Friction Stir Welding of Light Weight Sandwich Materials

2005 ◽  
Vol 6-8 ◽  
pp. 607-614 ◽  
Author(s):  
S. Dörfler ◽  
Andrea Otto
Keyword(s):  
Friction Stir Welding ◽  
Sheet Metal ◽  
Weld Seam ◽  
Solidus Temperature ◽  
Core Layer ◽  
Aluminum Sheet ◽  
Light Weight ◽  
Process Chain ◽  
Friction Stir ◽  
Temperature Capability

Ever since its invention, friction stir welding has been of great interest for the joining of light weight materials. Due to joining in the solid state, friction stir welding inheres characteristic advantages that are unmatched by conventional fusion welding techniques. At the Chair of Manufacturing Technology friction stir welding is employed to develop a process chain for the production of highly load adapted car body components out of aluminum sheet metal and aluminum foam sandwich (AFS) by tailored blanking. In contrast to friction stir welding other materials, special measures have to be taken, since AFS comprises a layered material structure out of two solid aluminum sheet metal cover layers and a powder metallurgically produced core layer. After welding, the tailored blank is subjected to forming, foaming and a final laser cutting process. High temperature capability of the weld seam must be assured, hence foaming of the powder metallurgic core layer requires temperatures of up to 95% of core layer-solidus temperature. Therefore not only mechanical properties are revealed, but also temperature capability is assessed by differential scanning calorimetry (DSC). Additionally the weld seams are tested during foaming by the use of special specimen geometry. Due to the high deformation and temperature while welding and foaming, the metallurgical structure at the weld seam undergoes some modifications, which are subject to metallographic analysis and hardness testing. As an outlook, new material developments towards 6000 aluminum alloys as cover sheet materials will be discussed with regard to the process chain.

Enhanced Numerical Results on Friction Stir Welded Aluminium Butt Joints

2007 ◽  
Vol 344 ◽  
pp. 759-766 ◽  
Author(s):  
Detlev Staud ◽  
Arthur Giera ◽  
Marion Merklein ◽  
Manfred Geiger
Keyword(s):  
Friction Stir Welding ◽  
Sheet Metal ◽  
Aluminium Alloys ◽  
Weld Seam ◽  
Fe Simulation ◽  
Solid Phase ◽  
Base Material ◽  
Tensile Tests ◽  
Tensile Specimen ◽  
Friction Stir

Friction stir welding is a newer technology to join materials in the solid phase. Therefore plenty of problems which appear by melting phase welding technologies for aluminium alloys are avoided by this process. This is the main chance for friction stir welding to be accepted and integrated in forthcoming applications, especially for uses out of aluminium alloys. Starting from former results for friction stir welding of aluminium this article deals with the determination of the constitutive material properties of friction stir welded aluminium tailored blanks with regard to the finite-element (FE) simulation of sheet metal forming. The FE simulation of the formability of welded sheet metal demands the knowledge of the precise mechanical properties of the base material as well as the characteristic zones of the weld seam, which are affected by friction stir welding. While ordinary tensile tests can only determine the constitutive behaviour of a simple tensile specimen, an optical strain measurement can be used to determine flow stresses of the base and of the welded material with an adapted tensile specimen, respectively. By the usage of the so called rule of mixture the advantages of this new approach is demonstrated with a comparison of the tensile forces within FE simulations and experimental validations. For this purpose specimen with the weld seam oriented perpendicular and parallel to the uniaxial loading direction are utilized.

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.

Friction Stir Welding of 3D Industrial Parts: Joint Strength Analysis

2006 ◽  
Author(s):  
Livan Fratini ◽  
Mario Piacentini
Keyword(s):  
Friction Stir Welding ◽  
Joint Strength ◽  
Fusion Welding ◽  
Strength Analysis ◽  
Light Weight ◽  
Industrial Environment ◽  
Friction Stir ◽  
Complex Shapes ◽  
3D Geometry ◽  
Welding Line

In the recent years Friction Stir Welding (FSW) has become an important joining technique since it allows to weld light weight alloys rather difficult to be welded or even “un-weldable” with the classic fusion welding operations. In the paper the authors present the application of the FSW process to the joining of 3D complex shapes typical of the industrial environment. In particular the research was aimed to highlight the joint mechanical strength at the varying of the 3D geometry of the welding line.

scholarly journals Evaluation of Tensile Toughness and Also Turnout Toughness of Abrasion Uproar Soldered Dissimilar Aluminium Lightweight Metal

2019 ◽  
Vol 8 (10) ◽  
pp. 1985-1989
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Light Weight ◽  
High Corrosion Resistance ◽  
Friction Stir ◽  
Jump Intensity ◽  
Welding Procedure ◽  
Effective Friction ◽  
Tensile Toughness

Aluminium alloys reveals good mechanical properties when soldered with Friction Stir welding. Thus to get these preferred mechanical properties, particular welding procedure parameters are to become examined. Nowadays aluminium alloys have actually been actually extensively used in industrial uses like aerospace and automobile as a result of their light weight, really good mechanical properties as well as high corrosion resistance. In this work, 3 process parameters including spindle rate, assembly rate and also jump intensity were actually looked at for abrasion rouse assembly. The paper pays attention to technique guidelines that sought after producing effective friction stir welding function.

scholarly journals Force feedback-based quality monitoring of the friction stir welding process utilizing an analytic algorithm

2020 ◽  
Author(s):  
P. Rabe ◽  
A. Schiebahn ◽  
U. Reisgen
Keyword(s):  
Friction Stir Welding ◽  
Monitoring System ◽  
Force Feedback ◽  
Weld Seam ◽  
Position Control ◽  
Welding Process ◽  
Quality Monitoring ◽  
Welding Parameters ◽  
Process Data ◽  
Friction Stir

AbstractThe friction stir welding (FSW) process is known as a solid-state welding process, comparatively stable against external influences. Therefore, the process is commonly used with fixed welding parameters, utilizing axial force control or position control strategies. External and internal process disturbances introduced by workpiece, gap tolerance, tool wear, or machine/tool inadequacies are rarely monitored, and conclusions about the weld seam quality, based on the recorded process data, are not drawn. This paper describes an advancement, improving on research into the correlation of process force feedback events or gradual force changes and the resulting weld seam characteristics. Analyzing the correlation between examined weld sections and high-resolution rate force data, a quality monitoring system based on an analytic algorithm is described. The monitoring system is able to accurately distinguish sound welds from such with internal (void) and external (flash) defects.

Review Paper on Hardness Improvement Studies on Friction Stir Welded Alloys

2020 ◽  
pp. 1-4
Author(s):  
Divya S ◽  
Kameshkumar A ◽  
Karthikeyan M ◽  
Kavin K R ◽  
Arun Kumar S
Keyword(s):  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Review Paper ◽  
Light Weight ◽  
Strength Of Materials ◽  
Friction Stir ◽  
Strong State ◽  
Improvement Method ◽  
Joining Process ◽  
Crude Material

Magnesium amalgam one of the significant crude material utilized in these businesses because of its light weight, great warm conductivity and so on. Additionally, Friction Stirs welding is the joining process that is being utilized in these businesses as it is a strong state joining process. A friction stir welding is widely used in automobile and aerospace sectors for smooth finishing and strength of materials, there is still scoped to take up further research in this area. In this paper, it is discussed the improvement method of friction stir welded magnesium alloy plates.

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