The Extrinsic Influence of Tool Plunge Depth on Friction Stir Welding of an Aluminum Alloy

2011 ◽  
Vol 410 ◽  
pp. 206-215 ◽  
Author(s):  
K. Kandasamy ◽  
Satish V. Kailas ◽  
Tirumalai S. Srivatsan
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Rotation Speed ◽  
Tool Material ◽  
Traverse Speed ◽  
Test Machine ◽  
Plunge Depth ◽  
Friction Stir ◽  
Scientific Approach ◽  
Tool Rotation

The axial force during friction stir welding is sensitive to plunge depth of the tool and is one of the prime factors, which exercises control over heat generation during welding. Consequently, the plunge depth for a given tool rotation speed, traverse speed, material and test machine needs to be optimized so as to get a defect-free weld. In this paper, we present and briefly discuss the results of an elaborate and enriching investigation aimed at understanding the extrinsic influence of plunge depth of the tool on weld formation in aluminium alloy 7020-T6 for a range of rotation rate and traverse speed and using two different tools. The critical need for use of a scientific approach to optimize plunge depth for a given tool material and test machine in fewer number of steps is emphasized. Key Words: Friction Stir Welding, Tool Plunge, Rotation speed, Traverse speed, Aluminium Alloy 7020

scholarly journals PENGARUH TOOL ROTATION SPEED TERHADAP SIFAT MEKANIK SAMBUNGAN ALUMINIUM PADUAN 6061-T6 PADA PROSES FRICTION STIR WELDING

2019 ◽  
Vol 25 (3) ◽  
Author(s):  
Tarmizi Tarmizi ◽  
Riki Indrawan ◽  
Irfan Irfan
Keyword(s):  
Friction Stir Welding ◽  
Rotation Speed ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

PENGARUH TOOL ROTATION SPEED TERHADAP SIFAT MEKANIK SAMBUNGAN ALUMINIUM PADUAN 6061 T6 PADA PROSES FRICTION STIR WELDING. Pengelasan aduk tekan merupakan proses pengelasan yang baru dikembangkan pada tahun 1991, hingga saat ini berbagai penelitian terus dilakukan untuk menemukan parameter yang dapat menghasilkan sambungan las yang optimum sebagai alternatif proses pengelasan fusi yang masih memiliki beberapa kekurangan. Penelitian ini bertujuan untuk mengetahui pengaruh kecepatan putar tool yang menjadi salah satu parameter penting dalam friction stir welding pada pelat aluminium paduan 6061-T6 dengan tebal 6 mm terhadap sifat mekanik sambungan las, dengan variasi kecepatan putar yang digunakan 910 rpm, 1175 rpm, 1555 rpm, 1700 rpm dan 2000 rpm untuk mendapatkan parameter yang optimum. Berdasarkan penelitian yang telah dilakukan didapatkan hasil bahwa sambungan las dengan kecepatan putaran 910 rpm, 1175 rpm dan 1555 rpm tidak terdapat cacat dan memenuhi kriteria sambungan las berdasarkan standar AWS D17.3 sedangkan sambungan las yang memiliki sifat mekanik yang paling optimum yaitu sambungan las dengan kecepatan putar tool 910 rpm karena pengkasaran butir dan larutnya presipitat tidak terlalu signifikan dibandingkan dengan kecepatan putaran lainnya.Kata kunci: Pengelasan aduk tekan, pengelasan fusi, kecepatan putar, tool, aluminium paduan 6061-T6.

Studies on Friction Stir Welding of AA2014, AA6082 and AA7075 Simillar and Dissimillar Joints

2020 ◽  
Vol 37 ◽  
pp. 15-24
Author(s):  
P. Gunasekaran ◽  
K.T. Thilagham ◽  
D. Noorullah
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotation Speed ◽  
Hardness Distribution ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Profile ◽  
Tool Rotation

The joining of similar and dissimilar AA2014, AA6068 and AA7075 aluminium plates of 6mm thickness was carried out by friction stir welding (FSW) technique. FSW of Aluminium to Aluminium has caught significant consideration from assembling industries, such as Shipbuilding, Automotive, Railway and Aircraft generation. Here, the chosen process parameters are tilt angle (2º), tool rotation speed (900rpm) and transverse feed of (80mm/min) at constant axial force 2kN. An attempt was made to join the similar and dissimilar aluminium plate of 6 mm thickness with a conical tapered tool profile. Then, the effect of welding speed on microstructures, hardness distribution and tensile properties of the welded similar and dissimilar joints AA2014, AA6068 and AA7075 were investigated.

Path Force Control for Friction Stir Welding Processes

2008 ◽  
Author(s):  
Xin Zhao ◽  
Prabhanjana Kalya ◽  
Robert G. Landers ◽  
K. Krishnamurthy
Keyword(s):  
Friction Stir Welding ◽  
Force Control ◽  
Rotation Speed ◽  
Smith Predictor ◽  
Communication Delay ◽  
Pole Placement ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Welding Processes ◽  
Tool Rotation

In Friction Stir Welding (FSW) processes, force control can be used to achieve good welding quality. This paper presents the systematic design and implementation of a FSW path force controller. The path force is modeled as a nonlinear function of the FSW process parameters (i.e., plunge depth, tool traverse rate, and tool rotation speed). An equipment model, which includes a communication delay, is constructed to relate the commanded and measured tool rotation speed. Based on the dynamic process and equipment models, a feedback controller for the path force is designed using the Polynomial Pole Placement technique. The controller is implemented in a Smith Predictor–Corrector structure to compensate for the inherent equipment communication delay and the controller parameters are tuned to achieve the best closed loop response possible given equipment limitations. In the path force controller implementation, a constant path force is maintained, even in the presence of gaps, and wormhole generation during the welding process is eliminated by regulating the path force.

scholarly journals Parametric Optimization of Friction Stir Welding Factors (FSWF) for Yellow Brass 405-20

2021 ◽  
Author(s):  
Syed Farhan Raza ◽  
Sarmad Ali Khan ◽  
Muhammad Salman Habib ◽  
Naveed Ahmed ◽  
Kashif Ishfaq ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Weld Zone ◽  
Tool Material ◽  
Traverse Speed ◽  
Weld Strength ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Wide Range ◽  
Percent Contribution

Abstract Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. Industries are really interested in adopting FSW in its various applications e.g., automobile, aerospace, marine, construction, etc. FSW can successfully weld a wide range of materials (similar/dissimilar parent materials) including aluminum, copper, steel, different alloys from these materials, plastics, composites, and this material range is subjected to extension if FSW research efforts develop further in future. FSW of brass has already been accomplished by fewer researchers. In this research, yellow brass 405-20 is, therefore, welded with FSW that was never welded before. In this study, tool material utilized was M2 HSS that was also novel. Effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters i.e., weld temperature, weld strength and weld hardness. Weld temperature was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 82.78% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Based on main effects of Anova Analysis, optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in maximum (max.)/optimal temperature, max./optimal weld strength, and minimum/optimal hardness. Rotational speed (RS) was found to be significant to affect the weld temperature only at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. Transverse speed (TS) was found to be overall insignificant for affecting weld temperature, weld strength and hardness. However, PCR of transverse speed was found to be maximum for affecting weld strength as compared to its PCR towards both weld temperature and weld hardness. Error PCR was found to be the lowest for weld zone temperature, then for weld strength, and finally the highest for weld hardness. Interaction Plots (IPs) were also made for those FSWF which were found to be insignificant and to investigate any combined effect of FSWF on output parameters causing increased error PCR towards weld temperature, weld strength, and weld hardness.

scholarly journals Effect of Tool Rotation Speed on Mechanical Properties and Microstructure as the Results of Friction Stir Welding Method on Aluminium 5083-7075

2016 ◽  
Vol 27 (1) ◽  
pp. 9-17
Author(s):  
Maryati Maryati ◽  
Bambang Soegijono ◽  
M Yudi Masduky ◽  
Tarmizi Tarmizi
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Incomplete Fusion ◽  
Connection Form ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Speed Rotation ◽  
Tool Rotation

Friction Stir Welding (FSW) is a new method of welding process which is affordable and provide good quality. Aluminium 5083-7075 has been connected successfully by using friction stir welding (FSW) method into butt joint connection form. Tool rotation speed is one of the important parameters in FSW. The changes of rotation speed will affect the characteristics of mechanical properties and microstructure. The parameters of welding being used are welding speed of 29 mm/minutes by varying the speed rotation of 525 rpm, 680 rpm, 910 rpm, and 1555 rpm. In order to find out the mechanical strength of welds, tensile strength and hardness testing is done while finding out the microstructure will be done by using optical microscope and Scanning Electron Microscope (SEM). The result of the research showed that the highest tensile strength obtained at 910 rpm speed rotation about 244.85 MPa and the greatest hardness values was found on aluminium 5083 around the wheel zone area about 96 HV with rotary speed of 525 rpm. Then, the result of testing the macro and microstructure on all samples indicated defect which is seen as incomplete fusion and penetration causing the formation of onion rings. In other words, it is which showed that the result of stirring and tacking in the welding area is less than perfect.

Effect of welding parameters on mechanical properties and microstructure of friction stir welded brass joints

2018 ◽  
Vol 106 (6) ◽  
pp. 606 ◽  
Author(s):  
İnan Geçmen ◽  
Zarif Çatalgöl ◽  
Mustafa Kemal Bilici
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Stir Zone ◽  
Weld Strength ◽  
Welding Parameters ◽  
Feed Speed ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

Friction stir welding is a method developed for the welding of high-alloy aluminum materials which are difficult to combine with conventional welding methods. Friction stir welding of MS 63 (brass) plates used different tools (tapered cylindrical, tapered threaded cylindrical), tool rotational speeds (1040, 1500, 2080 rpm) and traverse speeds (30,45,75,113 mm.min−1). Tensile, bending, radiography and microstructure tests were carried out to determine the mechanical properties of brass plates joined by friction stir welding technique. Microstructure characterization studies were based on optical microscope and SEM analysis techniques. In addition, after joining operations, radiographs were taken to see the internal structure failure. Brass sheets were successfully joined to the forehead in the macrostructure study. In the evaluation of the microstructure, it was determined that there were four regions of base metal, thermomechanically affected zone (TMEB), heat-affected zone (HAZ) and stir zone. In both welding tools, the weld strength increased with increasing tool rotation speed. The particles in the stir zone are reduced by increasing of the tool rotation speed. Given the strength and % elongation values, the highest weld strength was achieved with tapered pin tool with a tool rotation speed of 1040 rpm and a tool feed speed of 113 min−1.

Effect of tool pin geometry on microstructure and mechanical properties of friction stir spot welds of 7075-T651 aluminium alloy

2021 ◽  
Vol 118 (1) ◽  
pp. 110
Author(s):  
Omer Ekinci ◽  
Zulkuf Balalan
Keyword(s):  
Aluminium Alloy ◽  
Fracture Mode ◽  
Impact Energy ◽  
Rotation Speed ◽  
Tensile Shear ◽  
Spot Welds ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Shear Loads ◽  
Tool Rotation

7075-T651 aluminium alloy sheets were overlapped and friction stir spot welded using two welding tools having different pin geometries (one with a conical pin and other with a triangular pin) and 800, 1200 and 1600 revolution per minute (rpm) tool rotation speeds at a constant tool plunge and removal speed of 7.3 mm/min, tool plunge depth of 3.8 mm and tool dwell time of 5 s. Microstructure, Vickers microhardness, tensile shear strength, fracture surface after tensile shear test and impact energy of the produced friction stir spot welds were examined. As a result, the welds made via triangular pin tool had considerably higher tensile shear loads than the welds made via conical pin tool since the weld bond widths (stir zones) of the welds made via triangular pin tool were larger. The strongest welds made at 1200 rpm for conical pin tool and triangular pin tool. The tensile shear loads of the welds increased significantly when tool rotation speed increased from 800 to 1200 rpm for both welding tools and then decreased slightly for triangular pin tool and dramatically for conical pin tool with further increasing tool rotation speed from 1200 to 1600 rpm. Maximum tensile shear load of 7.776 kN and impact energy of 16 J obtained in the weld made at 1200 rpm using triangular pin tool. The welds made at 800 rpm had lowest impact energy. The lowest hardness values found in the heat affected zones of the welds. Circumferential fracture mode for conical pin tool welds and nugget pull-out fracture mode for triangular pin tool welds observed after tensile tests.

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