Estimation of the Mechanical Properties and Temperature Distribution in Friction Stir Welding Technique of Aluminum Alloys

2013 ◽  
Vol 773-774 ◽  
pp. 803-811 ◽  
Author(s):  
K.M. Adel
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Thick Plate ◽  
Travel Speed ◽  
Structural Components ◽  
Friction Stir ◽  
Medium Strength ◽  
Weld Pool Geometry ◽  
Fsw Parameters ◽  
Welding Technique

Friction stir welding of AA 7020-T6 aluminum alloys, 5 mm thick plate is an Al-Zn-Mg grade alloy of 7XXX series heat treatable of medium strength alloys and employed for welded engineering structural components. The effect of FSW parameters (rotational speeds and travel speeds) on joint strength and welding zone dimensions have been investigated experimentally. Four different rotational speeds are used: 450, 560, 710 and 900 r.p.m. with three travel speeds 16, 25 and 40 mm.min-1. The experimental investigation included tensile test and weld pool geometry determination. It was found the that best welding conditions for FSW was the weldments which have 247 Mpa yield strength, 340 MPa ultimate tensile strength, 7.3% elongation, 11020N bending forces for both face and root and hardness value ranging from (133-138) Hv 0.05 for the different welding regions under the optimal welding conditions at a rotational speed of 900 r.p.m. and travel speed of 25mm.min-1.

Properties of Friction-Stir Welded Aluminum Alloys 6111 and 5083

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
W. Gan ◽  
K. Okamoto ◽  
S. Hirano ◽  
K. Chung ◽  
C. Kim ◽  
...  
Keyword(s):  
Aluminum Alloys ◽  
Weld Zone ◽  
Base Material ◽  
Natural Aging ◽  
Tensile Tests ◽  
Travel Speed ◽  
Minimum Phase ◽  
Friction Stir ◽  
Base Materials ◽  
Fsw Parameters

Friction-stir welding (FSW) promises joints with low porosity, fine microstructures, minimum phase transformation, and low oxidation compared with conventional welding techniques. It is capable of joining combinations of alloys not amenable to conventional welding. Certain combinations of FSW parameters were used to create FSWs of aluminum alloys 5083-H18 and 6111-T4, and the physical weld defects were measured. The mechanical behavior of FSW welds made under the most favorable choice of parameters was determined using tensile tests and hardness measurements and was correlated to the microstructures of the weld and base material. Stir zones (SZs) in the 5083 specimens were much softer than the strain-hardened base materials. SZs in the 6111 material are approximately as hard as the base material. Natural aging of 6111 FSW specimens occurred in some parts of the heat-affected zone and produced hardening for up to 12weeks after welding. Annealing of 5083 FSW specimens produced abnormal grain growth (AGG) for welds produced under certain welding conditions and in certain parts of the weld zone. AGG is more severe for low-heat conditions, i.e., higher tool travel speed but lower rotational speed. The conditions for most favorable FSW are presented, as well as the expected microstructures and mechanical properties, along with the weld conditions that promote AGG.

Dissimilar friction stir welding of thick plate AA5052-AA6061 aluminum alloys: effects of material positioning and tool eccentricity

2019 ◽  
Vol 105 (1-4) ◽  
pp. 889-904 ◽  
Author(s):  
Luqman Hakim Ahmad Shah ◽  
Seyedhossein Sonbolestan ◽  
Abdelbaset R. H. Midawi ◽  
Scott Walbridge ◽  
Adrian Gerlich
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Thick Plate ◽  
Friction Stir ◽  
Dissimilar Friction Stir Welding

scholarly journals ANALYSIS OF TENSILE STRENGTH, CRYSTALLINITY, CRYSTALLITE SIZE, AND THERMAL STABILITY OF POLYPROPYLENE JOINED BY FRICTION STIR WELDING

2021 ◽  
pp. 1-6
Author(s):  
Bambang Kusharjanta ◽  
Rudy Soenoko ◽  
Anindito Purnowidodo ◽  
Yudy Surya Irawan
Keyword(s):  
Thermal Stability ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tensile Test ◽  
Crystallite Size ◽  
Travel Speed ◽  
Degree Of Crystallinity ◽  
Friction Stir ◽  
The Difference ◽  
Fsw Parameters

This paper aims to investigate the joining of polypropylene using friction stir welding (FSW). FSW parameters were the rotation speed of 620 rpm, the travel speed of 7.3 mm/min, and 13 mm/min. The tensile test was performed using a universal testing machine, and the results of the tensile test were related to the crystallite size and degree of crystallinity. X-ray diffraction (XRD) was performed to examine the crystallite size and degree of crystallinity while thermal analysis was carried out using TGA/DSC. Besides, the effect of the degree of crystallinity on the thermal stability at the weld nugget area due to travel speed is explained in this paper. The findings showed that FSW with a travel speed of 7.3 mm/min had a higher crystallite size and degree of crystallinity than that with a travel speed of 13 mm/min, because there is a fusion of crystals and also recrystallization occurs, as an effect of the difference in the length of time exposed to heat during the FSW process. From the study results, it can be seen that the FSW with a 7.3 mm/minute travel speed has a higher crystal size and degree of crystallinity compare with the use of 13 mm/minute travel speed. The reason for that, the difference in heat exposure time during FSW affects crystal fusion and recrystallization. A sample with a travel speed of 7.3 mm/min had high tensile strength because it obtains sufficient heat for a more complete joint. In terms of thermal stability, the specimen with a lower travel speed showed a higher stability level than the specimen with a higher travel speed in that of the higher degree of crystallinity.

Mechanical property and characterization of 7A04-T6 aluminum alloys bonded by friction stir welding

2020 ◽  
Vol 52 ◽  
pp. 263-269 ◽  
Author(s):  
Jianing Li ◽  
Molin Su ◽  
Wenjun Qi ◽  
Chen Wang ◽  
Peng Zhao ◽  
...  
Keyword(s):  
Mechanical Property ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Friction Stir

Effect of Porosity Content on the Weldability of Powder Metal Parts Produced by Friction Stir Welding

2007 ◽  
Vol 534-536 ◽  
pp. 789-792 ◽  
Author(s):  
Adem Kurt ◽  
Ilyas Uygur ◽  
Hakan Ates
Keyword(s):  
Friction Stir Welding ◽  
Powder Metal ◽  
Aluminum Powders ◽  
Friction Stir ◽  
Metal Parts ◽  
Constant Friction ◽  
Sintered Powder ◽  
Hardness Values ◽  
Welding Technique ◽  
Traveling Speed

Friction stir welding technique (FSW) has many advantages in terms of tool design, rotational speed and traveling speed, and can be adjusted in a precise manner. It enables heat input into the system to be controlled. In this study, Aluminum powders were compacted at 350,400 and 450 MPa pressure and sintered at 450 oC temperature for 30 minutes in Ar atmosphere. Sintered powder metal parts were joined to each other by FSW at the speed of 1800 rpm and traveling welding speed 200 mm/min under a constant friction force. The results show that the amount of porosity affects the weldability of powder metallurgy (P/M) parts. Furthermore, the porosity and microstructural evolution of the Aluminum also affected the hardness values of the tested materials.

Microstructure and Mechanical Properties at the Unsteady Areas of Non-Linear Friction Stir Welding

2007 ◽  
Vol 561-565 ◽  
pp. 1059-1062 ◽  
Author(s):  
H. Takahara ◽  
Masato Tsujikawa ◽  
Sung Wook Chung ◽  
Y. Okawa ◽  
Kenji Higashi
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Parameter ◽  
Butt Joints ◽  
Friction Stir ◽  
Non Linear ◽  
Linear Friction ◽  
Fsw Parameters ◽  
Five Axis ◽  
Welding Direction

The influence of tool control in non-linear friction stir welding (FSW) on mechanical properties of joints was investigated. FSW is widely applied to linear joints. It is impossible for five axis FSW machines, however, to keep all the FSW parameters in optimum conditions at non-linear welding. Non-linear FSW joints should be made by compromise with the order of priority for FSW parameters. The tensile test results of butt joints with rectangular change in welding direction on plate plane (L-shaped butt joints) with various welding parameter change. It was found that turn to the retreating side is encouraged when welding direction change. And the method of zero inclination tool angle is effective at non-linear and plane welding.

Numerical Simulation of Plunge Force During the Plunge Phase of Friction Stir Welding and Ultrasonic Assisted FSW

2008 ◽  
Author(s):  
Kwanghyun Park ◽  
Bongsuk Kim ◽  
Jun Ni
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
High Frequency ◽  
Hybrid Welding ◽  
Ultrasonic Vibrations ◽  
Welding Quality ◽  
Friction Stir ◽  
Ultrasonic Assisted ◽  
Welding Force ◽  
Welding Technique

Ultrasonic assisted friction stir welding (UaFSW) is an hybrid welding technique, where high frequency vibration is superimposed on the movement of a rotating tool. The benefit of using ultrasonic vibration in the FSW process refers to the reduction in the welding force and to the better welding quality. The UaFSW system is being developed and its mechanism needs to be understood using both the experiments and the numerical simulations. In this paper, FE simulations of FSW and UaFSW using ABAQUS/Explicit were carried out to examine plunge forces during the plunge phase of FSW and UaFSW, respectively. First, the simulations of the conventional FSW process were validated. Then, simulation of UaFSW process was performed by imposing sinusoidal horizontal ultrasonic vibrations on the tool.

Effect of plasma preheating on weld quality and tool life during friction stir welding of DH36 steel

2021 ◽  
pp. 095440542199013
Author(s):  
Avinish Tiwari ◽  
Pardeep Pankaj ◽  
Saurav Suman ◽  
Piyush Singh ◽  
Pankaj Biswas ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Tool Life ◽  
Force Measurement ◽  
Deep Understanding ◽  
High Strength ◽  
Microstructural Characterization ◽  
Stir Zone ◽  
Friction Stir ◽  
Allotriomorphic Ferrite ◽  
Fsw Parameters

Friction stir welding (FSW) of high strength materials is challenging due to high tool cost and low tool life. To address this issue, the present investigation deals with an alternative of plasma-assisted friction stir welding (PFSW) of DH36 steel with WC-10%Co tool. Plasma preheating current (13 A, 15 A, and 17 A) was varied by keeping other FSW parameters as constant. During the FSW and PFSW process, force measurement and thermal history aided in a deep understanding of the process, tool degradation mechanisms, accompanied by the mechanical and microstructural characterization of the welded joints. The stir zone hardness was increased from 140 HV0.5 to about 267 HV0.5. The yield and tensile strength of weld increased from 385 MPa and 514 MPa to about 391 MPa and 539 MPa, respectively. Weld joint elongation (%) was increased from ~10% of weld 1 to ~13.89% of weld 4. During PFSW, the process temperature was increased, the cooling rate was lowered, and the weld bead was widened. The results also revealed that the plasma-assisted weld resulted in polygonal ([Formula: see text]) and allotriomorphic ferrite as the major constituents in the stir zone. Pearlite dissolution and spheroidization were observed in the ICHAZ and SCHAZ, respectively. Additionally, the plasma preheating reduced the tungsten tool’s wear by 58% compared to FSW.

Features of structure formation processes in AA2024 alloy joints formed by the friction stir welding with bobbin tool

2021 ◽  
Vol 23 (2) ◽  
pp. 98-115
Author(s):  
Alexey Ivanov ◽  
◽  
Valery Rubtsov ◽  
Andrey Chumaevskii ◽  
Kseniya Osipovich ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Structure Formation ◽  
Welded Joints ◽  
Heat Input ◽  
Welded Joint ◽  
Welding Process ◽  
Tool Material ◽  
Travel Speed ◽  
Material System ◽  
Friction Stir

Introduction. One of friction stir welding types is the bobbin friction stir welding (BFSW) process, which allows to obtain welded joints in various configurations without using a substrate and axial embedding force, as well as to reduce heat loss and temperature gradient across the welded material thickness. This makes the BFSW process effective for welding aluminum alloys, which properties are determined by their structural-phase state. According to research data, the temperature and strain rate of the welded material have some value intervals in which strong defect-free joints are formed. At the same time, much less attention has been paid to the mechanisms of structure formation in the BFSW process. Therefore, to solve the problem of obtaining defect-free and strong welded joints by BFSW, an extended understanding of the basic mechanisms of structure formation in the welding process is required. The aim of this work is to research the mechanisms of structure formation in welded joint of AA2024 alloy obtained by bobbin tool friction stir welding with variation of the welding speed. Results and discussion. Weld formation conditions during BFSW process are determined by heat input into a welded material, its fragmentation and plastic flow around the welding tool, which depend on the ratio of tool rotation speed and tool travel speed. Mechanisms of joint formation are based on a combination of equally important processes of adhesive interaction in “tool-material” system and extrusion of metal into the region behind the welding tool. Combined with heat dissipation conditions and the configuration of the “tool-material” system, this leads to material extrusion from a welded joint and its decompaction. This results in formation of extended defects. Increasing in tool travel speed reduce the specific heat input, but in case of extended joints welding an amount of heat released in joint increases because of specific heat removal conditions. As a result, the conditions of adhesion interaction and extrusion processes change, which leads either to the growth of existing defects or to the formation of new ones. Taking into account the complexity of mechanisms of structure formation in joint obtained by BFSW, an obtaining of defect-free joints implies a necessary usage of various nondestructive testing methods in combination with an adaptive control of technological parameters directly in course of a welding process.

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