Advances and Potentials in Friction Stir Welding of Aluminum Alloys

2016 ◽  
Vol 710 ◽  
pp. 137-142 ◽  
Author(s):  
Jean Pierre Bergmann ◽  
Michael Grätzel ◽  
René Schürer ◽  
Anna Regensburg ◽  
Markus Weigl
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Fusion Welding ◽  
Product Development Process ◽  
Cast Aluminum ◽  
Friction Stir ◽  
Cast Aluminum Alloys ◽  
Electrical Components ◽  
Welding Processes

Within the last decade, Friction Stir Welding (FSW) has increasingly been gaining relevance for joining nonferrous metals, especially aluminum alloys. Possible applications range from the aerospace and automotive sector up to manufacturing electrical components. Compared to conventional fusion welding processes, FSW offers numerous advantages, as it for example does not require shielding gas or filler material. However, FSW is still not applied or taken into account during the product development process in proportion to its potential. This is mainly caused by the lack of data in order to evaluate the process economically and differentiate it to other processes like arc and laser welding, also regarding technological factors. Therefore, this investigation focusses on the possibilities and limits when joining wrought and cast aluminum alloys, like EN AW-6082 T6, EN AW-7075 T651 and AlSi11Mg0,3, respectively, by FSW compared to MIG. The weld quality of the samples is characterized by tensile testing, hardness measurements and microstructure analysis. Furthermore, an approach to reduce the process forces by using FSW tools with reduced diameters and respectively adjusted process parameters is presented.

Friction Stir Welding of Dissimilar A319 and A413 Cast Aluminum Alloys

2014 ◽  
Vol 39 (8) ◽  
pp. 6363-6373 ◽  
Author(s):  
A. Karam ◽  
T. S. Mahmoud ◽  
H. M. Zakaria ◽  
T. A. Khalifa
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Cast Aluminum ◽  
Friction Stir ◽  
Cast Aluminum Alloys

Metallurgical Studies on the Friction Stir Welding of Dissimilar A356 and A413 Alloys

2012 ◽  
Vol 488-489 ◽  
pp. 345-349
Author(s):  
G. Elatharasan ◽  
V.S. Senthil Kumar
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Structural Characteristics ◽  
Grain Structure ◽  
Cast Aluminum ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Cast Aluminum Alloys ◽  
Welding Defects

Friction stir welding is a technique useful for joining aluminum alloys that are difficult to weld. In recent years, however the focuses has been on welding dissimilar aluminum alloys, and analyze their mechanical properties and micro-structural characteristics. In the present study, the less investigated welding of cast aluminum alloys is considered. Cast aluminum alloys, A356 and A413, commonly used in automotive and aerospace industries, were friction-stir welded and their mechanical properties and micro-structural characteristics were analyzed. On testing their welded region, no welding defects were observed. The welded region exhibited a maximum tensile strength of 90 N/mm2 and Vickers micro-hardness of 56.8. The micro-structural observations at the nugget region revealed a refined grain structure.

scholarly journals Performance evaluation of a novel force measuring device for Friction Stir Welding (FSW) of aluminum alloys

DYNA ◽  
2019 ◽  
Vol 86 (210) ◽  
pp. 150-155
Author(s):  
Elizabeth Hoyos Pulgarín ◽  
María Zuluaga-Posada ◽  
Yesid Montoya
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Force Measurement ◽  
Butt Joint ◽  
Fusion Welding ◽  
Significant Information ◽  
Measuring Device ◽  
Friction Stir ◽  
Aa 7075 ◽  
Welding Processes

Friction Stir Welding (FSW) has the advantage of generating sound welds on materials that generally present low weldability by traditional fusion welding processes, such as 2xxx and 7xxx aluminum alloys. Force measurement in FSW provides significant information about the process, the machine requirements, the effect of selected parameters, and weld soundness. In this paper, an axial force measuring device was designed, built, and tested to be used in a CNC adapted system. All tests were performed using AA 7075-T6 and a butt joint configuration. The forces obtained by the device match, in profile, key values, and trends, the ones found in literature which allows to conclude that this is a functional and sufficient device for the application.

Possibilities to Apply Friction Stir Processing FSP in Surface Engineering

2021 ◽  
Vol 890 ◽  
pp. 56-65
Author(s):  
Cristian Ciucă ◽  
Lia Nicoleta Boțilă ◽  
Radu Cojocaru ◽  
Ion Aurel Perianu
Keyword(s):  
Aluminum Alloys ◽  
Friction Stir Processing ◽  
Surface Engineering ◽  
Copper Alloys ◽  
Welding Process ◽  
Industrial Applications ◽  
Process Conditions ◽  
Cast Aluminum ◽  
Friction Stir ◽  
Cast Aluminum Alloys

The results obtained by ISIM Timisoara to the development of the friction stir welding process (FSW) have supported the extension of the researches on some derived processes, including friction stir processing (FSP). The experimental programs (the researches) were developed within complex research projects, aspects regarding the principle of the process, modalities and techniques of application, experiments for specific applications, being approached. The paper presents good results obtained by friction stir processing of cast aluminum alloys and copper alloys. The optimal process conditions, optimal characteristics of the processing tools were defined. The complex characterization of the processed areas was done, the advantages of the process applying being presented, especially for the cast aluminum alloys: EN AW 4047, EN AW 5083 and EN AW 7021. The characteristics of the processed areas are compared with those of the base materials. The results obtained are a solid basis for substantiating of some specific industrial applications, especially in the automotive, aeronautical / aerospace fields.

scholarly journals Design and Fabrication of Friction Stir Welding End-Effector for an ABB IRB1410 Robot

2016 ◽  
Vol 5 (2) ◽  
pp. 98
Author(s):  
Santosh Vanama
Keyword(s):  
Friction Stir Welding ◽  
High Strength ◽  
Fusion Welding ◽  
Fusion Temperature ◽  
End Effector ◽  
Friction Stir ◽  
Aluminum Sheets ◽  
Operation Pressure ◽  
Welding Processes ◽  
Tool Rotation

<p>The paper propose modelling and fabrication of friction stir welding end-effector for ABB IRB1410 robot. A dynamically developing version of pressure welding processes, join material without reaching the fusion temperature called friction stir welding. As friction stir welding occurs in solid state, no solidification structures are created thereby eliminating the brittle and eutectic phase’s common to fusion welding of high strength aluminium alloys. In this paper, Friction stir welding is applied to aluminum sheets of 2 mm thickness. A prototype setup is developed to monitor the evolution of main forces and tool temperature during the operation. Pressure of a gripper plays a major role for tool rotation and developing torque.  Fabrication of the tool has done. Force calculations are done by placing the sensors on the outer surface of gripper. Methods of evaluating weld quality are surveyed as well.</p>

Establishing the Dependence of Output Parameters Depending on Local Process Conditions for Friction Stir Welding of Pure Copper Plates

2018 ◽  
Vol 1146 ◽  
pp. 32-37 ◽  
Author(s):  
Marius Adrian Constantin ◽  
Ana Boşneag ◽  
Eduard Niţu ◽  
Lia Nicoleta Boţilă
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Speed ◽  
Frictional Heating ◽  
Pure Copper ◽  
Fusion Welding ◽  
Process Conditions ◽  
Friction Stir ◽  
Local Process ◽  
Welding Processes

Welding copper and its alloys is usually difficult to achieve by conventional fusion welding processes because of high thermal diffusivity of the copper, which is at least 10 times higher than most steel alloys, in addition to this, there are the well-known disadvantages of conventional fusion welding represented by necessity of using alloying elements, a shielding gas and a clean surface. To overcome these inconveniences, Friction Stir Welding (FSW), a solid state joining process that relies on frictional heating and plastic deformation, is being 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) which generates and adds heat to the process. The research includes two experiments for the FSW process and one experiment for tungsten inert gas assisted FSW process. The process parameters that varied were the rotational speed of the tool [rpm] and the welding speed [mm/min] while the compressive force remained constant. The purpose of this paper is to correlate the evolution of temperature, tensile strength, elongation and microscopic aspect with the linear position on the joint (local process parameters) for each experimental case and then make comparisons between them, and to identify and present the set of process parameters that has the best mechanical properties for this material.

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.

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