General Aspects Concerning Possibilities of Joining by Friction Stir Welding for some of Couples of Materials Usable in the Automotive Industry

2019 ◽  
Vol 1153 ◽  
pp. 27-35 ◽  
Author(s):  
Radu Cojocaru ◽  
Lia Nicoleta Boţilă ◽  
Cristian Ciucă ◽  
Bogdan Radu ◽  
Victor Verbiţchi ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Automotive Industry ◽  
Ferrous Metal ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Industrial Applications ◽  
Friction Stir ◽  
Metal Materials ◽  
Materials Used ◽  
General Aspects

In recent years, due to its extraordinary qualities, friction stir welding process FSW has found its utility in more and more industrial applications in fields such as: aerospace, aeronautics, naval, automotive and railway. The paper summarizes several achievements in the FSW joining of couples of similar and dissimilar materials used in the automotive industry. There are presented aspects regarding the welding of ferrous metal materials (DD13), couples of non-ferrous metallic materials (Al Cu range) and steels with aluminum. The behavior of FSW of material couples in terms of analysis of microstructural improvements and mechanical characteristics is analyzed. The preliminary results obtained have shown that the FSW process can be successfully applied to the joining of the approached material couples, but with the use of optimized welding tools and technologies.

New Joining Techniques for the Production of the Electrical Components in the Automotive Industry

2018 ◽  
Vol 1146 ◽  
pp. 98-105 ◽  
Author(s):  
Radu Cojocaru ◽  
Cristian Ciucă ◽  
Lia Nicoleta Boţilă ◽  
Victor Verbiţchi ◽  
Ion Aurel Perianu
Keyword(s):  
Friction Stir Welding ◽  
Production Process ◽  
Automotive Industry ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Butt Welding ◽  
Friction Stir ◽  
Preliminary Results ◽  
Friction Stir Welding Process ◽  
Electrical Components

In the paper are presented some preliminary results regarding the possibilities of using of the friction stir welding process (FSW) and FSW assisted with TIG (FSW – TIG) welding for joining of the electrical components in the automotive industry. Couples of dissimilar materials approached in experiments were Aluminium EN AW 1200 and Copper Cu99, with thicknesses in conformity with real cases in the production process. The results obtained for butt welding an overlap welding of different thicknesses of materials (aluminium thickness s1 = 2mm and copper thickness s2 = 5mm) are presented. There are some general conclusions regarding the possibilities of joining the two materials under the specified conditions.

ISIM Contributions to the Development of Friction Welding Procedures

2021 ◽  
Vol 890 ◽  
pp. 82-94
Author(s):  
Radu Cojocaru ◽  
Lia Nicoleta Boțilă ◽  
Cristian Ciucă ◽  
Victor Verbiţchi
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Research Direction ◽  
Industrial Applications ◽  
Butt Welding ◽  
Main Research ◽  
Friction Stir ◽  
Welding Equipment ◽  
Protective Gas

During the last 15 years, the friction stir welding process (FSW) and the techniques developed based on the FSW principle have been a main research direction within ISIM Timisoara. The paper summarizes activities and results obtained by the FSW research team within the institute. The paper presents a synthesis that aims a briefly presentation of its own achievements and contributions from recent years regarding the development of the FSW process, especially on the following directions:- Friction stir welding on couples of similar and dissimilar materials;- Use of FSW-TIG (friction stir welding – tungsten inert gas assisted) and FSW-US hybrid processes friction stir welding - ultrasonic assisted);- Friction stir welding in protective gas environment;- Friction stir welding equipment and tools;- Systems for monitoring of the welding process. Results obtained at friction stir butt welding or by overlapping of some couples of materials that are difficult or impossible to be joined using conventional welding procedures, were presented. The results obtained during these years, as well as their scientific and technical level, have allowed the proposal for implementation of solutions that involve FSW welding for specific industrial applications (especially for the automotive field).

Friction stir welding of aluminium alloys: An overview of experimental findings – Process, variables, development and applications

2017 ◽  
Vol 233 (6) ◽  
pp. 1191-1226 ◽  
Author(s):  
Pratik H Shah ◽  
Vishvesh J Badheka
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Copper Alloys ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Industrial Applications ◽  
Future Research ◽  
Welding Parameters ◽  
Friction Stir ◽  
Friction Stir Welding Process

The never ending appetite of the mankind to produce more and more competitive products results in continuous development of newer and newer manufacturing processes. One of such a kind, a solid state welding process highly appreciated for joining of a variety of aluminium and copper alloys, is friction stir welding. The process is also an accomplished method for joining dissimilar materials efficiently. The process finds its major application for joining hard-to-weld metals, especially the precipitation hardenable aluminium alloys and is widely adopted by industries for the welding of such aluminium alloys. However, the process has still not found an economical way for welding of steels and hence found limited applications in industries for welding steels. This paper aims at providing a comprehensive review of the work undertaken in the field of friction stir welding and provides an insight into the friction stir welding of aluminium alloys. The article pays critical attention and analytical evaluation of classification of aluminium alloys, friction stir welding process parameters, the mechanical testing and properties of the friction stir welding joints, macrostructure and microstructure evolution during friction stir welding, friction stir welding defects and industrial applications of the process. The friction stir welding process variants are discussed as well. Special accentuation has been given to (i) effect of friction stir welding parameters on the microstructure evolved and thus the ultimate mechanical properties (viz. tensile strength, hardness, fatigue strength, fracture toughness and residual stresses), (ii) the texture formation, microstructure refinement and the role of intermetallics. However, studies related to welding of dissimilar aluminium alloys, temperature, and heat transfer modeling and material flow are out of the scope of this paper. Finally, the directions of future research are examined.

Influence of Friction Stir Welding Process on the Weld Formation and Tensile Strength of Titanium and Aluminum Dissimilar Alloys Welded Joint

2011 ◽  
Vol 189-193 ◽  
pp. 3266-3269 ◽  
Author(s):  
Yu Hua Chen ◽  
Peng Wei ◽  
Quan Ni ◽  
Li Ming Ke
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Welded Joint ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Influence Of Process Parameters ◽  
Friction Stir ◽  
Dissimilar Alloys ◽  
Titanium Aluminum

Titanium alloy TC1 and Aluminum alloy LF6 were jointed by friction stir welding (FSW), and the influence of process parameters on formation of weld surface, cross-section morphology and tensile strength were studied. The results show that, Titanium and Aluminum dissimilar alloy is difficult to be joined by FSW, and some defects such as cracks and grooves are easy to occur. When the rotational speed of stir head(n) is 750r/min and 950r/min, the welding speed(v) is 118mm/min or 150mm/min, a good formation of weld surface can be obtained, but the bonding of titanium/aluminum interface in the cross-section of weld joint is bad when n is 750r/min which results in a low strength joint. When n is 950r/min and v is 118mm/min，the strength of the FSW joint of Titanium/Aluminum dissimilar materials is 131MPa which is the highest．

scholarly journals Analysis of the influence of position of welding materials on the FSW seams properties for three dissimilar aluminium alloy

2018 ◽  
Vol 178 ◽  
pp. 03003 ◽  
Author(s):  
Ana Bosneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Monica Iordache
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Workpiece Material ◽  
Friction Stir ◽  
Welding Joints ◽  
Welding Materials

Friction Stir Welding, abbreviated FSW is a new and innovative welding process. This welding process is increasingly required, more than traditional arc welding, in industrial environment such us: aeronautics, shipbuilding, aerospace, automotive, railways, general fabrication, nuclear, military, robotics and computers. FSW, more than traditional arc welding, have a lot of advantages, such us the following: it uses a non-consumable tool, realise the welding process without melting the workpiece material, can be realised in all positions (no weld pool), results of good mechanical properties, can use dissimilar materials and have a low environmental impact. This paper presents the results of experimental investigation of friction stir welding joints to three dissimilar aluminium alloy AA2024, AA6061 and AA7075. For experimenting the value of the input process parameters, the rotation speed and advancing speed were kept the same and the position of plates was variable. The exit date recorded in the time of process and after this, will be compared between them and the influence of position of plate will be identified on the welding seams properties and the best position of plates for this process parameters and materials.

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

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.

Numerical Modeling of Thermal Field Distribution during Friction Stir Welding (FSW) of Dissimilar Materials

2016 ◽  
Vol 254 ◽  
pp. 261-266
Author(s):  
Bogdan Radu ◽  
Cosmin Codrean ◽  
Radu Cojocaru ◽  
Cristian Ciucă
Keyword(s):  
Numerical Modeling ◽  
Friction Stir Welding ◽  
Solid State ◽  
Thermal Field ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Dissimilar Joints ◽  
Element Analysis ◽  
Friction Stir ◽  
The Cost

Friction Stir Welding (FSW) is an innovative solid state welding process, relatively new in industry, which allow welding of two or more materials which have very different properties, particularly thermal properties as fusion temperature, thermal expansion coefficient, specific heat and thermal conduction and have a predisposition to form intermetallic brittle phases, neither one of the components to be weld reach to the melting point. Being a solid state welding process temperature field is very important for the quality of the welded joint, and a lot of researches focused on this topic. This paper presents some results in modeling and estimation of thermal field developed during FSW of dissimilar joints, using Finite Element Analysis. Numerical modeling of thermal field allows engineers to predict, in advance, the evolution of temperature and to estimate the behavior of the welded materials during the welding process. This will reduce significantly the time and number of experiments that have to be carried out, in the process of establishing a good FSW technology, as well as reducing significantly the cost of the tests.

scholarly journals Micro Friction Stir Welding Process: State of the Art

2018 ◽  
Vol 8 (02) ◽  
Author(s):  
Akshansh Mishra
Keyword(s):  
Friction Stir Welding ◽  
Copper Alloys ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Zinc Alloys ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Thin Walled Structures ◽  
Current State ◽  
Mechanical Assemblies

IMicro friction stir welding (µFSW) process is mainly adapted from the Friction Stir Welding Process. This process is mainly used for joining dissimilar materials. Micro friction stir welding (µFSW) find its applications in thin walled structures, electrical, electronic and micro-mechanical assemblies. The significant challenges are faced when we downscale to achieve µFSW. This paper addresses the current state of the understanding and development of Micro friction stir welding. This paper further outlines the results achieved after Micro friction stir processing of Aluminium alloys, Copper alloys and Zinc alloys.

scholarly journals Friction Stir Spot Welding of Aluminum and Copper: A Review

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 156 ◽  
Author(s):  
Mingshen Li ◽  
Chaoqun Zhang ◽  
Dayong Wang ◽  
Li Zhou ◽  
Daniel Wellmann ◽  
...  
Keyword(s):  
Material Flow ◽  
Spot Welding ◽  
Dissimilar Materials ◽  
Industrial Applications ◽  
Friction Stir Spot Welding ◽  
Research Progress ◽  
Current Status ◽  
Friction Stir ◽  
Dissimilar Metal ◽  
Metal Materials

Aluminum (Al) and copper (Cu) have been widely used in many industrial fields thanks to their good plasticity, high thermal conductivity and excellent electrical conductivity. An effective joining of dissimilar Al and Cu materials can make full use of the special characteristics of these two metals. Friction stir spot welding (FSSW), as an efficient solid-state welding method suitable for joining of dissimilar metal materials, has great prospects in future industrial applications. In this paper, the FSSW studies on Al-Cu dissimilar materials are reviewed. The research progress and current status of Al-Cu FSSW are reviewed with respect to tool features, macroscopic characteristics of welded joints, microstructures, defects in welds and mechanical properties of joints. In addition, some suggestions on further study are put forward in order to promote the development and progress of Al-Cu FSSW studies in several respects: material flow, thermal history, addition of intermediate layer, auxiliary methods and functionalization of Al-Cu FSSW joint.

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