Study of Heat Dissipation Generated in Tool Designed for Friction Stir Welding Process (FSW)

2015 ◽  
Vol 1125 ◽  
pp. 171-175
Author(s):  
G. Paramo ◽  
A. Benitez
Keyword(s):  
Friction Stir Welding ◽  
Heat Dissipation ◽  
Welding Process ◽  
Experimental Tests ◽  
Tool Design ◽  
Milling Machine ◽  
Technical Parameters ◽  
Friction Stir ◽  
Heat Dispersion ◽  
The Right

Friction stir welding (FSW) is an alternative method of joining materials with low melting point, patented in 1991 by the American Welding Institute (UK). This method uses the heat generated by mechanical friction between two moving parts, one is the tool rotates and is fastened on the spindle of a conventional milling machine and the other is the part that is attached and is gagged on the bed of the machine. Among the variables identified as the most important for a successful run of the process are the revolutions per minute (RPM) at which the tool rotates, the speed advance at which the workpiece and the tool design as such moves [1]. In this paper the design of several tools applied to FSW process is studied in specific dissipation of heat generated by mechanical friction between the parts, its relation to tool design and qualities of successful meetings is presented, the methodology to achieve this goal was first identify the possible and applicable materials for the tools, second his respective designs to ensure the right function for operation, and finally define FSW technical parameters (RPM, Head angle, speed advance) for experimental tests. The findings and conclusions attribute a novel analysis in the design of tools for this innovative manufacturing process, in the analysis of the results obtained for each of the assemblies experimentation it was discovered that the use of rings at the parts are not decisive for a good weld even heat dispersion is not good.

scholarly journals 3D modeling of material flow and temperature in Friction Stir Welding

2009 ◽  
Vol 14 (3) ◽  
pp. 248-256 ◽  
Author(s):  
Diego Santiago ◽  
Santiago Urquiza ◽  
Guillermo Lombera ◽  
Luis de Vedia
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Frictional Heating ◽  
Welding Process ◽  
Experimental Tests ◽  
General Purpose ◽  
Friction Stir ◽  
Welding Equipment ◽  
Reducing Costs ◽  
Visualization Techniques

The process of Friction Stir Welding (FSW) is a welding method developed by the "The Welding Institute" (TWI) of England in 1991. The welding equipment consists of a tool that rotates and progresses along the joint of two restrained sheets. The joint is produced by frictional heating which causes the softening of both components into a viscous-plastic condition and also by the resultant flow between the sheets to be joined. Numerical Modeling of the process can provide realistic prediction of the main variables of the process, reducing the number of experimental tests, thus accelerating the design processes while reducing costs and optimizing the involved technological variables. In this study the friction stir welding process is modeled using a general purpose finite element based program, reproducing the material thermal map and the corresponding mass flow. Numerical thermal results are compared against experimental thermographic maps and numerical material flow results are compared with material flow visualization techniques, with acceptable concordance.

Influence of Different Anvil Back Plates on Heat Dissipation Velocity of the Micro-Friction Stir Welding Process

2015 ◽  
Vol 786 ◽  
pp. 415-420 ◽  
Author(s):  
Wan Shun Chu ◽  
Farazila binti Yusof
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Heat Dissipation ◽  
Welding Process ◽  
Temperature Fields ◽  
Thin Sheets ◽  
Friction Stir ◽  
Conventional Steel ◽  
Back Plate ◽  
Two Temperature

The objective of this study is to investigate effects of different anvil back plates on heat dissipation velocity of the micro-friction stir welding (micro-FSW or) process. For this purpose, temperature field simulations are conducted for the micro-friction stir welding of AA5083-H323 aluminum alloy thin sheets by using the ceramic anvil back plate and conventional steel anvil back plate, respectively. Comparing the obtained two temperature fields, it is found that the ceramic anvil back plate significantly decreases the heat dissipation velocity of the micro-FSW process.

scholarly journals Influence of Tool Pin Profile and Tool Rotating Speed on Mechanical Properties of Al6082 Alloy

2019 ◽  
Vol 8 (12) ◽  
pp. 3342-3345
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Automatic Process ◽  
Work Piece ◽  
Milling Machine ◽  
Friction Stir ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Tool Pin

Friction stir welding is a solid state welding which uses non consumable welding tool. It is an automatic process which generally performs on the vertical milling machine. In this type of welding, the relative motion between the tools and work piece creates heat which uses the region of work piece to be welded get softened and to joint the two work pieces. Friction stir welding process is more reliable for the materials which are generally non heat treatable. In this present investigation it will observe that how the rotational speeds of the tool and different shapes of the tool pins effects the mechanical properties of the aluminium alloy 6082. For this purpose three tools with different profiles, i.e triangular, cylindrical and square was designed and fabricated. At three different rotational speeds of 560 rpm, 900 rpm, 1800 rpm work pieces are joined using vertical milling machine. Specimens are prepared and tested for mechanical properties, tensile, impact, and hardness tests are performed and to detect the defects and voids x-ray test performed on the weld joints. And it was observed that highest tensile strength was presented when the square pin tool used at 560 rpm. The rotational speed increased mechanical properties are reducing significantly.

Taguchi Analysis of the Effect of Process Parameters in Friction Stir Welding

2010 ◽  
Vol 636-637 ◽  
pp. 1150-1156 ◽  
Author(s):  
Rui Louro ◽  
Carlos Leitão ◽  
Helena Gouveia ◽  
Altino Loureiro ◽  
Dulce Maria Rodrigues
Keyword(s):  
Friction Stir Welding ◽  
Taguchi Method ◽  
Welding Process ◽  
Experimental Tests ◽  
Experimental Methods ◽  
Butt Joint ◽  
Welding Parameters ◽  
Published Data ◽  
Friction Stir ◽  
Friction Stir Welding Process

The task of obtaining suitable welding parameters for the friction stir welding process is often a difficult one, due to the lack of published data and the fact that the exact mechanism by which the process operates has not yet been fully determined. Therefore, suitable welding parameters often need to be obtained by using extensive, time consuming and expensive experimental methods. The work detailed in this paper pertains to the use of the Taguchi method as a mean to reduce the disadvantages of these experimental methods, more specifically, their cost. The Taguchi method accomplishes this task by substantially reducing the number of welding trials that are needed to obtain suitable welding parameters. This reduction leads to the parameters being obtained more rapidly and at a substantially smaller cost. In this paper a procedure for applying the Taguchi method to the friction stir welding process is presented as well as its application to the welding of a specific component. The method was applied to the welding of 4mm thick AA5083-H111 plates in a butt joint configuration, which constitutes one of the most common industrial welding scenarios. The purpose of the experimental tests was to maximize the welding speed whilst ensuring an acceptable welding quality. The quality of the welds was determined through visual inspection and tensile and bending tests. The application of the Taguchi method allowed, with a relatively small number of experimental welds, to provide some insight into the manner by which the parameters should be altered in order to optimize the process.

Temperature Distribution Analysis in Plates Joined by Friction Stir Welding

2009 ◽  
Author(s):  
Mauricio Rangel Pacheco ◽  
Jean Paul Kabche ◽  
Ivan Thesi ◽  
Fabiano Nunes Diesel
Keyword(s):  
Finite Element ◽  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Large Scale ◽  
Heat Dissipation ◽  
Welding Process ◽  
Experimental Investigations ◽  
Welding Parameters ◽  
Distribution Analysis ◽  
Friction Stir

Friction Stir Welding (FSW) is a solid-state welding process which generates heat through mechanical friction between a moving workpiece and a fixed component, in order to plastically combine materials. This process has been gaining considerable attention due to several key advantages, which include: good mechanical properties of the combined materials after welding, absence of toxic fumes and molten material spatter, low environmental impact, and low concentration of defects while allowing a large variation of parameters and materials. Although a reasonable number of experimental investigations on FSW are available in the literature, numerical modeling of this process has not been performed on a large scale. In that light, this paper presents a numerical investigation of the temperature distribution in plates welded by FSW, using finite element analysis. The finite element model developed includes friction between the workpiece and the fixed component, as well as the corresponding heat dissipation that results from plastic deformation of the material. The model was found appropriate for estimating important welding characteristics, such as the heat-affected zone (HAZ), and their sensitivity to various welding parameters.

scholarly journals Experimental Study the Effect of Tool Design on the Mechanical Properties of Bobbin Friction Stir Welded 6061-T6 Aluminum Alloy

2018 ◽  
Vol 14 (3) ◽  
pp. 1-11 ◽  
Author(s):  
Samir Ali Amin ◽  
Mohannad Yousif Hanna ◽  
Alhamza Farooq Mohamed
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Rolling Direction ◽  
Welding Process ◽  
Tool Design ◽  
Flat Surfaces ◽  
Friction Stir ◽  
Welding Joints

Bobbin friction stir welding (BFSW) is a variant of the conventional friction stir welding (CFSW); it can weld the upper and lower surface of the work-piece in the same pass. This technique involves the bonding of materials without melting. In this work, the influence of tool design on the mechanical properties of welding joints of 6061-T6 aluminum alloy with 6.25 mm thickness produced by FSW bobbin tools was investigated and the best bobbin tool design was determined. Five different probe shapes (threaded straight cylindrical, straight cylindrical with 3 flat surfaces, straight cylindrical with 4 flat surfaces, threaded straight cylindrical with 3 flat surface and threaded straight cylindrical with 4 flat surfaces) with various dimensions of the tool (shoulders and pin) were used to create the welding joints. The direction of the welding process was perpendicular to the rolling direction for aluminum plates. Tensile and bending tests were performed to select the right design of the bobbin tools, which gave superior mechanical properties of the welded zone.  The tool of straight cylindrical with four flats, 8 mm probe and 24 mm shoulders diameter gave better tensile strength (193 MPa), elongation (6.1%), bending force (5.7 KN), and welding efficiency (65.4%) according to tensile strength.     

scholarly journals Effect of High Rotational-Speed Friction-Stir Welding on Microstructure and Properties of Welded Joints of 6061-T6 Al Alloy Ultrathin Plate

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 6012
Author(s):  
Hao Zhang ◽  
Shujin Chen ◽  
Yuye Zhang ◽  
Xinyi Chen ◽  
Zhipeng Li ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Heat Dissipation ◽  
Temperature Drop ◽  
Precipitation Amount ◽  
Large Angle ◽  
Welding Process ◽  
Al Alloy ◽  
High Rotational Speed ◽  
Friction Stir

The butt joint of an Al alloy ultrathin plate with a thickness of 0.5 mm is realized by a high rotational-speed friction-stir welding process. It overcomes the welding difficulty that the ultrathin plate is often torn, and it cannot be formed by conventional friction-stir welding. The results show that the weld surface is well-formed at a high-rotational speed (more than 8000 rpm), and there are no obvious defects in each area of the joint section. The nugget zone (NZ) is a recovery recrystallization structure dominated by large-angle grain boundaries, with a grain size of about 4.9 μm. During grain growth, the texture is randomly and uniformly distributed, and the strength is balanced. The microhardness of the NZ increases significantly with the increase in rotational speed, and the fluctuation range of hardness value is small. The NZ β–Mg2Si is finer and significantly less than the base metal (BM). The heat dissipation of the thin plate is fast, so a Cu plate is used as the backing plate to slow down the steep temperature-drop process in the weld area. Compared with a low rotational speed, the precipitation amount of brittle phase Al–Cu–Mg–Cr and Al–Fe–Si–Mn is significantly reduced, which is conducive to improving the mechanical properties of the joint. At a high rotational speed, 12,000 rpm, the best tensile strength of the joint is 220 MPa, which is about 76% of the BM (290 MPa), and the highest elongation is 9.3%, which is about 77.5% of the BM (12%). The fracture mode of the joint is a typical plastic fracture.

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