Friction Stir Forming for Mechanical Interlocking of Ultra-Thin Stainless Steel Strands and Aluminum Alloys

2018 ◽  
Vol 382 ◽  
pp. 114-119 ◽  
Author(s):  
Hamed Mofidi Tabatabaei ◽  
Tadashi Nishihara
Keyword(s):  
Stainless Steel ◽  
Aluminum Alloys ◽  
Tensile Tests ◽  
Al Alloys ◽  
Milling Machine ◽  
Mechanical Interlocking ◽  
Friction Stir ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Novel Method

In this study, a novel method of mechanical interlocking of super-thin stainless steel strands with different aluminum alloys was conducted by using friction stir forming (FSF). The potential for the development of a multi-functional composite material was studied experimentally. It was concluded that FSF can successfully interlock stainless steel strands and different Al alloys and presents the possibility of improving the mechanical properties of the alloy. Trials of FSF were carried out on a modified vertical milling machine. The results are discussed in terms of microstructure observations, hardness distributions and tensile tests.

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.

Reconfiguration of a Milling Machine to Achieve Friction Stir Welds

2012 ◽  
Vol 232 ◽  
pp. 86-91 ◽  
Author(s):  
Akinlabi Esther Titilayo ◽  
Madyira Daniel Makundwaneyi ◽  
Akinlabi Stephen Akinwale
Keyword(s):  
Control System ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Friction Stir Processing ◽  
Joint Strength ◽  
Milling Machine ◽  
Friction Stir ◽  
Backing Plate ◽  
Vertical Milling ◽  
Vertical Milling Machine

This paper reports on the reconfiguration of a milling machine to produce friction stir welds of aluminium and copper and friction stir processing of 6086 aluminium alloy. Friction stir welding tools were designed and manufactured from tool steel. The tools were inserted into the chuck of the milling machine. A backing plate was also specially designed and manufacturedfrom mild steel to protect the milling machine table and was placed on the bed with the use of T-nuts. The plates were secured firmly on the backing plate with the use of specially designed clamping fixtures. The varied welding speeds and the rotational speeds were achieved using the control system on the vertical milling machine. The reconfigured milling machine was successfully employed to produce friction stir processing of aluminium and friction stir welds of aluminium and copper. An optimum joint strength of 74% was achieved.

scholarly journals A Research on Friction Stir Welding using M42 Tool on Aisi 1018 Steel Plates

2019 ◽  
Vol 8 (12S) ◽  
pp. 362-366
Keyword(s):  
Friction Stir Welding ◽  
High Speed ◽  
High Speed Steel ◽  
Steel Plates ◽  
Milling Machine ◽  
Friction Stir ◽  
High Melting Temperature ◽  
Ferrous Material ◽  
Vertical Milling ◽  
Vertical Milling Machine

Friction Stir Welding was mainly suitable for aluminum alloys due to low softening temperatures. It is challenging to join the high melting temperature metals due to the lack of tool materials. The main focus of this work is to study the feasibility of joining the similar or dissimilar ferrous material. The molybdenum based high speed steel acts a rotating non consumable tool to weld the two ferrous plates. The friction stir welding was achieved using vertical milling machine. Welding samples were examined by destructive and nondestructive test. The welds were produced by 3 mm plate over a range of spindle speed from 500 to 1000 rpm. The results of FSW, stir zone of hardness varies from 139 to 145 HV executed on AISI 1018 plate steel.

Production of a Superplastic Vibration-Damping Steel Sheet Composite Using Friction Stir Forming

2016 ◽  
Vol 838-839 ◽  
pp. 574-580 ◽  
Author(s):  
Hamed Mofidi Tabatabaei ◽  
Takahiro Hara ◽  
Tadashi Nishihara
Keyword(s):  
Mechanical Properties ◽  
Steel Sheet ◽  
Superplastic Forming ◽  
Vibration Damping ◽  
Milling Machine ◽  
Mechanical Interlocking ◽  
Friction Stir ◽  
Superplastic Alloy ◽  
Novel Method ◽  
And Diffusion

This study proposes a novel method of manufacturing composite vibration-damping steel sheet with Zn-22Al superplastic alloy using friction stir forming (FSF). Trials of mechanical interlocking of steel sheet with Zn-22Al superplastic alloy using FSF were carried out on a modified milling machine. The results are discussed in terms of residual microstructures and mechanical properties. We concluded that cladding steel sheet with Zn-22Al superplastic alloy using FSF results in superplastic forming and diffusion bonding.

Mechanical Interlocking of Titanium and Steel Using Friction Stir Forming

2018 ◽  
Vol 792 ◽  
pp. 59-64
Author(s):  
Hamed Mofidi Tabatabaei ◽  
Shun Orihara ◽  
Tadashi Nishihara ◽  
Takahiro Ohashi
Keyword(s):  
Steel Sheet ◽  
Pure Titanium ◽  
Mechanical Interlocking ◽  
Titanium Plate ◽  
Screw Hole ◽  
Microstructural Observation ◽  
Friction Stir ◽  
Hardness Tests ◽  
Dissimilar Alloys ◽  
Novel Method

This study presents a novel method for mechanically interlocking dissimilar alloys of pure titanium with steel through using the principles of friction stir forming (FSF) technique. In present study, titanium plate is placed on top of a steel sheet containing a screwed hole. FSF is conducted on top of the titanium alloy, which produces sufficient heat to plasticize the alloy. This results in a flow of titanium into the screw hole in the steel, due to the plastic deformation, thereby mechanically interlocking titanium with the steel. The mechanical properties of the developed interlock are investigated through tensile and hardness tests and microstructural observation.

Mathematical Approach for Geometric Error Modeling of Three Axis CNC Vertical Milling Machine

2016 ◽  
Vol 842 ◽  
pp. 303-310 ◽  
Author(s):  
Widyanti Kwintarini ◽  
Agung Wibowo ◽  
Yatna Yuwana Martawirya
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
Machining Process ◽  
Cnc Machine Tools ◽  
Milling Machine ◽  
Cnc Machine ◽  
Geometrical Errors ◽  
Vertical Milling ◽  
Vertical Milling Machine ◽  
Accuracy And Repeatability

The aim of this paper overviews about to find out the errors that come from three axis CNC vertical milling machine. The errors come from, the CNC milling machine can be modelled into mathematical models and later on these error models will be used to analyse the errors in the measured data. Many errors from CNC machine tools have given significant effects toward the accuracy and repeatability of manufacturing process. There are two error sources come from CNC machine tools such as tool deflection and thermal distortions of machine tool structure. These errors later on will contribute to result in the geometrical deviations of moving axis in CNC vertical milling machine. Geometrical deviations of moving axis such as linear positioning errors, roll, pitch and yaw can be designated as volumetric errors in three axis machine tool. Geometrical deviations of moving axises happen at every axis in three axis CNC vertical milling machine. Geometrical deviations of moving axises in linear and angular movement has the amount of errors up to twenty one errors. Moreover, this geometrical errors play the major role in the total amount of errors and for that particular reason extra attention towards the geometrical deviation errors will be needed along machining process. Each of geometrical error of three axes vertical machining center is modeled using a homogeneous transformation matrix (HTM). The developed mathematical model is used to calculate geometrical errors at each axis and to predict the resultant error vector at the interface of machine tool and workpiece for error compensation.

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