  
Author(s):  
P. Sevvel ◽  
V. Jaiganesh
Keyword(s):  
Experimental Investigation ◽  
High Carbon Steel ◽  
Base Material ◽  
Welding Process ◽  
Tool Material ◽  
Tool Geometry ◽  
Flat Plates ◽  
Friction Stir ◽  
Tool Pin ◽  
The Impact

In this paper, a detailed experimental investigation was carried on the impact of the effects of tool pin and shoulder diameter in joining the Al 63400 aluminium alloy using FSW process. Flat plates of 6 mm thickness have been selected as the base material for obtaining single butt welded joints. The tool materials used for joining these base material plates are High Speed Steel (HSS) and High Chromium High Carbon Steel (HCHCr). This paper experimentally investigates and suggests the appropriate, suitable tool material & tool geometry for producing good quality welds in joining of Al 63400 alloy using FSW process.

scholarly journals Analysis of Tools used in Friction Stir Welding process

2018 ◽  
Vol 8 (6) ◽  
Author(s):  
Akshansh Mishra ◽  
Adarsh Tiwari ◽  
Mayank Kumar Shukla ◽  
A. Razal Rose
Keyword(s):  
Friction Stir Welding ◽  
Critical Role ◽  
Base Material ◽  
Welding Process ◽  
Tool Geometry ◽  
Work Piece ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Pin ◽  
Joining Process

A relatively new joining process, friction stir welding (FSW) produces no fumes; uses no filler material; and can join aluminium alloys, copper, magnesium, zinc, steels, and titanium. FSW sometimes produces a weld that is stronger than the base material. The tool geometry plays a critical role in material flow and governs the transverse rate at which FSW can be conducted. The tool serves three primary functions, i.e., (a) heating of the work piece, (b) movement of material to produce the joint, and (c) containment of the hot metal beneath the tool shoulder. Heating is created within the work piece by friction between both the rotating tool pin and shoulder and by severe plastic deformation of the work.

Numerical Study of the Tool Rake Angle Effect on the Material Flow in Friction Stir Welding Process

2007 ◽  
Author(s):  
Hosein Atharifar ◽  
Radovan Kovacevic
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Numerical Study ◽  
Welding Process ◽  
Rake Angle ◽  
Heat Transfer Analysis ◽  
Tool Geometry ◽  
Friction Stir ◽  
Tool Pin ◽  
Welding Processes

Minimizing consumed energy in friction stir welding (FSW) is one of the prominent considerations in the process development. Modifications of the FSW tool geometry might be categorized as the initial attempt to achieve a minimum FSW effort. Advanced tool pin and shoulder features as well as a low-conductive backing plate, high-conductive FSW tools equipped with cooling fins, and single or multi-step welding processes are all carried out to achieve a flawless weld with reduced welding effort. The outcomes of these attempts are considerable, primarily when the tool pin traditional designs are replaced with threaded, Trifiute or Trivex geometries. Nevertheless, the problem remains as to how an inclined tool affects the material flow characteristics and the loads applied to the tool. It is experimentally proven that a positive rake angle facilitates the traverse motion of the FSW tool; however, few computational evidences were provided. In this study, numerical material flow and heat transfer analysis are carried out for the presumed tool rake angle ranging from −4° to 4°. Afterwards, the effects of the tool rake angle to the dynamic pressure distribution, strain-rates, and velocity profiles are numerically computed. Furthermore, coefficients of drag, lift, and side force and moment applied to the tool from the visco-plastic material region are computed for each of the tool rake angles. Eventually, this paper confirms that the rake angle dramatically affects the magnitude of the loads applied to the FSW tool, and the developed advanced numerical model might be used to find optimum tool rake angle for other aluminum alloys.

Behaviour of Threaded Cylinder Tool in the Friction Stir Welding of Al–ZrB2 Composite

2019 ◽  
Vol 16 (2) ◽  
pp. 719-724 ◽  
Author(s):  
P. Jayaseelan ◽  
T. V. Christy ◽  
Prabhu G. Rubesh ◽  
R. Srinivasan
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Tool Material ◽  
Hardness Test ◽  
Material Base ◽  
Matrix Composites ◽  
Friction Stir ◽  
Tool Pin ◽  
Aluminum Metal Matrix Composites ◽  
Solid State Joining

Friction Stir welding is a solid state joining process with no filler material. In this work, we specifically investigated the Tool Pin Profile, Tool Material, Base Material and the process parameters in the Aluminum metal matrix composites especially reinforced with Zirconium diboride (Al–ZrB2 . Tools of Various Materials and the corresponding tensile strength of the weld specimen, microstructure analysis and Hardness test are evaluated. Threaded Cylinder made of various materials are OHNS, HCHCr, H13 tools are carried out in the process with D/d Ratio are used. The result will be stated with the Threaded Cylinder pin with which tool material provides highest strength to the Bas material.

Microstructural Characterization and Mechanical Properties in Friction Stir Welding of AA6061 and AA6101 Aluminum Alloys

2021 ◽  
Vol 40 ◽  
pp. 1-11
Author(s):  
Gagandeep Singh ◽  
Khushdeep Goyal ◽  
Baljinder Ram ◽  
Bal Krishan
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Welding Process ◽  
Microstructural Characterization ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Fine Grain ◽  
Metal Plates ◽  
Frictional Forces ◽  
Tool Pin

In this research paper, two different metal plates of aluminum alloy viz. AA6061 and AA6101 were welded with friction stir welding process. Round tool and square tool pin profiles were used to weld the alloys. Weld microstructures, hardness, and tensile properties were evaluated in as-welded condition. The tensile strength of the joints fabricated with round tool pin profile were lower than the square tool pin profile because of the pulsating effect, in square tool pin profile this effect was produced along with the higher frictional forces. The micro-hardness of friction stir zone was higher than the base material due to active recrystallization occurrence which resulted in fine grain size in case of weld joint with round pin profile. Microstructure indicated uniformly distribution of materials with minimum heat affected zone and dense welded zone without any defects.

Application of Neural Network for the Prediction of Tensile Properties of Friction Stir Welded Composites

2016 ◽  
Vol 880 ◽  
pp. 128-131 ◽  
Author(s):  
Arun Kumar Shettigar ◽  
Subramanya Prabhu ◽  
Rashmi Malghan ◽  
Shrikantha Rao ◽  
Mervin Herbert
Keyword(s):  
Neural Network ◽  
Back Propagation ◽  
Base Material ◽  
Welding Process ◽  
Weld Strength ◽  
Back Propagation Algorithm ◽  
Friction Stir ◽  
Error Back Propagation ◽  
The Neural Network ◽  
Tool Pin

In this paper, an attempt has been made to apply the neural network (NN) techniques to predict the mechanical properties of friction stir welded composite materials. Nowadays, friction stri welding of composites are predominatally used in aerospace, automobile and shipbuilding applications. The welding process parameters like rotational speed, welding speed, tool pin profile and type of material play a foremost role in determining the weld strength of the base material. An error back propagation algorithm based model is developed to map the input and output relation of friction stir welded composite material. The proposed model is able to predict the joint strength with minimum error.

Multi sensor based strategies for accurate prediction of friction stir welding of polycarbonate sheets

2020 ◽  
pp. 095440622096077
Author(s):  
Santosh K Sahu ◽  
Debasish Mishra ◽  
Kamal Pal ◽  
Surjya K Pal
Keyword(s):  
Experimental Investigation ◽  
Friction Stir Welding ◽  
Process Monitoring ◽  
High Performance ◽  
Joint Strength ◽  
Welding Process ◽  
Traverse Speed ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

High performance thermoplastic is often used in automotive and aerospace sectors. Friction stir welding (FSW) has been a suitable method for joining these thermoplastic materials. However, the process characteristics vary dynamically, even at same parametric conditions due to process disturbances. While quite a few studies have been reported in experimental investigation, the usage of sensors for the process monitoring during welding has not been explored. Therefore, the present paper focuses on various sensor-based approaches on process monitoring. The study includes an in-depth experimental investigation for joining of polycarbonate sheets using full factorial design of experiments. Three different tool pin profiles like cylindrical, square and triangular have been selected, whereas tool rotational speed and traverse speed are considered as primary process variables. Various statistical time domain features of the force and torque signals starting from average, its deviation and root mean square as well as thermal cycle based weld peak temperature and its cooling rate were found to have a strong correlation with weld bead profile. The axial force and thermal cycles were found to be the major indicators of joint strength efficiency rather than torque as per regression models developed by using response surface methodology. Finally, an attempt has been made for improving the joint strength predictability by using various sensor-based approaches. This work can be used potentially to real time welding process monitoring in industrial sectors.

Experimental Investigation and Optimization of Friction Stir Welding Process - A Review

2014 ◽  
Vol 550 ◽  
pp. 39-47 ◽  
Author(s):  
K.P. Yuvaraj ◽  
B. Senthilkumar
Keyword(s):  
Experimental Investigation ◽  
Friction Stir Welding ◽  
Welded Joint ◽  
Welding Process ◽  
Tool Geometry ◽  
Weld Quality ◽  
Comprehensive Review ◽  
Friction Stir ◽  
Friction Stir Welding Process

Friction stir welding process parameters plays an important role in determining the quality of welded joint. The weld quality of the joint can be assessed in terms of properties such as lack of defects, tensile strength, hardness and desired microstructure. The objective of the friction stir welding process is to obtain a good welded joint with the desired strength and microstructure. This intended to present comprehensive review of application of tool geometry, different process setups computing techniques, design of experiment (DOE) and evolutionary algorithms used to obtain the good weld joint with desired weld quality.

scholarly journals Structural analysis of a friction stir-welded small trailer

DYNA ◽  
2015 ◽  
Vol 82 (190) ◽  
pp. 192-197
Author(s):  
Fabio Bermudez Parra ◽  
Fernando Franco Arenas ◽  
Fernando Casanova
Keyword(s):  
Friction Stir Welding ◽  
Structural Analysis ◽  
Welded Joint ◽  
Base Material ◽  
Welding Process ◽  
Field Tests ◽  
Element Model ◽  
Structural Element ◽  
Friction Stir ◽  
The Impact

This paper introduces the analysis of a trailer structure made of 6063-T5 aluminum alloy using the Friction Stir-Welding process. The base material and the welded joint were characterized by tension tests. The loads for the structural analysis were obtained from field tests where stresses were measured on critical points at a 2.73 m long 0.95 m width trailer while it was driven on an unpaved road. The stresses on the whole trailer were found by using a finite element model, where the joint with the maximum stresses was identified. This joint was constructed with a tubular structural element using Friction Stir Welding and was evaluated by bending tests. Using the impact factor obtained from the field test, fatigue analysis was performed on the welded joint. It was found that the strength of the joint was sufficient to carry the loads on the trailer.

Friction Stir Welding on Light-Weight Metal - Aluminum Alloy Al6061

2016 ◽  
Vol 879 ◽  
pp. 1233-1238
Author(s):  
Vasanth Chakravarthy Shunmugasamy ◽  
Bilal Mansoor
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Yield Strength ◽  
Base Material ◽  
Frictional Heat ◽  
Tensile Yield Strength ◽  
Impact Properties ◽  
Friction Stir ◽  
Tool Pin ◽  
The Impact

Friction stir welding (FSW) is a solid state joining process in which metals are joined together using frictional heat and severe plastic deformation. The heating and the mixing of the metals is performed using a hardened tool with a shoulder and pin. FSW of lightweight metal alloy Al6061 has been carried out in the present study. For welding aluminum the parameters used were a constant tool rotation speed of 1600 rpm and varying tool translation speeds of 250, 500, 750 and 1000 mm/min. The welded coupons were characterized for microstructural observations and mechanical properties such as tensile and Charpy impact properties. The tensile and impact properties were studied at two different temperature namely, room temperature (RT) and 300°C. The FS welded aluminum specimens showed 86% – 98% tensile yield strength, in comparison to the base material at RT. At 300°C, the yield strength was observed to be 85% to 93% of the base material value. For the impact properties, the Al specimens showed 60% – 140% specific impact energy, in comparison to their respective base materials. Based on the mechanical properties and microstructural examination, the optimal weld parameter was identified as 1600 rpm and 250 mm/min which is dependent on the tool pin and shoulder design utilized in the study.

EXPERIMENTAL INVESTIGATION ON FRICTION STIR WELDING OF CRYOROLLED AA2219 ALUMINUM ALLOY JOINTS

2016 ◽  
Vol 24 (01) ◽  
pp. 1750001 ◽  
Author(s):  
K. KAMAL BABU ◽  
K. PANNEERSELVAM ◽  
P. SATHIYA ◽  
A. NOORUL HAQ ◽  
S. SUNDARRAJAN ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Corrosion Resistance ◽  
Friction Stir Welding ◽  
Base Material ◽  
Weld Nugget ◽  
Friction Stir ◽  
Temperature Operating ◽  
Aa2219 Aluminum Alloy ◽  
Large Clusters ◽  
Tool Pin

In this paper, experimental investigation on cryorolled aluminum AA2219-T87 plate by using friction stir welding (FSW) process is carried out. AA2219-T87 plates with a size of 200[Formula: see text]100[Formula: see text]22.4 mm were rolled and reduced to 12.2[Formula: see text]mm thickness (more than 45% of reduction in total thickness of the base material) at cryogenic temperature (operating temperature range [Formula: see text]90–[Formula: see text]30[Formula: see text]C). The cryorolled (CR) plates have reduced grain size, improved hardness and increased corrosion resistance property compared with the uncryorolled AA2219-T87 plates. FSW joints of cryorolled AA2219-T87 plates were prepared using cylindrical threaded FSW tool pin profile. Mechanical and metallurgical behaviors of friction stir welded joints were analyzed and the effects of the FSW process parameters are discussed in this paper. The variation of microhardness in the FSW joint regions were correlated with the microstructure of FSW joints. Cryorolled plate and FSW joints were tested for corrosion resistance using potentiodynamic polarization test. FSW joints shows better result during the corrosion resistance analysis compared to base AA2219-T87. The X-ray diffraction (XRD) test results showed that fine [Formula: see text]-Al grains with eutectic phase (Al2Cu) were present in the weld nugget (WN). The large clusters of strengthening precipitates were reduced in size and merged with the weld nugget portion.

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