Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
Anganan K ◽  
Narendran RJ ◽  
Naveen Prabhu N ◽  
Rahul Varma R ◽  
Sivasubramaniyam R
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
K. Anganan ◽  
R.J . Narendran ◽  
N Naveen Prabhu ◽  
R Rahul Varma ◽  
R Sivasubramaniyam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

Effect of Friction Stir Welding Process Parameters on Temperature Profile and Tensile Strength of Dissimilar Aluminum Alloys

2015 ◽  
Vol 813-814 ◽  
pp. 425-430
Author(s):  
Saurabh Kumar Gupta ◽  
K.N. Pandey ◽  
Rajneesh Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Temperature Profile ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Peak Temperature ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

The aim of this research is to study the effect of Friction Stir Welding (FSW) process parameters such as tool rotational speed and welding speed on temperature distribution and tensile strength of dissimilar AA5083-O and AA6063-T6 joint welded by FSW. Peak temperature at retreating side was observed lower as compared to advancing side for each experiment. Peak temperature decreases with decreasing the tool rotational speed but vice versa with welding speed. ANOVA indicated that the temperature profile was strongly dependent on the tool rotation speed than the welding speed and it also showed that welding speed is the main process parameter that has highest effect on tensile strength of welded joint.

Mechanical Property of Friction Stir Welded Retardant Magnesium Alloy Joint

2011 ◽  
Vol 295-297 ◽  
pp. 1929-1932
Author(s):  
Yi Min Tu ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Xin Zhang ◽  
Ke Ke Zhang
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Welding Speed ◽  
Rotational Speed ◽  
Maximum Strength ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir

In order to obtain better understanding of the friction stir weldability of the magnesium alloy and provide some foundational information for improving mechanical properties of retardant magnesium alloy joints. A retardant magnesium alloy was weld using the method of friction stir welding. The influence of welding parameters on the strength of the joint was investigated. The maximum strength of 230 MPa was obtained from the joint welded at the tool rotational speed of 1000 r/min and welding speed of 750 mm/min.

scholarly journals Modeling and Optimization of Bobbin Friction Stir Welding for AA6061-T6 alloy Utilizing Response Surface Methodology

2018 ◽  
Vol 26 (4) ◽  
pp. 1-17
Author(s):  
Samir Ali Amin ◽  
Mohannad Yousif Hanna ◽  
Alhamza Farooq Mohamed
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Bending Force ◽  
Speed Range

Bobbin friction stir welding (BFSW) is special kind of friction stir welding. This investigation aims to develop empirical models through mathematical relationships between the welding process parameters and mechanical properties of Aluminum alloy AA6061-T6 welded joint created by using bobbin tool and to find the optimum welding parameters. The welding speed range (40-200 mm/min) and rotational speed range (340-930 rpm) were utilized (as the used input factors) to find their effects on elongation, tensile strength and maximum bending force as the main responses.  These models were built using Design of Experiment (DOE) software ‘version 10’ with Response Surface Methodology (RSM) technique. The models adequacy were tested via the (ANOVA) analysis. The obtained models appeared that as the welding speed or rotational speed increases, the elongation, tensile strength and maximum bending force of the welded joint firstly rise to a maximum value and then drop. The optimum welding parameters were rotational speed (623.949 rpm) and welding speed (128.795 mm/min) with (6.33%), (204 MPa) and (6.216 KN) of elongation, tensile strength and maximum bending force, respectively. A proper harmonization was obtained between the models predicted results and the optimized ones with actual trial with 95% level of confidence.

Effect of Al2O3 nanoparticles on microstructure and mechanical properties of friction stir-welded dissimilar aluminum alloys AA7075-T6 and AA6061-T6

2021 ◽  
pp. 095440892110655
Author(s):  
Sumit Jain ◽  
R.S. Mishra
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Particle Dispersion ◽  
Al2o3 Nanoparticles ◽  
Tool Rotational Speed ◽  
Micro Hardness ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

In this research, a defect-free dissimilar weld joint of AA7075-T6 and AA6061-T6 reinforced with Al2O3 nanoparticles was fabricated via friction stir welding (FSW). The influence of tool rotational speed (700, 900 and 1100 rpm), traverse speed (40, 50 and 60 mm/min) with varying volume fractions of Al2O3 nanoparticles (4%, 7% and 10%) on microstructural evolution and mechanical properties were investigated. The augmentation of various mechanical properties is based on the homogeneity of particle dispersion and grains refinement in the SZ of the FSWed joint. The findings revealed that the remarkable reduction in grain size in the SZ was observed owing to the incorporation of Al2O3 nanoparticles produces the pinning effect, which prevents the growth of grain boundaries by dynamic recrystallization (DRX). The increasing volume fraction of Al2O3 nanoparticles enhanced the mechanical properties such as tensile strength, % elongation and micro-hardness. Agglomeration of particles was observed in the SZ of the FSWed joints produced at lower tool rotational speed of 700 rpm and higher traverse speed of 60 mm/min due to unusual material flow. Homogenous particle dispersion and enhanced material mixing ensue at higher rotational speed of 1100 rpm and lower traverse speed of 40 mm/min exhibit higher tensile strength and micro-hardness.

Study of Friction Stir Welding Technics and Weld Performance of Dissimilar 6063-3A21 Aluminum Alloys

2011 ◽  
Vol 299-300 ◽  
pp. 1095-1098 ◽  
Author(s):  
Lei Wang ◽  
Jian Jun Zhu ◽  
Wei Zhang ◽  
Xing Mei Feng ◽  
Zhan Ying Feng
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloys ◽  
Base Material ◽  
Post Weld Heat Treatment ◽  
Weld Strength ◽  
Welding Parameters ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Performance Results ◽  
Better Than

Several rotating rates and welding speeds were chosen to joint 6063/3A21 dissimilar aluminum alloys, tensile strength of the welds were measured to analyze effect of welding parameters on weld performance. Results show that tensile strength of the weld is better than the base material. Weld tensile strength will decrease under a too high or too low welding speed while effect of rotating rate on weld strength is relatively small. The weakest position is at heat affected zone at 3A21 side after T6 post weld heat treatment.

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

2020 ◽  
Vol 17 (4) ◽  
pp. 491-507 ◽  
Author(s):  
Nitin Panaskar ◽  
Ravi Prakash Terkar
Keyword(s):  
Experimental Data ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Central Composite

Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

Process Parameters Optimization of Friction Stir Welding in Aluminium Alloy 6063-T6 by Taguchi Method

2017 ◽  
Vol 867 ◽  
pp. 97-104 ◽  
Author(s):  
T. Ganapathy ◽  
K. Lenin ◽  
K. Pannerselvam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Taguchi Method ◽  
Axial Force ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Process Parameter ◽  
Main Process ◽  
Friction Stir

This paper deals with the effective application of friction stir welding similar to butt joining technique.AL6063 T-6 alloys prepared in 125x 100 x 7mm thickness plate and FSW tool setup were H13 of diameter 25mm rotary tool with straight cylindrical pin profile. The maximum strength was considered for selection of combined process parameter. The process parameters were optimized using Taguchi method. The Rotational speed, welding speed, and axial speed are the main process parameter which taken into our consideration. The optimum process parameters are determined with reference to tensile strength of the joint. From the experiments, it was found the effects of welding parameter are the axial force is highest substantial parameter to determining the tensile strength of the joint. The paper which revealed the optimal values of process parameter are to acquire a maximum tensile strength of friction stir welded AL6063-T6 plates is 101.6Mpa with the combination level of rotational speed, welding speed and axial force are found to be 1100 RPM, 60 mm/min and 12.5 KN. validation test was carried out and results were nearer to the optimized results confirmed by the optimum results.

Analysis of process parameters effects on underwater friction stir welding of aluminum alloy 6082-T6

2018 ◽  
Vol 233 (6) ◽  
pp. 1700-1710 ◽  
Author(s):  
Mohd Atif Wahid ◽  
Zahid A Khan ◽  
Arshad Noor Siddiquee ◽  
Rohit Shandley ◽  
Nidhi Sharma
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Underwater Friction Stir Welding ◽  
Optimal Setting

In friction stir welding of heat treatable aluminum alloys, the thermal cycles developed during the joining process result in softening of the joints which adversely affect their mechanical properties. Underwater friction stir welding can be a process of choice to overcome this problem due to low peak temperature and short dwell time involved during the process. Consequently, this article presents a study pertaining to the underwater friction stir welding of aluminum alloy 6082-T6 with an aim to develop a mathematical model to optimize the underwater friction stir welding process parameters for obtaining maximum tensile strength. The results of the study reveal that the tool shoulder diameter (d), tool rotational speed (ω), welding speed (v), and second-order term of rotational speed, that is, ω2, significantly affect the tensile strength of the joint. The maximum tensile strength of 241 MPa which is indeed 79% of the base metal strength and 10.7% higher than that of conventional (air) friction stir welding joint was achieved at an optimal setting of the underwater friction stir welding parameters, that is, tool rotational speed of 900 r/min, the welding speed of 80 mm/min, and a tool shoulder of 17 mm. The article also presents the results of temperature variation, the macrostructural and microstructural investigations, microhardness, and fractography of the joint obtained at the optimal setting for underwater friction stir welded (UFSWed) joint.

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