scholarly journals Improvement on Mechanical Properties of Submerged Friction Stir Joining of Dissimilar Tailor Welded Aluminum Blanks

2021 ◽  
Vol 2021 ◽  
pp. 1-6
Author(s):  
R. Suryanarayanan ◽  
V. G. Sridhar ◽  
L. Natrayan ◽  
S. Kaliappan ◽  
Anjibabu Merneedi ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mechanical Performance ◽  
Weld Zone ◽  
Tensile Tests ◽  
Welding Parameters ◽  
Negative Effects ◽  
Friction Stir ◽  
Tailor Welded Blanks ◽  
Secondary Precipitates

Friction stir welding is a solid-state welding method that produces joints with superior mechanical and metallurgical properties. However, the negative effects of the thermal cycle during welding dent the mechanical performance of the weld joint. Hence, in this research study, the joining of aluminum tailor welded blanks by friction stir welding is carried out in underwater conditions by varying the welding parameters. The tensile tests revealed that the underwater welded samples showed better results when compared to the air welded samples. Maximum tensile strength of 229.83 MPa was obtained at 1000 rpm, 36 mm/min. The improved tensile strength of the underwater welded samples was credited to the suppression of the precipitation of the secondary precipitates due to the cooling action provided by the water. The lowest hardness of 72 HV was obtained at the edge of the stir zone which indicated the weakest region in the weld zone.

scholarly journals Investigation and development of friction stir welding process for unreinforced polyphenylene sulfide and reinforced polyetheretherketone

2018 ◽  
Vol 32 (9) ◽  
pp. 1242-1267 ◽  
Author(s):  
Hossain Ahmed ◽  
MJL van Tooren ◽  
Jonathan Justice ◽  
Ramy Harik ◽  
Addis Kidane ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Traverse Speed ◽  
Tensile Tests ◽  
Polyphenylene Sulfide ◽  
Analytical Models ◽  
Welding Parameters ◽  
Stress Concentrations ◽  
Friction Stir

The joining of thermoplastics through welding offers numerous advantages over mechanical joining. Most importantly, it eliminates the use of costly fasteners and has only a limited effect on the strength of the parts being joined. Since it does not require the introduction of holes, loading pins, and the associated stress concentrations, a specific form of welding, friction stir welding (FSW), was investigated for the creation of butt joints of unreinforced polyphenylene sulfide (PPS) and short carbon fiber (CF)-reinforced polyetheretherketone (PEEK) plates. Unlike metals, analytical models and experimental results show that the heat generated by the FSW tool is insufficient to produce the heat required to weld thermoplastic materials. Therefore, a second heat source is required for preheating these thermoplastics. In this research, a resistance type surface heater was placed at the bottom of two identical weld pieces to produce good quality welds. Two types of shoulder design such as rotating shoulder and stationary shoulder were developed in this study. Taguchi’s design of experiment method was utilized to develop the welding process, where heating duration, material temperature, tool rotational speed, and tool traverse speed were used as the welding parameters. One of the process parameters, tool traverse speed, had significant influence on the tensile strength of PPS samples. While PPS sample showed relatively lower tensile strength with higher traverse speed, short CF-reinforced PEEK samples had higher tensile strength with a higher traverse speed. In addition to tensile tests, fracture toughness tests were performed for both PPS and PEEK samples to observe the influence of unwelded segments in the welded parts. In this study, joint efficiency of PEEK samples was found to be higher than that of PPS samples. Micrographs of PEEK samples showed uniform homogenous mixture of part materials.

scholarly journals Study the effect of welding pass number on the mechanical and metallurgical properties of Aluminum type Al 1050 H14 produced by friction stir welding

2021 ◽  
Vol 28 (4) ◽  
pp. 1-13
Author(s):  
Najeeb Salman Abtan ◽  
Jawdat Ali Yagoob ◽  
Ayshan Mohammed Shukri
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Base Metal ◽  
Weld Zone ◽  
Welding Process ◽  
Tensile Tests ◽  
Mechanical Tests ◽  
Mechanical Mixing ◽  
Butt Welding ◽  
Friction Stir

Friction Stir Welding (FSW) is a solid-state welding technique with non-fusible rotary welds. Heat is generated by the friction produced between the weld tool and the two opposite surfaces of the two welded parts and the tool works on mechanical mixing with the presence of heat, pressure, and heat generated, reaching approximately (80-90%) of the melting point of the metal to be welded. In this study, Al 1050 H14 aluminum with a thickness of (6mm) was used for the purpose of welding it by means of the friction stir welding process in a butt welding method to obtain similar welding joints. A set with a square stitching tool Made of alloy steel was used by using a milling machine, with fixed (rotational speed of 1008 rpm and linear velocity of 40mm / min), an inclination angle of (2o), and counterclockwise rotation. The efficiency of welded joints was evaluated through static mechanical tests. Tensile tests, microscopic hardness, and visual examination. The results for all welds showed that the mixing zone (NZ) consists of fine grains of equal axes compared to the base metal. When welding on one side and in one path, the microstructure of HAZ was similar to the base metal. TAMZ was a transition region between HAZ and NZ. As for welding on one side, with two paths and three paths, the structure turned into a fine crystalline structure. By increasing the number of paths per side, the welding efficiency of the welded sample increased as the best efficiency was from one side and three paths (76.215%). Through the results, the tensile strength increases with the increase in the number of paths, as the best tensile strength was obtained when conducting the welding process from one side and by three paths, which is (93.653 MPa). It is equivalent to 76.21% of the tensile strength of the base metal. The hardness value in the weld zone (NZ) is higher than the other two zones (HAZ, TMAZ) due to the occurrence of dynamic recrystallization, which results in very fine and equiaxial crystals, but the hardness value in the weld zone remains less than the hardness value of the base metal.

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

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.

scholarly journals Innovate Method for Friction Stir Welding of Al-Mg-Si Alloy Thin Plate

2019 ◽  
Vol 269 ◽  
pp. 02006
Author(s):  
Li Fu ◽  
Fenjun Liu
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Base Metal ◽  
High Speed ◽  
Thick Plate ◽  
Welding Parameters ◽  
Butt Joints ◽  
Friction Stir ◽  
High Rotation Speed ◽  
Precipitated Phases

Al-Mg-Si (6061-T6) alloy with 0.8 mm thick plate was welded successfully by use of high speed friction stir welding (FSW) technology. The microstructural characteristics and mechanical property of the butt joints prepared by high speed FSW were analyzed in detail, the influence of welding parameters, fixture condition and after welding heat treatment were also explored. The results shown that sound surface topography and defect-free bonding interface were observed in the nugget zone (NZ). The microhardness of the as-welded joint was lower than that of the base metal because of the welding heat effect. Compared with the conventional speed FSW, the number of β-Mg2Si, Al2CuMg and Al8Fe2Si precipitated phases existed in the high speed FSWed NZ increased, which made the microhardness in the NZ improved significantly. The rod-shaped precipitates (Mg2Si) have the greatest influence on the microhardness distributions. The maximum tensile strength of 301.8 MPa, which was 85.8% of the base metal, was obtained at high rotation speed of 8000 rpm and fast welding speed of 1500 mm/min. The tensile strength of the ultra-high speed FSWed butt joints were improved significantly by post-weld artificial aging, with a maximum joint efficiency of 90.4%.

Heat Transfer Simulations and Analysis of Joint Cross-Sectional Microstructure on Friction Stir Welding between Steel and Aluminium

2020 ◽  
Vol 863 ◽  
pp. 85-95
Author(s):  
Truong Minh Nhat ◽  
Truong Quoc Thanh ◽  
Tu Vinh Thong ◽  
Tran Trong Quyet ◽  
Luu Phuong Minh
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Thermal Contact ◽  
Welding Process ◽  
Welding Parameters ◽  
Thermal Imager ◽  
Sem Images ◽  
Cross Sectional ◽  
Friction Stir

This study presents conducted heat simulations and experimental jointing flat-plate of aluminum alloy 6061 and SUS 304. Temperature is simulated by the COMSOL software in three states: (1) Preheat the Friction Stir Welding (FSW) by TIG welding, (2) Thermal contact resistance between Aluminium and steel, and (3) The welding process using stiring friction is simulated. The simulations intended to predicting the temperature which is used for preheat and welding process to ensuring the required solid-state welding. The temperature is also determined and checked by a thermal imager comparing with simulation results. Besides, the results of tensile strength is carried out. The Box - Behnken method is used to identify the relationship between the welding parameters (rotation, speed and offset), temperature and tensile strength. The maximum tensile strength is 77% compared to the strength of aluminum alloy. The optimal set of parameters for the process is n = 676 rpm, v = 46 mm / min and x = 0.6 mm. The optimizing welding parameters to achieving good quality of welding process are described. SEM images to determine some properties of welding materials. This is also the basis for initial research to identify some defects in welding of two different materials (IMC thickness and interconnected pores) and the cause of these defects.

scholarly journals Mechanical and microstructural properties of EN AW-6060 aluminum alloy joints produced by friction stir welding

2015 ◽  
Vol 63 (2) ◽  
pp. 475-478
Author(s):  
I. Küçükrendeci
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Room Temperature ◽  
Weld Zone ◽  
Tensile Tests ◽  
Optical Observations ◽  
Microstructural Properties ◽  
Micro Hardness ◽  
Friction Stir ◽  
Mechanical And Microstructural Properties

Abstract In the study, the mechanical and microstructural properties of friction stir welded EN AW-6060 Aluminum Alloy plates were investigated. The friction stir welding (FSW) was conducted at tool rotational speeds of 900, 1250, and 1500 rpm and at welding speeds of 100, 150 and 180 mm/min. The effect of the tool rotational and welding speeds such properties was studied. The mechanical properties of the joints were evaluated by means of micro-hardness (HV) and tensile tests at room temperature. The tensile properties of the friction stir welded tensile specimens depend significantly on both the tool rotational and welding speeds. The microstructural evolution of the weld zone was analysed by optical observations of the weld zones

Effect of Welding Parameters on Mechanical and Microstructural Properties of Dissimilar Aluminum Alloy Joints Produced by Friction Stir Welding

2014 ◽  
Vol 592-594 ◽  
pp. 250-254 ◽  
Author(s):  
Sabitha Jannet ◽  
P. Koshy Mathews
Keyword(s):  
Friction Stir Welding ◽  
Rolling Direction ◽  
Structural Evolution ◽  
Tensile Tests ◽  
Processing Parameters ◽  
Welding Parameters ◽  
Microstructural Properties ◽  
Rotating Speed ◽  
Friction Stir ◽  
Mechanical And Microstructural Properties

The effect of processing parameters on the mechanical and microstructural properties of dissimilar AA6061 t6–AA5083 0 joints produced by friction stir welding was studied. Different samples were produced by varying the advancing speeds of the tool as 20 and 40 mm/min and by varying the alloy positioned on the advancing side of the tool. In the various trials the rotating speed is varied from 600 to 900 RPM. All the welds were produced perpendicular to the rolling direction for both the alloys. Micro hardness (HV) and tensile tests performed at room temperature were used to evaluate the mechanical properties of the joints. Various tests were performed on the joints previously subjected to ageing. In order to analyze the micro structural evolution of the material, the welds’ zones were observed optically.

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