Experimental and Numerical Analysis on FSWed Magnesium Alloy Thin Sheets Obtained Using “Pin” and “Pinless” Tool

2012 ◽  
Vol 504-506 ◽  
pp. 747-752 ◽  
Author(s):  
Gianluca Buffa ◽  
Archimede Forcellese ◽  
Livan Fratini ◽  
Michela Simoncini
Keyword(s):  
Magnesium Alloy ◽  
Process Parameters ◽  
Material Flow ◽  
Base Material ◽  
Welding Process ◽  
Welding Parameters ◽  
Thin Sheets ◽  
Tool Geometries ◽  
Shoulder Diameter ◽  
Strength And Ductility

The present investigation aims at studying the effect of different tool geometries and process parameters on FSW of thin sheets in AZ31 magnesium alloy. In particular two properly designed tools, with shoulder diameters equal to 8 and 19 mm, were used; each of them was manufactured both in pin and pinless configurations. The effect of the different tool configurations and sizes, and welding parameters on mechanical properties of FSWed joints were analyzed in detail. The results were compared with those obtained on the base material. It was shown that FSWed joints are characterized by strength and ductility values lower than those of base material. Furthermore, the pin tool configuration, with a shoulder diameter of 8 mm, leads to the obtaining of strength and ductility values higher than those provided by the pinless one. A strong beneficial effect is obtained by increasing the shoulder diameter from 8 to 19 mm using the pinless configuration, whilst the FSW with the pin tool is critically affected by the welding conditions. The experimental work was joined to a numerical investigation based on finite element method (FEM) in order to study the material flow occurring during the welding process as well as the distribution of temperature, with the aim to identify a input window of the process parameters within which sound joints can be obtained.

Mechanical Properties and Corrosion Resistance of Friction Stir Welded Dissimilar Aluminum Alloys 2219 to 5083

2015 ◽  
Vol 813-814 ◽  
pp. 203-207
Author(s):  
M. Koilraj ◽  
A. Sathesh Kumar ◽  
D.L. Belgin Paul ◽  
S.R. Koteswara Rao
Keyword(s):  
Base Material ◽  
Welding Process ◽  
Weld Nugget ◽  
Welding Parameters ◽  
General Corrosion ◽  
Test Results ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Shoulder Diameter ◽  
Mechanical Properties And Corrosion

In this paper, 6 mm thickness dissimilar aluminium alloys of 5083 (H321) and 2219 (O) butt joints were fabricated successfully by friction stir welding process. The quality joints were obtained for the welding parameters of 35 mm/min and 650 rpm with the shoulder diameter to pin diameter ratio as 3. Macrostructure study shows that the interface between the weld nugget and TMAZ is smooth and clear with a flow arm extending towards the top surface of the weld in the 2219 side. The boundary on the 5083 side between the weld nugget and the TMAZ was irregular. The obtained joint efficiency is around 92.57% based on the UTS of the softer material (AA2219). The tensile test results showed that the specimens failed in the heat affected zone of the softer base material 2219. The hardness values in the stirred zone are higher than the softer base material of alloy 2219. The friction stir welded dissimilar joint 2219-5083 exhibited better general corrosion characteristics than the 2219-2219 weld and 2219 base material.

scholarly journals Forming and Properties of Friction Stir Welding Process for Dissimilar Mg Alloy

2015 ◽  
Vol 9 (1) ◽  
pp. 859-864
Author(s):  
Tielong Li ◽  
Zhenshan Wang
Keyword(s):  
Magnesium Alloy ◽  
Process Parameters ◽  
Welded Joints ◽  
Defect Formation ◽  
Base Material ◽  
Welding Process ◽  
Fracture Initiation ◽  
Line Defect ◽  
Influence Of Process Parameters ◽  
Friction Stir

For hot extrusions of magnesium alloy sheets, Dissimilar AZ80 and AZ31 were used, in which AZ80 was placed on advancing side and AZ31 on retreating side, using friction stir butt welding with different process parameters. Some defect-free welded joints with good weld surfaces could be obtained with some suitable welding conditions. The maximum tensile strength of welded joint which is 225.5 MPa can reach 98% that of the AZ31 base material. Influence of process parameters on defects, weld shaping and mechanical property were discussed systematically. And the microstructure of different zones was compared. The fracture of the welded joints takes place at the junction of mechanical heat affected zone and nugget zone in AZ31 magnesium alloy set retreating side, since existing difference in metallographic structure of alloy diversely suffered by heat, pressure and depositing impurities. Fracture initiation site may be the P line defect which should be eliminated, and the P line defect formation was analyzed.

scholarly journals A Weighting Grade-Based Optimization Method for Determining Refill Friction Stir Spot Welding Process Parameters

2019 ◽  
Vol 28 (10) ◽  
pp. 6471-6482
Author(s):  
Rafał Kluz ◽  
Andrzej Kubit ◽  
Tomasz Trzepiecinski ◽  
Koen Faes ◽  
Wojciech Bochnowski
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Spot Welding ◽  
Load Capacity ◽  
Base Material ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir

Abstract The welding process used in fabricating thin-walled structures by refill friction stir spot welding (RFSSW) should be characterized by a high strength of welds and high process repeatability which is demonstrated by a small dispersion of the load capacity of the joints. The present work is designed to optimize RFSSW process parameters for 7075-T6 Alclad aluminum alloy sheets used to fabricate aircraft structures. The optimization was performed by scalarization of the objective function using the weighting grades method. The study considers the effect of process parameters, i.e., tool plunge depth, duration of welding, tool rotational speed, on the tensile/shear strength of the joints, and dispersion of the load capacity. It was found that it was possible to choose the optimal welding parameters taking into account maximization of the load capacity and minimization of the dispersion of the joint strength via a best compromise between the tool rotational speed ensuring adequate plasticization of the base material and the duration of welding ensuring that a fine-grained joint microstructure is obtained.

Effect of Friction Stir Welding Parameters on Thermal and Tensile Behavior of Aluminum Weldments Using Double Shoulder Tools

2012 ◽  
Vol 622-623 ◽  
pp. 323-329
Author(s):  
Ebtisam F. Abdel-Gwad ◽  
A. Shahenda ◽  
S. Soher
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Tensile Behavior ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Friction Stir ◽  
Aluminum Base ◽  
Tool Pin ◽  
Strength And Ductility

Friction stir welding (FSW) process is a solid state welding process in which the material being welded does not melt or recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters and tool pin profile play major roles in deciding the weld quality. In this investigation, an attempt has been made to understand effects of process parameters include rotation speeds, welding speeds, and pin diameters on al.uminum weldment using double shoulder tools. Thermal and tensile behavior responses were examined. In this direction temperatures distribution across the friction stir aluminum weldment were measured, besides tensile strength and ductility were recorded and evaluated compared with both single shoulder and aluminum base metal.

Experimental Investigations on Aluminium Ultrasonic Welding Parameters

2014 ◽  
Vol 657 ◽  
pp. 306-310
Author(s):  
Lăcrămioara Apetrei ◽  
Vasile Rață ◽  
Ruxandra Rață ◽  
Elena Raluca Bulai
Keyword(s):  
Microstructural Analysis ◽  
Base Material ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Experimental Investigations ◽  
Welding Parameters ◽  
Material Structure ◽  
Welding Temperature ◽  
Wide Range ◽  
Made In

Research evolution timely tendencies, in the nonconventional technologies field, are: manufacture conditions optimization and complex equipments design. The increasing of ultrasonic machining use, in various technologies is due to the expanding need of a wide range materials and high quality manufacture standards in many activity fields. This paper present a experimental study made in order to analyze the welded zone material structure and welding quality. The effects of aluminium ultrasonic welding parameters such as relative energy, machining time, amplitude and working force were compared through traction tests values and microstructural analysis. Microhardness tests were, also, made in five different points, two in the base material and three in the welded zone, on each welded aluminium sample. The aluminum welding experiments were made at the National Research and Development Institute for Welding and Material Testing (ISIM) Timişoara. The ultrasonic welding temperature is lower than the aluminium melting temperature, that's so our experiments reveal that the aluminium ultrasonic welding process doesn't determine the appearance of moulding structure. In the joint we have only crystalline grains deformation, phase transformation and aluminium diffusion.

Comparison between Modelled Influence of GMAW Parameters and Corresponding Mechanical Properties of Group 1 and 2 According to ISO/TR 15608 Steel T Joints

2021 ◽  
Vol 890 ◽  
pp. 17-24
Author(s):  
Aurel Valentin Bîrdeanu ◽  
Alin Constantin Murariu ◽  
Horia Florin Daşcău ◽  
Iuliana Duma
Keyword(s):  
Process Parameters ◽  
High Performance ◽  
Hsla Steel ◽  
Welding Process ◽  
High Strength ◽  
Industrial Applications ◽  
Steel Plates ◽  
Experimental Program ◽  
Welding Parameters ◽  
T Joints

Reproducibility in respect to welded structures realization is one of the main requirements for a wide variety of industrial applications. One of the international tendencies regarding the use of the steel is the replacing, in critical areas, of structural steels with high performance steel, e.g. with HSLA steels. The paper presents the results of a factorial designed experimental program focused on determining mathematical correlations between the GMAW process parameters for T joints of 4mm thick steel plates of structural (S235JR+AR according to SR EN 10025-2) and hot-rolled, high-strength low-alloy (HSLA) steel plates (S420MC according to EN 10025-4), respectively. A comparison between the obtained mathematical correlations that connect the welding parameters and the main mechanical characteristics is presented. The correlations can be used for applying the optimal combination of welding process parameters for realizing the T-joints of welded products.

Microstructure and Impact Load Performance of Friction Stir Welded Joint of AZ31B Magnesium Alloy

2020 ◽  
Vol 866 ◽  
pp. 54-62
Author(s):  
Hong Feng Wang ◽  
Sheng Rong Liu ◽  
Xiao Le Ge ◽  
Jia Fei Pu ◽  
Lei Bao ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Impact Load ◽  
Base Material ◽  
Welding Parameters ◽  
Loading Test ◽  
Az31b Magnesium Alloy ◽  
Friction Stir ◽  
Joint Area ◽  
The Impact

10mm thickness AZ31B magnesium alloy was used as the friction stir welding object in this study. Different welding joints were obtained by setting different friction stir welding parameters. Metallographic analysis and impact loading test were carried out on the joint area. The experiment results show that (i) when the rotational speed of the stirring head is 600rpm and the welding speed is 120mm/min, the microstructure of the joint has the characteristics of compactness, thinning, and large-area twinning, which is beneficial to improve the plasticity of the joint area; (ii) the impact load of the joint is the highest, but lower than that of the base material, which is 95.5% of the base material; (iii) the fracture of impact specimen presents ductile fracture.

Recommendations for Submerged Arc Spiral Welding With Optimized CTOD Properties

2018 ◽  
Author(s):  
Martin Liebeherr ◽  
Özlem E. Güngör ◽  
Nuria Sanchez ◽  
Hervé Luccioni ◽  
Nenad Ilic
Keyword(s):  
Weld Metal ◽  
Base Material ◽  
Welding Process ◽  
Experimental Program ◽  
Welding Parameters ◽  
Pipe Production ◽  
Filler Wire ◽  
Crack Tip Opening Displacement ◽  
Wide Range ◽  
Submerged Arc

Many pipe mills may not be familiar with a Crack Tip Opening Displacement (CTOD) requirement on the pipe seam weld, nor will they find easily relevant information in open literature. Influencing — and certainly not independent — factors are: welding parameters, base material and consumable selection. Out of these, the welding parameters such as heat input and cooling rate cannot be varied over a wide range during the pipe production, which means that the leverage is rather limited at the given welding process. The properties of the heat affected zone will be mainly affected by the base material, while the properties of the weld metal will be affected by both, base material and filler wire selection. In particular with respect to the weld metal properties it will be difficult to obtain general quantitative information. For example, a welding consumable supplier will readily provide the properties of the filler wires but would be unable to predict the changes caused by the dilution from any base material in the weld pool and specific welding procedures that may have been used. To support the pipe mills in the selection of the consumables for submerged arc welding, an experimental program was launched with the aim to provide recommendations on how to optimize CTOD toughness of the spiral weld seam. For this, a large number of welds were produced on 20 mm thick X70 coil samples, with eight different filler wire combinations, using a 2-wire (tandem) set-up for both the inside and outside weld. Welding parameters were kept constant. The welding program was applied to two different X70 steels to determine a potential influence of the micro-alloying elements, particularly Nb. The results show clearly that a careful consumable selection is required for obtaining acceptable CTOD toughness in the weld metal. Ni-Mo and Ti-B additions to the weld metal are found to be beneficial with both steel concepts. Mo addition alone both to the ID and OD welds was clearly not a suitable selection.

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