Modeling and Analysis of Friction Stir Welding and Underwater Friction Stir Welding of Aluminium Alloy: A Review

2017 ◽  
Vol 867 ◽  
pp. 127-133 ◽  
Author(s):  
S. Shanavas ◽  
J. Edwin Raja Dhas
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Welded Joints ◽  
Energy Efficient ◽  
Modeling And Analysis ◽  
Friction Stir ◽  
Surface Method ◽  
Underwater Friction Stir Welding ◽  
Solid State Joining ◽  
Joining Process

The welding of aluminium and its alloys was a great challenge for researchers and technologists till 1991. Friction stir welding (FSW), a relatively new solid state joining process was first patented in 1991 by Thomas et. al. from ‘The welding Institute (TWI), England. Later its application found in various industries like aerospace, marine, automobile, etc. due to its high quality joints. The technique is energy efficient, ecofriendly and versatile too. In this review article, the modeling and analysis of friction stir welding and underwater friction stir welding (UFSW) of aluminium alloy are addressed. Commonly used method for modeling and analysis of welded joints such as Taguchi method and Response surface method (RSM) are considered for the review. Finally an attempt has been made to compare UFSW welded joints with FSW welded joints.

A Study on Influence of Underwater Friction Stir Welding on Microstructural, Mechanical Properties and Formability in 5052-O Aluminium Alloys

2019 ◽  
Vol 969 ◽  
pp. 27-33
Author(s):  
K. Tejonadha Babu ◽  
S. Muthukumaran ◽  
C.H. Bharat Kumar ◽  
C. Sathiya Narayanan
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Grain Refinement ◽  
Hardness Test ◽  
Friction Stir ◽  
Underwater Friction Stir Welding ◽  
Save Energy ◽  
Solid State Joining ◽  
Joining Process

Friction stir welding (FSW), a solid-state joining process is extensively using in the welding of aluminum alloy sheets. In order to save energy and reduce emission, lightweight materials like aluminum alloys were introduced into steel car body, which requires the development of effective joining processes. In the present study, welding was carried out in two different conditions, in the air (CFSW) and underwater (UWFSW) at various welding speeds to weld 5052-O aluminum alloy sheets. The effect of UWFSW on microstructural developments, mechanical properties, and formability was evaluated and compared. Grain refinement is an important opportunity to improve the mechanical properties of FS welds. Considerable grain refinement was obtained in UWFSW joints, which is smaller than that in the CFSW joints. The results indicated an increase in tensile strength, hardness, the percentage of elongation, and formability of UWFSW weld sheets. The results of the tensile test, hardness test, microstructure and fractography as in good correlation with improved properties.

scholarly journals Friction Stir Welding of Aerospace Alloys

2019 ◽  
Vol 48 (1) ◽  
pp. 37-46
Author(s):  
Akshansh Mishra ◽  
Devarrishi Dixit
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Space Vehicles ◽  
Friction Stir ◽  
Aerospace Applications ◽  
Aerospace Alloys ◽  
Fuel Tanks ◽  
Higher Temperature ◽  
Solid State Joining ◽  
Joining Process

Friction Stir Welding (FSW) is a solid state joining process which possesses a great potential to revolutionise the aerospace industries. Distinctive materials are selected as aerospace alloys to withstand higher temperature and loads. Sometimes these alloys are difficult to join by a conventional welding process but they are easily welded by FSW process. The FSW process in aerospace applications can be used for: aviation for fuel tanks, repair of faulty welds, cryogenic fuel tanks for space vehicles. Eclipse Aviation, for example, has reported dramatic production cost reductions with FSW when compared to other joining technologies. This paper will discuss about the mechanical and microstructure properties of various aerospace alloys which are joined by FSW process.

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.

Effects of Tool Pin Profile and Tool Shoulder Diameter on the Tensile Behaviour of Friction Stir Welded Joints of Aluminium Alloys

2014 ◽  
Vol 984-985 ◽  
pp. 586-591 ◽  
Author(s):  
R. Ashok Kumar ◽  
M.R. Thansekhar
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Tensile Properties ◽  
Welded Joints ◽  
Tensile Behaviour ◽  
Light Weight ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Weight Structures

— For fabricating light weight structures, it requires high strength-to weight ratio. AA6061 aluminium alloy is widely used in the fabrication of light weight structures. A356 aluminium alloy has wide spread application in aerospace industries. Friction stir welding is solid state joining process which is conducting for joining similar and dissimilar materials. The friction stir welding parameters play an important role for deciding the strength of welded joints. In this investigation, A356 and AA6061 alloys were friction stir welded by varying triangular, square, hexagonal pin profiles of tool keeping the remaining parameters same and AA6061 alloys were friction stir welded by varying tool shoulder diameter as 12mm,15mm,18mm without changing other parameters. Tensile properties of each joint have been analyzed microscopically. From the experimental results, it is observed that hexagonal pin profiled tool and 15mm shoulder diameter tool provides higher tensile properties when compared to other tools.

A Weld that Lasts for 100,000 Years: Friction Stir Welding of Copper Canisters

2003 ◽  
Vol 807 ◽  
Author(s):  
Lars Cederqvist
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Aluminium Alloys ◽  
Development Program ◽  
Production Level ◽  
Friction Stir ◽  
Solid State Joining ◽  
Joining Process ◽  
New Machine

ABSTRACTFriction Stir Welding (FSW) is a novel solid-state joining process where the work pieces are joined together using a rotating non-consumable tool. The process has mainly been used for joining aluminium alloys, and has not yet been used in production for any other metal. However, the results from the development program confirm that FSW can consistently seal 50mm thick copper canisters without creating defects. A new machine is now installed at SKB's Canister Laboratory to further automate the process to production level.

scholarly journals Friction Stir Welding of Thick Plates of 4Y3Gd Mg Alloy: An Investigation of Microstructure and Mechanical Properties

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 6924
Author(s):  
Khaja Moiduddin ◽  
Arshad Noor Siddiquee ◽  
Mustufa Haider Abidi ◽  
Syed Hammad Mian ◽  
Muneer Khan Mohammed
Keyword(s):  
Friction Stir Welding ◽  
Traverse Speed ◽  
Light Metal ◽  
Parent Material ◽  
Mg Alloy ◽  
Ferrous Alloys ◽  
Thick Plates ◽  
Friction Stir ◽  
Solid State Joining ◽  
Joining Process

Applications of non-ferrous light metal alloys are especially popular in the field of aerospace. Hence it is important to investigate their properties in joining processes such as welding. Solid state joining process such as friction stir welding (FSW) is quite efficient for joining non-ferrous alloys, but with thick plates, challenges increase. In this study, Mg alloy plates of thickness 11.5 mm were successfully welded via single-pass FSW. Due to the dynamic recrystallization, grain size in the stir zone was reduced to 16 µm which is ≈15 times smaller than the parent material. The optimized rotational speed and traverse speed for optimum weld integrity were found to be 710 rpm and 100 mm/min, respectively. A sound weld with 98.96% joint efficiency, having an Ultimate Tensile Strength (UTS) of 161.8 MPa and elongation of 27.83%, was accomplished. Microhardness of the nugget was increased by 14.3%.

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