Mechanical Properties Evaluation of Friction Stir Welded AA6061-AA7075 Alloys for Different Tool pin Geometries

2019 ◽  
Vol 895 ◽  
pp. 295-300
Author(s):  
Rao R. Raghavendra ◽  
N. Bharath ◽  
S. Pradeep ◽  
C.K. Yogisha
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Dissimilar Materials ◽  
Hardness Test ◽  
Green Technology ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Solidification Cracks ◽  
Tool Pin

The friction stir welding is a solid state welding in which welding takes place at a temperature below the melting point. This welding is also known as green technology welding as no harmful gases are generated, as well as fluxes are not formed. In this process joining of two dissimilar materials can be achieved. Through this welding one can overcome defects like porosity, solidification, cracks etc by selecting suitable wilding parameters. Present work investigates the effect of different tool pin geometries on mechanical properties of friction stir welded AA6061 and AA7075 alloys keeping the process parameters constant. The welding is carried with process parameters 1000rpm, 50mm/min and 5KN as tool rotational speed, welding speed and axial load respectively, and for four different pin geometries: (a) cylindrical pin, (B) triangular pin, (c) square pin and (d) hexagonal pin. The welded samples are characterized by mechanical properties like tensile strength and micro Vickers hardness test. By considering the both properties the hexagonal pin shown better characteristics under optimum process parameters.

Mathematical Model to Predict Tensile Strength of Underwater Friction Stir Welded (UFSW) on 5052 Aluminium Alloys

2018 ◽  
Author(s):  
Dhanis Paramaguru ◽  
Srinivasa Rao Pedapati ◽  
Mokhtar Awang ◽  
Hamed Mohebbi
Keyword(s):  
Mechanical Properties ◽  
Mathematical Model ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Polynomial Regression ◽  
Coefficient Of Determination ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Friction Stir

In this study, AA5052 joints are fabricated by underwater friction stir welding and the process parameters are optimized for maximum UTS value by utilizing a developed mathematical model. The experiments are conducted by using Taguchi’s L9 orthogonal array, and polynomial regression analysis is applied to generate the model. Statistical tools such as analysis of variance (ANOVA), coefficient of determination is applied to check the adequacy of the developed model at 95% confidence level. Type of welding tools is identified as the most influencing factor on deciding the mechanical properties of the joint, followed by tool rotational speed and tool welding speed. The optimum process parameters are identified by the Taguchi parametric design method. The results indicated that the optimum process parameters combinations for better mechanical properties is attained at tool rotational speed of 1500 rpm and tool welding speed of 100 mm/min, using taper threaded cylindrical tool. A maximum UTS value of 225.48 MPa is obtained and it is verified by confirmation test.

Parameters optimization in FSW of polypropylene based on RSM

2015 ◽  
Vol 11 (1) ◽  
pp. 32-42 ◽  
Author(s):  
K Panneerselvam ◽  
Kasirajan Lenin
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Optimization Techniques ◽  
Parameters Optimization ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Output Characteristics ◽  
Tool Pin

Purpose – The purpose of this paper is to weld polypropylene (PP) material by friction stir welding (FSW) process. The input process parameters considered were: tool pin profile, feed rate and tool rotational speed and the process output characteristics were tensile strength, Shore-D hardness, Rockwell hardness, Izod strength, Charpy strength and nugget area. Design/methodology/approach – Optimization of process parameters were carried out based on response surface methodology (RSM) and significant parameters were obtained by performing analysis of variance (ANOVA). Findings – The optimized results were the threaded pin profile for feed of 60 mm/min and tool rotational speed of 1,500 rpm. A confirmation test was carried out to verify the optimized results. Originality/value – In this paper, the process parameters were optimized based on RSM. This is newly adopted optimization techniques in the FSW process of PP materials and also it gives better results.

Optimization of Friction Stir Welding Process Parameters to Join Al 5052 and Al 6061 Alloy Plates Using Grey-Taguchi Technique

2017 ◽  
Author(s):  
R. Sandeep ◽  
D. Sudhakara ◽  
G. Prasanthi
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Fusion Welding ◽  
Optimum Process ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Grey Analysis ◽  
Grey Taguchi

Friction stir welding (FSW) is a solid state welding process used for welding similar and dissimilar materials. The process is widely used because it does not have common problems such as solidification and liquefaction cracking associated with the fusion welding techniques. The objective of the present research is to find the best combination of friction stir welding process parameters to join aluminium 5052 and 6061 alloy materials. The combination of process parameters is helpful to improve ultimate tensile strength, yield strength, percentage of elongation and hardness of welded joint. To achieve the research objective taguchi based grey analysis was used. The optimum process parameters were found be at rotational speed is 1400 rpm, transverse speed of 100 mm/min and axial force is at 11 KN.

scholarly journals Research the Effect of Process Parameters on Friction Stir Welded AA6063-ETP Copper joint using Taguchi Technique

2019 ◽  
Vol 8 (2S11) ◽  
pp. 884-888
Keyword(s):  
Thermal Conductivity ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Copper Plate ◽  
Heat Sinks ◽  
Optimum Process ◽  
Tool Rotational Speed ◽  
Alloy Plate ◽  
Friction Stir

Aluminium and copper, or their combination finds application in heat sinks because of their excellent thermal conductivity. In the present study, Al–6063 and ETP copper were lap welded using friction stir welding wherein the aluminum alloy plate was placed on top of the copper plate. The optimum process parameters were found using Taguchi L9 orthogonal array. The process parameters namely tool rotational speed, tool traverse speed and thickness of zinc inter-filler material were considered. The optimal process parameters were ascertained with respect to the thermal conductivity of weld. The predicted optimum value of thermal conductivity was verified by conducting the confirmation run using the optimal parameters. Analysis of variance depicted that all the three process parameters were significant, wherein the tool rotational speed and the tool traverse speed were the most dominant factors contributing to thermal conductivity.

Effects of friction stir welding on corrosion and mechanical properties of AA6063 in sea water

2021 ◽  
pp. 095440622199554
Author(s):  
Laxmana Raju Salavaravu ◽  
Lingaraju Dumpala
Keyword(s):  
Mechanical Properties ◽  
Electron Microscope ◽  
Friction Stir Welding ◽  
Corrosion Rate ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Pin

Submerged friction stir welding (FSW) is used to improve the weld zones mechanical properties in the present study. This research aims to obtain the optimized process parameters used to fabricate the AA6063 Submerged FSW joint. In the Submerged FSW process, the most important influential factors are tool rotational speed, traverse speed, and pin profile in a seawater environment. The different workpieces are friction stir welded while submerged in seawater at different tool rotational speeds, traverse speeds, and tool pin profiles such as square pin, cylindrical taper pin, and threaded pin. The produced weldments were tested for the mechanical properties of higher tensile strength, microhardness, corrosion rate, and the microstructure of weldments was characterized by using a scanning electron microscope, transmission electron microscope, and X-ray diffractometer. The corrosion rate is investigated by using an electrochemical analyzer by potential dynamic polarization open-circuit technique. For this investigation, The Taguchi method with the L9 orthogonal array design of experimentation is adopted. The maximum UTS was acquired in the weld joint fabricated with 1250 r/min of tool rotational speed, 45 mm/min traverse speed, and a square tool pin. The stirred zone is tested for microhardness. High hardness is achieved with high tool rotational speed and low traverse speed with a square tool pin profile. The corrosion rate is also decreased with high tool rotational speed, low traverse speed, and a square tool pin profile.

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 Influence of Tool Pin Profile on Mechanical Properties and Microstructure of Friction Stir Welded Aluminium AA7075 Alloy

2020 ◽  
Vol 6 (10) ◽  
pp. 7-11
Author(s):  
G.Venkateswarlu
Keyword(s):  
Mechanical Properties ◽  
Traverse Speed ◽  
Grain Structure ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Fine Grain ◽  
Shoulder Diameter ◽  
Aa 7075 ◽  
7075 Alloy ◽  
Tool Pin

The present investigation describes the effect of different tool pin profiles on microstructure and mechanical properties of friction stir welded aluminium AA-7075 alloy. The tool pin profiles namely taper cylindrical threaded (TT), cylindrical (CT), square (SQ), triangular (TR), pentagonal (PT), hexagonal (HX) with constant shoulder diameter have been selected to make joints. The friction stir welding was done at constant tool rotational speed and traverse speed. From this study, it is noted that the weld joints prepared using taper cylindrical threaded pin profile exhibited good mechanical properties when compared to other pin profiles. It is due to more surface contact of tool pin and production of equiaxed fine grain structure in the weld region.

A comparative study between weldability of polycarbonate and nylon-6 using different pin geometries in friction stir welding

2021 ◽  
pp. 095440542110407
Author(s):  
Santosh K Sahu ◽  
Debasish Mishra ◽  
Kamal Pal
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Solid State ◽  
Nylon 6 ◽  
Comparative Assessment ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Base Materials ◽  
Tool Pin ◽  
Material Mixing

The solid state friction stir welding (FSW) has been recently the choice for joining of thermoplastics. The present work aims at analyzing the implementation of FSW in joining of different thermoplastics namely, polycarbonate and nylon-6 sheets using varying tool pin profiles, cylindrical, square, and triangular. The novelty of this article is the comparative assessment that has been made on the weldability of these two thermoplastics by determining the mechanical properties of the joint along with real-time acquired force, torque, and temperature signals. Higher axial force with reduced torque has been observed for nylon-6 as compared to polycarbonate. The joint efficiency was found to be maximum (>50%) at tool rotational speed 1800 rpm and welding speed 20 mm/min using square tool pin profile for each of the base materials. Minor undercut defect along with improved material mixing has been seen during the tool stirring process. The study would be helpful for the industries to choose thermoplastics based on their applications.

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