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.

Review on Research Status of Friction Stir Welding Technology

2011 ◽  
Vol 335-336 ◽  
pp. 379-382 ◽  
Author(s):  
De Fen Zhang ◽  
Fei Long ◽  
Xiao Wen Chen ◽  
Xiang Qian Wen ◽  
Hong Song Luo
Keyword(s):  
Friction Stir Welding ◽  
Energy Saving ◽  
Magnesium Alloys ◽  
Aluminium Alloys ◽  
Solid Phase ◽  
Development Prospect ◽  
Friction Stir ◽  
Research Status ◽  
Welding Technology ◽  
Joining Technology

Friction stir welding(FSW) as a new，environmental and energy-saving solid phase joining technology has become the focus of research in the welding field at home and abroad in recent years. The technical characteristics，microstructure and application status of Friction Stir Welding were elaborated in this paper，meanwhile the studying situation of Friction stir welding for aluminium alloys, magnesium alloys and so on was stated. Finally development prospect of FSW in welding field was analyzed.

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.

The Use of Extruded Profiles as Filling Material in Friction Stir Welding (FSW)

2009 ◽  
Vol 424 ◽  
pp. 137-144
Author(s):  
Lorenzo Donati ◽  
Luca Tomesani
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Base Material ◽  
Tensile Tests ◽  
Filling Material ◽  
Processing Conditions ◽  
Friction Stir ◽  
Optimal Processing ◽  
Extrude Profile

In this paper, an innovative approach is presented for joining two sheets with an extruded profile all made by AA6082-T6 aluminum alloy. The tested configuration is the T-joint and the innovation presented in this paper is the use of a specially design appendix of the extruded profile as filler material during the friction welding. In particular three configurations were analyzed: without appendix, with I appendix and with T appendix. In the experiments, several process parameters and PIN shapes were investigated in order to determine optimal processing conditions able to produce an effective sound weld. Specimens were extracted from the joint and tensile tests were performed along the sheet direction thus allowing a comparison of the welded sections respect to the base material. It was found that the appendixes of the extrude profile are able to effectively fill the distance between the sheets and, in particular with the T shape, a gap up to 1,7 mm on the retreating side was successfully welded.

scholarly journals Shoulder Related Temperature Thresholds in FSSW of Aluminium Alloys

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4375
Author(s):  
David G. Andrade ◽  
Sree Sabari ◽  
Carlos Leitão ◽  
Dulce M. Rodrigues
Keyword(s):  
Heat Generation ◽  
Process Parameters ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Spot Welding ◽  
Base Material ◽  
Main Process ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Diameter

Friction Stir Spot Welding (FSSW) is assumed as an environment-friendly technique, suitable for the spot welding of several materials. Nevertheless, it is consensual that the temperature control during the process is not feasible, since the exact heat generation mechanisms are still unknown. In current work, the heat generation in FSSW of aluminium alloys, was assessed by producing bead-on-plate spot welds using pinless tools. Coated and uncoated tools, with varied diameters and rotational speeds, were tested. Heat treatable (AA2017, AA6082 and AA7075) and non-heat treatable (AA5083) aluminium alloys were welded to assess any possible influence of the base material properties on heat generation. A parametric analysis enabled to establish a relationship between the process parameters and the heat generation. It was found that for rotational speeds higher than 600 rpm, the main process parameter governing the heat generation is the tool diameter. For each tool diameter, a threshold in the welding temperature was identified, which is independent of the rotational speed and of the aluminium alloy being welded. It is demonstrated that, for aluminium alloys, the temperature in FSSW may be controlled using a suitable combination of rotational speed and tool dimensions. The temperature evolution with process parameters was modelled and the model predictions were found to fit satisfactorily the experimental results.

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

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