A Study on Friction Stir Welding Process for AA2219/AA2195 Joints

2018 ◽  
Vol 762 ◽  
pp. 339-342
Author(s):  
Ho Sung Lee ◽  
Koo Kil No ◽  
Joon Tae Yoo ◽  
Jong Hoon Yoon
Keyword(s):  
Friction Stir Welding ◽  
Welded Joints ◽  
Rotation Speed ◽  
Microstructural Analysis ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Manufacturing Cost ◽  
Significant Saving ◽  
Friction Stir ◽  
Rotation Direction

The object of this study was to study mechanical properties of friction stir welded joints of AA2219 and AA2195. AA2219 has been used as an aerospace materials for many years primarily due to its high weldability and high specific strength in addition to the excellent cryogenic property so to be successfully used for manufacturing of cryogenic fuel tank for space launcher. Relatively new Aluminum-Lithium alloy, AA2195 provides significant saving on weight and manufacturing cost with application of friction stir welding. Friction stir welding is a solid-state joining process, which use a spinning tool to produce frictional heat in the work piece. To investigate the effect of the rotation direction of the tool, the joining was performed by switching the positions of the two dissimilar alloys. The welding parameters include the travelling speed, rotation speed and rotation direction of the tool, and the experiment was conducted under the condition that the travelling speed of the tool was 120-300 mm/min and the rotation speed of the tool was 400-800 rpm. Tensile tests were conducted to study the strength of friction stir welded joints and microhardness were measured with microstructural analysis. The results indicate the failure occurred in the relatively weaker TMAZ/HAZ interface of AA2219. The optimum process condition was obtained at the rotation speed of 600-800 rpm and the travelling speed of 180-240 mm/min.

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.

Influences of Tool pin Profile and Tool Shoulder Curvature on the Formation of Friction Stir Welding Zone in AA6061 Aluminium Alloy

2012 ◽  
Vol 445 ◽  
pp. 789-794 ◽  
Author(s):  
Vahid Moosabeiki ◽  
Ghasem Azimi ◽  
Mostafa Ghayoor
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Zone Formation ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Tool Shoulder ◽  
Aa6061 Aluminium Alloy ◽  
Tool Pin

Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the weld quality. Friction stir tool plays a major role in friction stir welding process. In this investigation, it is tried to evaluate the effect of tool pin thread and tool shoulder curvature on FSW zone formation in AA6061 aluminium alloy. In this regard, six different tool pin geometries (threadless triangular pin with/without conical shoulder, threaded triangular pin with conical shoulder, threadless square pin with/without conical shoulder, threaded square pin with conical shoulder) are used to fabricate the joints. The formation of FSP zones are analyzed macroscopically. Tensile properties of the joints are evaluated and correlated with the FSP zone formation. Consequently, it is obtained that welding creates a higher quality compared to other tool pin profiles using the square tool with curved shoulder and having threaded pin.

Effect of welding parameters on mechanical properties and microstructure of friction stir welded brass joints

2018 ◽  
Vol 106 (6) ◽  
pp. 606 ◽  
Author(s):  
İnan Geçmen ◽  
Zarif Çatalgöl ◽  
Mustafa Kemal Bilici
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Stir Zone ◽  
Weld Strength ◽  
Welding Parameters ◽  
Feed Speed ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

Friction stir welding is a method developed for the welding of high-alloy aluminum materials which are difficult to combine with conventional welding methods. Friction stir welding of MS 63 (brass) plates used different tools (tapered cylindrical, tapered threaded cylindrical), tool rotational speeds (1040, 1500, 2080 rpm) and traverse speeds (30,45,75,113 mm.min−1). Tensile, bending, radiography and microstructure tests were carried out to determine the mechanical properties of brass plates joined by friction stir welding technique. Microstructure characterization studies were based on optical microscope and SEM analysis techniques. In addition, after joining operations, radiographs were taken to see the internal structure failure. Brass sheets were successfully joined to the forehead in the macrostructure study. In the evaluation of the microstructure, it was determined that there were four regions of base metal, thermomechanically affected zone (TMEB), heat-affected zone (HAZ) and stir zone. In both welding tools, the weld strength increased with increasing tool rotation speed. The particles in the stir zone are reduced by increasing of the tool rotation speed. Given the strength and % elongation values, the highest weld strength was achieved with tapered pin tool with a tool rotation speed of 1040 rpm and a tool feed speed of 113 min−1.

Investigation on Friction Stir Welding Parameters of Aluminium Metal Matrix Composites

2019 ◽  
Vol 11 (2) ◽  
Author(s):  
M. Sucharitha ◽  
B. Ravisankar
Keyword(s):  
Friction Stir Welding ◽  
Metal Matrix ◽  
Rotation Speed ◽  
Friction Stir Weld ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Wide Range ◽  
Tool Rotation ◽  
Aluminium Metal

Friction stir welding could be a solid-state welding has a wide range of applications in industries like aerospace and automobile industries. In this work, the friction stir weld ability of aluminium metal matrix composite(AMMC) using H13 tool and sensitivity of parameters like tool rotation speed, traverse speed and axial force are assessed on final durability, hardness and microstructure. It was observed that the tensile strength and hardness are increased by increasing the tool rotation speed. The microstructure showed fine Al-Mg-Si eutectic particles in a matrix of Al solid solution.

Microstructural Assessment of Copper Friction Stir Welds

2009 ◽  
Vol 131 (3) ◽  
Author(s):  
A. Polar ◽  
J. E. Indacochea
Keyword(s):  
Grain Size ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Microstructural Analysis ◽  
Welding Parameters ◽  
Optimum Process ◽  
Cnc Milling ◽  
Friction Stir ◽  
The Difference ◽  
Electron Microscopes

Friction stir welding (FSW) of electrolytic tough pitch copper plates was conducted using a conventional CNC milling machine. The microstructure evolution of the weld was correlated with the process parameters used in the study and in conjunction with increasing temperatures during processing. When the optimum process parameters were achieved, a sound weld joint was obtained. The weldments were evaluated by microstructural analysis, using optical and scanning electron microscopes, and in terms of mechanical properties. At early stages of FSW and/or when using less than optimum welding parameters low temperatures result, metal does not plasticize effectively producing defects, such as large cavities, porosity, and poor bonding, due to the lack of plasticized material. Cavities were found at the advancing region of the weld, and in this area the finest grains were observed from the entire weld. The cavities were reduced, and the grain size increased further along in the weld as the temperature increased also. The typical weld nugget found in the friction stir welding of other metals was not observed in this case. Dynamic recrystallization was observed in the “stirred zone” of the weld; considering that the strain rate in this region was the same in all three cases, the difference in grain size was attributed to the differences in process temperature.

scholarly journals Study of the Forces Generated during Nonlinear Friction Stir Welding: Circular Trajectory

2013 ◽  
Vol 554-557 ◽  
pp. 1007-1013
Author(s):  
Nejah Jemal ◽  
Sandra Chevert ◽  
Laurent Langlois ◽  
Gabriel Abba
Keyword(s):  
Friction Stir Welding ◽  
Rotation Speed ◽  
Welding Process ◽  
Friction Stir Weld ◽  
Welding Parameters ◽  
Feed Speed ◽  
Circular Trajectory ◽  
Friction Stir ◽  
Plane Plate ◽  
Tool Trajectory

Friction stir welding is known for his capability to achieve a linear weld. However, more investigation on a curved friction stir weld trajectory is still required to industrialize this promising process. In the same perspective, this study is aimed at analyzing the influence of nonlinear tool trajectory in friction stir welding. The study considers a variety of circular trajectories on the plane plate and uses them for experimentation while considering different welding parameters of rotation speed feed speed, axial force and tilt angle.In FSW, the tool is generally needed to be tilted with a constant angle in the travel direction during welding process. Therefore, for circular trajectory, an adequate roll and pitch angle are assigned to the spindle in all tool positions. The paper presents the effect of circular trajectory on longitudinal and transversal forces generated during circular welding. The results are then compared with the experimental results which are obtained using linear FSW. Furthermore, the experimental investigation includes relationship between tool trajectory and weld quality.

On the friction stir welding, tool design optimization, and strain rate-dependent mechanical properties of HDPE–ceramic composite joints

2017 ◽  
Vol 31 (3) ◽  
pp. 291-310 ◽  
Author(s):  
Kabeer Raza ◽  
Muhammad Shamir ◽  
Muhammad Kashan Akhtar Qureshi ◽  
Abdul Shaafi Shaikh ◽  
Muhammad Zain-ul-abdein
Keyword(s):  
Friction Stir Welding ◽  
Strain Rate ◽  
Tensile Properties ◽  
Welded Joints ◽  
Tool Design ◽  
Welding Parameters ◽  
Composite Joints ◽  
Friction Stir ◽  
Composite Joint ◽  
Joint Efficiency

Friction stir welding is a recently developed technique for joining low-melting metals and polymers. In the present work, friction stir welded joints of high-density polyethylene (HDPE) sheets were produced using a newly designed tool with a concave shoulder and a grooved conical pin. The joints were produced with and without the additions of ceramic particulates including silicon carbide (SiC), alumina, graphite, and silica. The effect of strain rate on the tensile properties of base material and plain welded joints was examined. In addition to tensile properties of composite joints, hardness profiles across the weld nugget were analyzed. It was observed that the increasing strain rate improved both the tensile strength and the ductility of the plain welded joints. The tool was able to yield a joint efficiency of around 84% in the plain welded samples. Although, in terms of joint efficiency, the composite joints were less efficient than the plain welded HDPE, SiC additions were found to yield better material properties relative to other reinforcements. Finally, it was concluded that an SiC–HDPE composite joint can be of practical importance in high strain rate applications, provided the optimum tool design and stir welding parameters are available.

Study the Role of Friction Stir Welding Tilt Angle on Microstructure and Hardness

2015 ◽  
Vol 799-800 ◽  
pp. 434-438 ◽  
Author(s):  
H.A.D. Hamid ◽  
A.A. Roslee
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotation Speed ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Pin ◽  
Tool Rotation

This paper presents an investigation of research objectives on the effect of tilt angle on microstructure and mechanical properties of dissimilar aluminum alloy sheets between AA5083 and AA6061, 5mm plates by using Friction Stir Welding (FSW) process in butt joint. The base materials of AA5083 and AA6061 were located on the retreating side (RS) and advancing side (AS), respectively. The welding process and the welding parameters such as tool pin profile, tool rotation speed, welding speed and tilt angle influenced the mechanical properties of the Friction Stir Welding joints significantly. For this experiment, the Friction Stir Welding materials joined under five different tilt angles (from 0oto 4o) with 86mm/min of welding speed and 910 rpm of tool rotation speed which were set similarly. Microscopic examination on the weld samples showed significant variation in the microstructure especially in the region of heat-affected zone (HAZ), weld nugget or dynamically recrystallized zone (DXZ) and in the base metal.

scholarly journals Influence of Welding Speed on Fracture Toughness of Friction Stir Welded AA2024-T351 Joints

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1561
Author(s):  
Miodrag Milčić ◽  
Dragan Milčić ◽  
Tomaž Vuherer ◽  
Ljubica Radović ◽  
Igor Radisavljević ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Welding Speed ◽  
Fracture Behavior ◽  
Welded Joint ◽  
Rotation Speed ◽  
High Reliability ◽  
Welding Parameters ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

In order to ensure a quality welded joint, and thus safe operation and high reliability of the welded part or structure achieved by friction stir welding, it is necessary to select the optimal welding parameters. The parameters of friction stir welding significantly affect the structure of the welded joint, and thus the mechanical properties of the welded joint. Investigation of the influence of friction stir welding parameters was performed on 6-mm thick plates of aluminum alloy AA2024 T351. The quality of the welded joint is predominantly influenced by the tool rotation speed n and the welding speed v. In this research, constant tool rotation speed was adopted n = 750 rpm, and the welding speed was varied (v = 73, 116 and 150 mm/min). By the visual method and radiographic examination, imperfections of the face and roots of the welded specimens were not found. This paper presents the performed experimental tests of the macro and microstructure of welded joints, followed by tests of micro hardness and fracture behavior of Friction Stir Welded AA2024-T351 joints. It can be concluded that the welding speed of v = 116 mm/min is favorable with regard to the fracture behavior of the analysed FSW-joint.

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