Development of Friction Stir Welding Technique and Machine for Aluminum Sheet Metal Assembly- Friction Stir Welding of Aluminum for Automotive Applications (2) -

2005 ◽  
Author(s):  
K. Okamoto ◽  
F. Hunt ◽  
S. Hirano
Keyword(s):  
Friction Stir Welding ◽  
Sheet Metal ◽  
Aluminum Sheet ◽  
Automotive Applications ◽  
Friction Stir ◽  
Sheet Metal Assembly ◽  
Welding Technique

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.

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.

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.

scholarly journals The Effects of In-Process Cooling during Friction Stir Welding of 7475 Aluminium Alloy

2021 ◽  
Vol 50 (9) ◽  
pp. 2743-2754
Author(s):  
Ashish Jacob ◽  
Sachin Maheshwari ◽  
Arshad Noor Siddiquee ◽  
Abdulrahman Al-Ahmari ◽  
Mustufa Haider Abidi ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welded Joints ◽  
Positive Impact ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir ◽  
Cooling Conditions ◽  
Zero Degree ◽  
Welding Technique

Certain age hardenable alloys such as AA7475 cannot be joined with perfection using fusion welding techniques. This requires non-conventional welding technique such as friction stir welding process to join these ‘difficult to weld’ alloys. In this study, three different cooling conditions i.e. cryogenic, sub-zero, and zero-degree Celsius temperature conditions have been analyzed to understand its impact on the welding process. In-process cooling was found to behave effectively and also enhanced the mechanical properties of the welded joints. A stable microstructure was clearly seen in the images observed under the metallurgical microscope. The weld efficiencies were found to be good in each of the samples which are indicative of a strong metallic joint. The effective cooling conditions employed had an overall positive impact on the joint.

scholarly journals Friction stir welding of Aluminium matrix composites – A Review

2018 ◽  
Vol 144 ◽  
pp. 03002 ◽  
Author(s):  
Prabhu Subramanya ◽  
Murthy Amar ◽  
Shettigar Arun ◽  
Herbert Mervin ◽  
Rao Shrikantha
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Fusion Welding ◽  
Aluminium Matrix ◽  
Future Research ◽  
Matrix Composites ◽  
Aluminium Matrix Composites ◽  
Friction Stir ◽  
Tool Profiles ◽  
Welding Technique

Friction stir welding (FSW) is established as one of the prominent welding techniques to join aluminium matrix composites (AMCs). It is a solid state welding process, takes place well below the melting temperature of the material, eliminates the detrimental effects of conventional fusion welding process. Although the process is capable to join AMCs, challenges are still open that need to be fulfill to widen its applications. This paper gives the outline of the friction stir welding technique used to join AMCs. Effect of process variables on the microstructure and mechanical properties of the joints, behavior of reinforcing materials during welding, effect of tool profiles on the joint strength are discussed in detail. Few improvements and direction for future research are also proposed.

scholarly journals Temperature based validation of the analytical model for the estimation of the amount of heat generated during friction stir welding

2012 ◽  
Vol 16 (suppl. 2) ◽  
pp. 337-350 ◽  
Author(s):  
Dragan Milcic ◽  
Miroslav Mijajlovic ◽  
Nenad Pavlovic ◽  
Mica Vukic ◽  
Dragan Mancic
Keyword(s):  
Friction Stir Welding ◽  
Analytical Model ◽  
Material Flow ◽  
Mechanical Energy ◽  
Relative Difference ◽  
Parent Material ◽  
Contact Conditions ◽  
Friction Stir ◽  
Influence Of Temperature On ◽  
Welding Technique

Friction stir welding is a solid-state welding technique that utilizes thermomechanical influence of the rotating welding tool on parent material resulting in a monolith joint - weld. On the contact of welding tool and parent material, significant stirring and deformation of parent material appears, and during this process, mechanical energy is partially transformed into heat. Generated heat affects the temperature of the welding tool and parent material, thus the proposed analytical model for the estimation of the amount of generated heat can be verified by temperature: analytically determined heat is used for numerical estimation of the temperature of parent material and this temperature is compared to the experimentally determined temperature. Numerical solution is estimated using the finite difference method - explicit scheme with adaptive grid, considering influence of temperature on material's conductivity, contact conditions between welding tool and parent material, material flow around welding tool, etc. The analytical model shows that 60-100% of mechanical power given to the welding tool is transformed into heat, while the comparison of results shows the maximal relative difference between the analytical and experimental temperature of about 10%.

Evaluating the Strength of the Friction Stir Welded Joints at Various Rotational Speeds

2013 ◽  
Vol 446-447 ◽  
pp. 312-315
Author(s):  
Ramaraju Ramgopal Varma ◽  
Abdullah Bin Ibrahim ◽  
B. Ravinder Reddy
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Yield Strength ◽  
Welded Joints ◽  
Rotational Speed ◽  
Testing Machine ◽  
Friction Stir ◽  
Universal Testing ◽  
Welding Technique

The present research paper aims in evaluating the strength of the welded AA6351 alloy plates of 6 mm thick by using friction stir welding technique at different rotational speeds The applied welding technique is capable of achieving the mechanical properties of the alloy close to that of the original alloy. In the present investigation, the speeds of the spindle were varied from 1100 rpm to 1500 rpm with a constant transverse speed of 20 mm/min. The tensile strength of the joints is determined by an universal testing machine. The results from the present investigation show that the values of the yield strength were very much closer to the values of the AA6351Alloy prior to welding. It has been found from the experiments that the strength of the joints increases with the increase in the rotational speed; however, the same is decreasing after achieving certain speed.

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