A Comparison Study between Friction Stir Welding and Metal Inert Gas Welding in Joining Similar Al-Al Strips

2014 ◽  
Vol 925 ◽  
pp. 180-184 ◽  
Author(s):  
Hasan I. Dawood ◽  
Kahtan S. Mohammed ◽  
Mumtaz Y. Rajab ◽  
Nurafifah R. Ismail
Keyword(s):  
Friction Stir Welding ◽  
Arc Welding ◽  
Pure Aluminum ◽  
Welding Process ◽  
Cost Effective ◽  
Power Input ◽  
Butt Joint ◽  
Inert Gas ◽  
Friction Stir ◽  
Welding Processes

In this study, two sets of pure aluminum strips 3 mm in thickness were friction stir welding (FSW) together in a regular Butt joint pattern. Two rotational speeds of 1750 RPM and 2720 RPM were utilized to perform the welding process. The transverse speed and the axial load were kept constant at 45 mm/min and 6.5 kN respectively. As a welding tool, cylindrical shoulder and pin geometry was selected. For comparison purposes other similar strip pair sets were butt welded using the conventional metal inert gas arc welding technique (MIGAW). The welding quality, power input, microstructure, macrostructure and the mechanical properties of the weld joints yielded from these two welding techniques were examined. The types of the fumes and the amount of the released gases during these two welding processes were measured and compared. The results proved that the solid state friction stir welding is clean, cost effective and environment friendly process as opposed to the conventional metal inert gas arc welding.

Friction Stir and Gas Tungsten Arc Welding of ZM21 Magnesium Alloy

2014 ◽  
Vol 909 ◽  
pp. 77-82
Author(s):  
Hari Krishna Kallipudi ◽  
Rama Koteswara Rao Sajja ◽  
Venkata Subba Rao Veera
Keyword(s):  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Arc Welding ◽  
Welding Process ◽  
Gas Tungsten Arc Welding ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Gas Tungsten Arc ◽  
Gas Tungsten ◽  
Welding Processes

Magnesium alloy ZM21 plates were welded using friction stir welding, a solid state process and gas tungsten arc welding which is a fusion welding process. Defect free, full penetration welds were obtained after several trials using different process parameters. The effect of welding processes on mechanical properties of Mg-Zn-Mn joints were evaluated using tensile tests, bend test, vickers micro hardness measurements and optical microscopy. Welds produced by Friction stir welding process exhibited superior tensile properties compared to Gas Tungsten Arc Welding process. Hardness reduction in the weld metals were observed for both the welding techniques. Friction stir welds showed finer grains in the weld nugget and in the heat affected zone. Both types of welds exhibited good bend ductility comparable to that of the base material. It has been concluded that both the processes are well suited to obtain sound welds of the magnesium alloy ZM21 and Friction stir welding process offers stronger welds.

scholarly journals Comparative study on microhardness between friction stir welding and tungsten inert gas assisted friction stir welding of pure copper

2018 ◽  
Vol 178 ◽  
pp. 03002 ◽  
Author(s):  
Marius Adrian Constantin ◽  
Ana Boşneag ◽  
Eduard Niţu ◽  
Monica Iordache
Keyword(s):  
Friction Stir Welding ◽  
Pure Copper ◽  
Welding Process ◽  
Fusion Welding ◽  
Inert Gas ◽  
Friction Stir ◽  
Temperature Loss ◽  
High Thermal Diffusivity ◽  
Welding Processes ◽  
Solid State Joining

Welding copper and its alloys is usually difficult to achieve by conventional fusion welding processes because of high thermal diffusivity of copper, which is at least 10 times higher than most steel alloys. In order to reduce the increased temperature loss, it would be advantageous to use a process that is carried out at lower temperatures. Friction Stir Welding (FSW) is a solid state joining process that involves the joining of two metal pieces at the molecular level without melting and was explored as a feasible welding process. In order to achieve an increased welding speed and a reduction in tool wear, this process is assisted by another one (TIG - tungsten inert gas) which generates and adds heat to the process. The research includes two experiments for the FSW process and two experiments for TIG assisted FSW process. It is presented the evolution of the temperature and of the axial force during the process and is determined the microhardness for each experimental case. The aim of this paper is to make known the effects of using TIG assisted FSW process on the microhardness of the pure copper joints and to present some conditions in which it is less affected.

Microstructural Effects between AHSS Dissimilar Joints Using MIG and TIG Welding Process

2015 ◽  
Vol 1766 ◽  
pp. 29-35 ◽  
Author(s):  
G.Y. Pérez Medina ◽  
M. Padovani ◽  
M. Merlin ◽  
A.F. Miranda Pérez ◽  
F.A. Reyes Valdés
Keyword(s):  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
High Hardness ◽  
Inert Gas ◽  
Mechanical Degradation ◽  
Low Alloy Steels ◽  
Dissimilar Joints ◽  
Lap Shear ◽  
Welding Processes

ABSTRACTGas tungsten arc welding-tungsten inert gas (GTAW-TIG) is focused in literature as an alternative choice for joining high strength low alloy steels; this study is performed to compare the differences between gas metal arc welding-metal inert gas (GMAW-MIG) and GTAW welding processes. The aim of this study is to characterize microstructure of dissimilar transformation induced plasticity steels (TRIP) and martensitic welded joints by GMAW and GTAW welding processes. It was found that GMAW process lead to relatively high hardness in the HAZ of TRIP steel, indicating that the resultant microstructure was martensite. In the fusion zone (FZ), a mixture of phases consisting of bainite, ferrite and small areas of martensite were present. Similar phase’s mixtures were found in FZ of GTAW process. The presence of these mixtures of phases did not result in mechanical degradation when the GTAW samples were tested in lap shear tensile testing as the fracture occurred in the heat affected zone. In order to achieve light weight these result are benefits which is applied an autogenous process, where it was shown that without additional weight the out coming welding resulted in a high quality bead with homogeneous mechanical properties and a ductile morphology on the fracture surface. Scanning electron microscopy (SEM) was employed to obtain information about the specimens that provided evidence of ductile morphology.

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.

A Friction Stir Welding Platform of Thin Plates

2012 ◽  
Vol 628 ◽  
pp. 206-210 ◽  
Author(s):  
Jia Liang Zhang ◽  
Bei Zhi Li ◽  
Xin Chao Zhang ◽  
Qing Xia Wang
Keyword(s):  
Friction Stir Welding ◽  
Virtual Instrument ◽  
Production Efficiency ◽  
Cost Effective ◽  
Field Analysis ◽  
Sensor Data ◽  
Thin Plates ◽  
Increase Production Efficiency ◽  
Friction Stir ◽  
Welding Processes

Friction stir welding processes involve many variables. Engineers and operators often find it difficult to effectively design or control it. The objective of this work is to develop a friction stir welding platform of thin plates to improve welding quality and to increase production efficiency. The study is conducted by using finite element modeling and temperature field analysis technology to obtain optimization parameters, and using virtual instrument, multi-sensor data fusion to monitor the force of the stirring spindle. Experiment results show that the developed platform can reach the requirements of processing quality and is cost-effective.

Microstructure and mechanical properties of ADC12/6063-T6 aluminum alloy butt joint achieved by metal inert gas groove welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2120-2124
Author(s):  
Ye Wang ◽  
Mi Zhao ◽  
Hongyu Xu ◽  
Maoliang Hu ◽  
Zesheng Ji
Keyword(s):  
Mechanical Properties ◽  
Arc Welding ◽  
Welding Process ◽  
Weld Interface ◽  
Butt Joint ◽  
Inert Gas ◽  
Butt Joints ◽  
Arc Welding Process ◽  
The Impact ◽  
Silicon Particles

Metal inert gas arc welding process was implemented to join 6063T6 wrought alloy and ADC12 die-casting alloy using ER4047 filler metal. The microstructure of the weld seam and weld interface was investigated. The bonding strength of the butt joints was tested by Charpy U-notch impact test and tensile test. The results showed that a sound welding butt joint with finely silicon particles and excellent mechanical properties was formed, and the size of the silicon particles was nearly 2 μm. Compared with 6063T6 wrought alloy, the impact absorbing energies and the tensile strengths of the butt joint were higher and reached 1.173 kJ/cm2 and 205 MPa, respectively, and the fractures of all tensile specimens occur at the 6063T6 aluminum.

scholarly journals Effect of Trailing Intensive Cooling on Residual Stress and Welding Distortion of Friction Stir Welded 2060 Al-Li Alloy

2018 ◽  
Vol 37 (5) ◽  
pp. 397-403 ◽  
Author(s):  
Shude Ji ◽  
Zhanpeng Yang ◽  
Quan Wen ◽  
Yumei Yue ◽  
Liguo Zhang
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Plastic Strain ◽  
Welding Process ◽  
Butt Joint ◽  
Welding Distortion ◽  
Welding Temperature ◽  
Friction Stir ◽  
Numerical Simulation Methods ◽  
Conventional Cooling

AbstractTrailing intensive cooling with liquid nitrogen has successfully applied to friction stir welding of 2 mm thick 2060 Al-Li alloy. Welding temperature, plastic strain, residual stress and distortion of 2060 Al-Li alloy butt-joint are compared and discussed between conventional cooling and trailing intensive cooling using experimental and numerical simulation methods. The results reveal that trailing intensive cooling is beneficial to shrink high temperature area, reduce peak temperature and decrease plastic strain during friction stir welding process. In addition, the reduction degree of plastic strain outside weld is smaller than that inside weld. Welding distortion presents an anti-saddle shape. Compared with conventional cooling, the reductions of welding distortion and longitudinal residual stresses of welding joint under intense cooling reach 47.7 % and 23.8 %, respectively.

A study on sustainability assessment of welding processes

2019 ◽  
Vol 234 (3) ◽  
pp. 501-512 ◽  
Author(s):  
Jaber Jamal ◽  
Basil Darras ◽  
Hossam Kishawy
Keyword(s):  
Arc Welding ◽  
Social Impact ◽  
Sustainability Assessment ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Friction Stir ◽  
Gas Tungsten Arc ◽  
Metal Arc Welding ◽  
Sustainability Assessments ◽  
Welding Processes

The concept of “sustainability” has recently risen to take the old concept of going “green” further. This article presents general methodologies for sustainability assessments. These were then adapted to measure and assess the sustainability of welding processes through building a complete framework, to determine the best welding process for a particular application. To apply this methodology, data about the welding processes would be collected and segregated into four categories: environmental impact, economic impact, social impact, and physical performance. The performance of each category would then be aggregated into a single sustainability score. To demonstrate the capability of this methodology, case studies of three different welding processes were performed. Friction stir welding obtained the highest overall sustainability score compared to gas tungsten arc welding and gas metal arc welding.

Evaluation of dissimilar joints properties of 5083-H12 and 6061-T6 aluminum alloys produced by tungsten inert gas and friction stir welding

2015 ◽  
Vol 231 (3) ◽  
pp. 297-308 ◽  
Author(s):  
Morteza Ghaffarpour ◽  
Mohammad Kazemi ◽  
Mohammad Javad Mohammadi Sefat ◽  
Ahmad Aziz ◽  
Kamran Dehghani
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Traverse Speed ◽  
Inert Gas ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
The Difference ◽  
Welding Processes

In the present study, friction stir welding (FSW) and tungsten inert gas (TIG) techniques were used to join the dissimilar aluminum alloys of 5083-H12 and 6061-T6. The laboratory tests were designed using design of experiment (DOE) method. Variables for the FSW process were the rotational speed, traverse speed, shoulder diameter, and pin diameter. They changed in ranges of 700–2500 r/min, 25–400 mm/min, 10–14 mm, and 2–4 mm, respectively. In the case of TIG process, the variables were current intensity, traverse speed, and tilt angle. These parameters varied from 80 to 90 A, 200 to 400 mm/min, and 3° to 12°, respectively. The optimum amounts of parameters were obtained using response surface methodology (RSM). The RSM-based model was developed to predict ultimate tensile strength (UTS) of the welds produced. In FSW, the difference between predicted and measured UTS was about 1.28% and in TIG it was 1.78%. The good agreement between experimental and predicted results indicates the high accuracy of the developed model. Mechanical properties and also the microstructure of the welds were compared after optimizing both welding processes using RSM. The results showed that the welds produced by FSW indicated a considerably higher quality and also improved mechanical properties compared to TIG. Properties of the joints obtained by FSW in single-sided joints were more desirable. In the double-sided welds obtained by FSW these differences were of an even higher significance.

Numerical Study of the Tool Rake Angle Effect on the Material Flow in Friction Stir Welding Process

2007 ◽  
Author(s):  
Hosein Atharifar ◽  
Radovan Kovacevic
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Numerical Study ◽  
Welding Process ◽  
Rake Angle ◽  
Heat Transfer Analysis ◽  
Tool Geometry ◽  
Friction Stir ◽  
Tool Pin ◽  
Welding Processes

Minimizing consumed energy in friction stir welding (FSW) is one of the prominent considerations in the process development. Modifications of the FSW tool geometry might be categorized as the initial attempt to achieve a minimum FSW effort. Advanced tool pin and shoulder features as well as a low-conductive backing plate, high-conductive FSW tools equipped with cooling fins, and single or multi-step welding processes are all carried out to achieve a flawless weld with reduced welding effort. The outcomes of these attempts are considerable, primarily when the tool pin traditional designs are replaced with threaded, Trifiute or Trivex geometries. Nevertheless, the problem remains as to how an inclined tool affects the material flow characteristics and the loads applied to the tool. It is experimentally proven that a positive rake angle facilitates the traverse motion of the FSW tool; however, few computational evidences were provided. In this study, numerical material flow and heat transfer analysis are carried out for the presumed tool rake angle ranging from −4° to 4°. Afterwards, the effects of the tool rake angle to the dynamic pressure distribution, strain-rates, and velocity profiles are numerically computed. Furthermore, coefficients of drag, lift, and side force and moment applied to the tool from the visco-plastic material region are computed for each of the tool rake angles. Eventually, this paper confirms that the rake angle dramatically affects the magnitude of the loads applied to the FSW tool, and the developed advanced numerical model might be used to find optimum tool rake angle for other aluminum alloys.

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