scholarly journals Experimental analysis on friction stir welding using flat-faced pins in AA2024-T3 plate

2021 ◽  
Vol 49 (1) ◽  
pp. 78-86
Author(s):  
Stephen Leon ◽  
G. Bharathiraja ◽  
V. Jayakumar
Keyword(s):  
Friction Stir Welding ◽  
Tool Life ◽  
Thermal Environment ◽  
Softening Temperature ◽  
Peak Temperature ◽  
Friction Stir ◽  
Pin Geometry ◽  
Tool Pin ◽  
The Impact ◽  
Dwell Period

In friction stir welding, lesser tool life restricts the usage of non-circular pin in friction stir welding tool eventhough it delivers comparatively better weld joints than circular pin. Process peak temperature during the process affects the shear strength of the flowing material around the tool pin. Maintaining the process peak temperature as low as possible improves the properties in heat affected zone but on the other hand it increases the stress on the tool pin.Especially on the usage of non-circular pin, the pin surface experiences uneven stress distribution and causes premature tool failure. In this paper, optimum thermal environment through proper selection of process parameters and dwell period with respect to the pin geometry are analysed. A comparative analysis is also made to understand the impact of increase in flat surfaces in the pin surface on weld quality in the view of developing a suitable thermal environment that can improve tool life without compromising joint strength. Apart from this, optimum dwell period for the chosen tool pin geometry is analysed based on the empirical softening temperature of the material.

scholarly journals ANALYTICAL AND NUMERICAL THERMAL ANALYSIS ON FRICTION STIR WELDING USING POLYGONAL TOOL PIN

2021 ◽  
Vol 22 (2) ◽  
pp. 352-363
Author(s):  
Stephen Leon Joseph Leon ◽  
Alfred Franklin Varghese ◽  
Joseph Michel ◽  
Gopinath Gunasekaran
Keyword(s):  
Friction Stir Welding ◽  
Weld Line ◽  
Peak Temperature ◽  
Frictional Heat ◽  
Friction Stir ◽  
Proposed Model ◽  
Pin Geometry ◽  
Transient Thermal ◽  
Tool Pin ◽  
Solid State Joining

Frictional heat generation in the tool/matrix interface followed by the stirring of material along the weld line causes plasticized solid state joining in friction stir welding. In this paper, the existing torque based thermo-mechanical model for the tools with cylindrical pins is remodified for the polygonal tool pin profile by introducing novel multiplication factors with respect to the number of sides in the tool pin geometry. The variation in the effective heat supply with respect to the chosen pin geometry was analyzed. A comparative analysis of the proposed analytical model with the existing model was also carried out to understand the accuracy of the proposed model.  Furthermore, a transient thermal numerical modelling was carried out in the view of understanding the change in process peak temperature in the stir zone and change in temperature gradient along the heat affected zone with respect to the change in pin geometry for the opted set of process input parameters. An analytically estimated heat-input-based numerical model was adopted in the present study. It was observed that the process peak temperature was directly proportional to the number of sides in the tool pin. ABSTRAK: Penjanaan haba geseran antara muka pada alat/matrik diikuti dengan pengacauan material sepanjang garis kimpalan menyebabkan keadaan plastik pepejal melekat bersama geseran kimpalan pengacau. Kajian ini berkaitan tork sedia ada berdasarkan model mekanikal-terma bagi alat pin silinder yang terubah suai bagi profil pin alat poligon dengan memperkenalkan faktor gandaan berdasarkan bilangan sisi geometri alat pin. Perubahan pada bekalan haba efektif berdasarkan geometri pin pilihan telah dikaji. Analisis bandingan pada model analitik yang dicadang bersama model sedia ada, telah dilakukan bagi memahami ketepatan model cadangan. Tambahan, model transien numerikal terma telah dibuat bagi memahami proses perubahan suhu puncak ketika zon pengacauan dan perubahan gradien suhu sepanjang zon terkena haba perubahan geometri pin pada set proses parameter input terpilih. Kajian ini mengaplikasi model numerik berdasarkan input anggaran haba secara analitik. Dapatan kajian menunjukkan suhu puncak proses adalah berkadar langsung dengan bilangan sisi pin alat.

scholarly journals Pin Angle Thermal Effects on Friction Stir Welding of AA5058 Aluminum Alloy: CFD Simulation and Experimental Validation

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7565
Author(s):  
Supat Chupradit ◽  
Dmitry Olegovich Bokov ◽  
Wanich Suksatan ◽  
Michał Landowski ◽  
Dariusz Fydrych ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Heat Generation ◽  
Cfd Simulation ◽  
Fluid Dynamic ◽  
Critical Role ◽  
Internal Heat ◽  
Mechanical Action ◽  
Friction Stir ◽  
Pin Geometry ◽  
Tool Pin

The friction stir welding (FSW) of tool pin geometry plays a critical role in the final properties of the produced joint. The tool pin geometry directly affects the generation of heat and the flow of internal materials during the FSW process. The effects of the FSW tool pin angle on heat generation and internal flow have not been quantitatively investigated in detail. In this manuscript, a validated Computational Fluid Dynamic (CFD) model was implemented to analyze the effects of pin angle on the thermo-mechanical action during the FSW process of AA5058 Al-Mg alloy. Experimental test results validate the thermal outcomes of the used model. The obtained results revealed that, when the pin angle is increased, the heat generation decreases while the mechanical action of the tool increases. The internal heat distribution at a higher pin angle is symmetrical. The higher mechanical action of the tool decreases the viscosity of the internal materials and increases stirring action (materials flow) around the pin. Furthermore, plastic flow near the tool increased stirring action and formed a larger stir zone in the joint area.

scholarly journals Experimental investigations of friction stir welded AA6063 aluminum matrix composite

2018 ◽  
Vol 12 (4) ◽  
pp. 4127-4140
Author(s):  
Narinder Kaushik ◽  
Sandeep Singhal ◽  
Rajesh Rajesh ◽  
Pardeep Gahlot ◽  
B. N Tripathi
Keyword(s):  
Friction Stir Welding ◽  
Matrix Composite ◽  
Aluminum Matrix ◽  
High Speed Steel ◽  
Metal Composite ◽  
Composite Matrix ◽  
Friction Stir ◽  
Sic Particles ◽  
Tool Pin ◽  
The Impact

The advancement of friction stir welding for joining of aluminum alloys and aluminum centered matrix composite has replaced the traditional welding techniques. In this experimental study, AA6063/10.5wt%SiC composite has been produced by employing enhanced stir casting technique with the assistance of Mg metal powder. Specimen composite plates having thickness 6 mm were friction stir welded successfully. The impact of welding variables on mechanical and microstructural characteristics of weldments has been studied. The friction stir welding (FSW) was carried out at a rotation rate of tool of 1400 rpm with a tool transverse rate of 124 mm/min. A cylindrical tool fabricated of high-speed steel (HSS) with square pin shape has been used for FSW. The results revealed that the ultimate tensile strength of the welded joint was 163 MPa, which was very close to the strength of the as-cast composite matrix. The microstructural study showed the reason for higher joint strength and microhardness. The welded butt joint exhibited a change in the microstructure at various four welding zones which transforms the mechanical characteristics of welded joints has been due to the asymmetrical flow of material and thermal cycles around the pin. The intense stirring action of the tool pin during FSW cracked the SiC particles in the weld nugget.  In the weld region, a fine-grained structure and homogeneous dispersion of SiC particles have been observed. The micro porosities associated with the base metal composite matrix were eliminated after FSW.

Friction Stir Welding on Light-Weight Metal - Aluminum Alloy Al6061

2016 ◽  
Vol 879 ◽  
pp. 1233-1238
Author(s):  
Vasanth Chakravarthy Shunmugasamy ◽  
Bilal Mansoor
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Yield Strength ◽  
Base Material ◽  
Frictional Heat ◽  
Tensile Yield Strength ◽  
Impact Properties ◽  
Friction Stir ◽  
Tool Pin ◽  
The Impact

Friction stir welding (FSW) is a solid state joining process in which metals are joined together using frictional heat and severe plastic deformation. The heating and the mixing of the metals is performed using a hardened tool with a shoulder and pin. FSW of lightweight metal alloy Al6061 has been carried out in the present study. For welding aluminum the parameters used were a constant tool rotation speed of 1600 rpm and varying tool translation speeds of 250, 500, 750 and 1000 mm/min. The welded coupons were characterized for microstructural observations and mechanical properties such as tensile and Charpy impact properties. The tensile and impact properties were studied at two different temperature namely, room temperature (RT) and 300°C. The FS welded aluminum specimens showed 86% – 98% tensile yield strength, in comparison to the base material at RT. At 300°C, the yield strength was observed to be 85% to 93% of the base material value. For the impact properties, the Al specimens showed 60% – 140% specific impact energy, in comparison to their respective base materials. Based on the mechanical properties and microstructural examination, the optimal weld parameter was identified as 1600 rpm and 250 mm/min which is dependent on the tool pin and shoulder design utilized in the study.

scholarly journals A Review on Impact of Tool pin Geometry on Friction Stir Welding of Aluminum alloys

2020 ◽  
Vol 981 ◽  
pp. 042018
Author(s):  
M Shiva Chander ◽  
M Ramakrishna ◽  
B Durga prasad ◽  
Adla Rajesh
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Friction Stir ◽  
Pin Geometry ◽  
Tool Pin

Microstructural and Mechanical Behaviour Evaluation of Mg-Al-Zn Alloy Friction Stir Welded Joint

2020 ◽  
Vol 17 (3) ◽  
pp. 8150-8159
Author(s):  
Kulwant Singh ◽  
Gurbhinder Singh ◽  
Harmeet Singh
Keyword(s):  
Heat Treatment ◽  
Friction Stir Welding ◽  
Magnesium Alloys ◽  
Mechanical Performance ◽  
Fuel Efficiency ◽  
Research Work ◽  
Grain Structure ◽  
Tensile Fracture ◽  
Friction Stir ◽  
The Impact

The weight reduction concept is most effective to reduce the emissions of greenhouse gases from vehicles, which also improves fuel efficiency. Amongst lightweight materials, magnesium alloys are attractive to the automotive sector as a structural material. Welding feasibility of magnesium alloys acts as an influential role in its usage for lightweight prospects. Friction stir welding (FSW) is an appropriate technique as compared to other welding techniques to join magnesium alloys. Field of friction stir welding is emerging in the current scenario. The friction stir welding technique has been selected to weld AZ91 magnesium alloys in the current research work. The microstructure and mechanical characteristics of the produced FSW butt joints have been investigated. Further, the influence of post welding heat treatment (at 260 °C for 1 h) on these properties has also been examined. Post welding heat treatment (PWHT) resulted in the improvement of the grain structure of weld zones which affected the mechanical performance of the joints. After heat treatment, the tensile strength and elongation of the joint increased by 12.6 % and 31.9 % respectively. It is proven that after PWHT, the microhardness of the stir zone reduced and a comparatively smoothened microhardness profile of the FSW joint obtained. No considerable variation in the location of the tensile fracture was witnessed after PWHT. The results show that the impact toughness of the weld joints further decreases after post welding heat treatment.

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.

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