Comparing the weld zone representation methods during the formability prediction of friction stir welded blanks

2011 ◽  
Author(s):  
Perumalla Janaki Ramulu ◽  
R. Ganesh Narayanan
Keyword(s):  
Weld Zone ◽  
Friction Stir ◽  
Formability Prediction ◽  
Friction Stir Welded Blanks

Effects of bottom plate in friction stir welding of AA6061-T6

2020 ◽  
Vol 118 (1) ◽  
pp. 108
Author(s):  
M.A. Vinayagamoorthi ◽  
M. Prince ◽  
S. Balasubramanian
Keyword(s):  
Mechanical Properties ◽  
Axial Load ◽  
Weld Zone ◽  
Welding Process ◽  
Bottom Plate ◽  
Welding Parameters ◽  
Nugget Zone ◽  
Friction Stir ◽  
Weld Joints ◽  
Fine Grain

The effects of 40 mm width bottom plates on the microstructural modifications and the mechanical properties of a 6 mm thick FSW AA6061-T6 joint have been investigated. The bottom plates are placed partially at the weld zone to absorb and dissipate heat during the welding process. An axial load of 5 to 7 kN, a rotational speed of 500 rpm, and a welding speed of 50 mm/min are employed as welding parameters. The size of the nugget zone (NZ) and heat-affected zone (HAZ) in the weld joints obtained from AISI 1040 steel bottom plate is more significant than that of weld joints obtained using copper bottom plate due to lower thermal conductivity of steel. Also, the weld joints obtained using copper bottom plate have fine grain microstructure due to the dynamic recrystallization. The friction stir welded joints obtained with copper bottom plate have exhibited higher ductility of 8.9% and higher tensile strength of 172 MPa as compared to the joints obtained using a steel bottom plate.

scholarly journals Mechanical and Microstructural Characterization of Friction Stir Welded SiC and B4C Reinforced Aluminium Alloy AA6061 Metal Matrix Composites

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 3110
Author(s):  
Kaveripakkam Suban Ashraff Ali ◽  
Vinayagam Mohanavel ◽  
Subbiah Arungalai Vendan ◽  
Manickam Ravichandran ◽  
Anshul Yadav ◽  
...  
Keyword(s):  
Wear Rate ◽  
Aluminium Alloy ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Weld Zone ◽  
Base Material ◽  
Matrix Composites ◽  
Wear Properties ◽  
Friction Stir ◽  
Behavioural Aspects

This study focuses on the properties and process parameters dictating behavioural aspects of friction stir welded Aluminium Alloy AA6061 metal matrix composites reinforced with varying percentages of SiC and B4C. The joint properties in terms of mechanical strength, microstructural integrity and quality were examined. The weld reveals grain refinement and uniform distribution of reinforced particles in the joint region leading to improved strength compared to other joints of varying base material compositions. The tensile properties of the friction stir welded Al-MMCs improved after reinforcement with SiC and B4C. The maximum ultimate tensile stress was around 172.8 ± 1.9 MPa for composite with 10% SiC and 3% B4C reinforcement. The percentage elongation decreased as the percentage of SiC decreases and B4C increases. The hardness of the Al-MMCs improved considerably by adding reinforcement and subsequent thermal action during the FSW process, indicating an optimal increase as it eliminates brittleness. It was seen that higher SiC content contributes to higher strength, improved wear properties and hardness. The wear rate was as high as 12 ± 0.9 g/s for 10% SiC reinforcement and 30 N load. The wear rate reduced for lower values of load and increased with B4C reinforcement. The microstructural examination at the joints reveals the flow of plasticized metal from advancing to the retreating side. The formation of onion rings in the weld zone was due to the cylindrical FSW rotating tool material impression during the stirring action. Alterations in chemical properties are negligible, thereby retaining the original characteristics of the materials post welding. No major cracks or pores were observed during the non-destructive testing process that established good quality of the weld. The results are indicated improvement in mechanical and microstructural properties of the weld.

Friction Stir Welding of Dissimilar Formed Mg Alloys (AZ31/AZ91)

2005 ◽  
Vol 486-487 ◽  
pp. 249-252 ◽  
Author(s):  
Chang Yong Lee ◽  
Won Bae Lee ◽  
Yun Mo Yeon ◽  
Seung Boo Jung
Keyword(s):  
Friction Stir Welding ◽  
Dynamic Recrystallization ◽  
Tensile Test ◽  
Intermetallic Compounds ◽  
Grain Growth ◽  
Weld Zone ◽  
Mg Alloys ◽  
Mg Alloy ◽  
Friction Stir ◽  
Az31 Mg Alloy

Friction stir welding of dissimilar formed Mg alloys(AZ31/AZ91) was successfully carried out at the limited welding conditions. In a sound joint, SZ was mainly consisted of AZ31 Mg alloy which was located the retreating side. Dynamic recrystallization and grain growth occurred and β intermetallic compounds of AZ 91 Mg alloy was not observed in SZ. BM had a higher hardness than that of the weld zone. The fracture location was not weld zone but BM of the AZ91 Mg alloy in tensile test.

scholarly journals Influence of Mx-Trivex, A-Skew, Three Flat Threaded and Concave Shouldered Mx-Triflute Tool Pin Profiles on Tensile Properties and Fractural Behaviour of Aa 6082-T6 Weldments During Friction Stir Welding

2020 ◽  
Vol 9 (4) ◽  
pp. 1376-1384
Keyword(s):  
Friction Stir Welding ◽  
Tensile Test ◽  
Weld Zone ◽  
Base Material ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Pin ◽  
Solid State Joining ◽  
Joining Process ◽  
Brass Wire

Friction Stir Welding (FSW) is a topical and propitious solid-state joining process producing economical and strengthened joints of age-hardened and heat-treatable Aluminium Alloy AA 6082-T6. Mechanical and fractural behaviour of weldments were investigated in order to find crack initiation and necking on the weld zone thereby perceiving the complete behaviour of fracture occurred near the weld zone. Weldments are fabricated by employing four tool pin profiles namely MX-TRIVEX, A-SKEW, Three flat threaded and Concave shouldered MX-TRIFLUTE tools at various rotational speeds 1000 rpm, 1200 rpm and 1400 rpm at single traverse speed 25 mm/min. EXCETEX-EX-40 CNC wire cut EDM with 0.25 mm brass wire diameter has been employed to perform the extraction of tensile test specimens from the weldments according to ASTM E8M-04 standard. Tensile test was performed on elctromechanically servo controlled TUE-C-200 (UTM machine) according to ASTM B557-16 standards Maximum Ultimate Tensile Strength (UTS) of 172.33 MPa (55.5% of base material) and 0.2% Yield Stress (YS) of 134.10 MPa (51.5% of base material) were obtained by using A-SKEW at 1400 rpm, 25 mm/min and maximum % Elongation (%El) of 11.33 (113.3% of base material) was obtained at MX-TRIVEX at 1000 rpm, 25 mm/min. Minimum UTS of 131.16 MPa (42.30% of base material) and 0.2% YS of 105.207 MPa (40.46% of base material )were obtained by using Concave shouldered MX-TRIFLUTE at 1400 rpm, 25 mm/min. Minimum % El of 5.42 ( 54.2% of base material) was obtained by using A-SKEW at 1000 rpm, 25 mm/min.

S–N curves for fatigue life estimation of friction stir welded 19501 aluminum alloy T-joint

2018 ◽  
Vol 233 (2) ◽  
pp. 664-674
Author(s):  
Prakash Chandra Gope ◽  
Harshit Kumar ◽  
Himanshu Purohit ◽  
Manish Dayal
Keyword(s):  
Aluminum Alloy ◽  
Fatigue Life ◽  
Fatigue Strength ◽  
Weld Zone ◽  
Stress Effect ◽  
Mean Stress ◽  
Friction Stir ◽  
Fracture Surfaces ◽  
Mean Stress Effect ◽  
Metallic Bonding

In this study, the mechanical properties and fatigue life of 19501 aluminum alloy friction stir welded T-joint is investigated. Tensile properties of friction stir welded joint show that there is a marginal reduction of about 5% in strength and ductility as compared to unwelded 19501 aluminum alloy. Fatigue test results of T-joint specimen at two stress ratios of 0 and -1 show that there is a reduction of 15% in fatigue strength due to change of stress ratio from -1 to 0. Also, higher variation is seen in fatigue strength in low cycle zone than the high cycle zone. Effect of mean stress on fatigue life is discussed on the basis of different mean stress effect models. Morrow’s mean stress effect model is found to be better than other models. Micrographs from the fracture surfaces of retreating side, mid weld zone, and advancing side of the T-joint indicates that fracture surfaces are cleavage fracture. Different sizes of inter-metallic bonding are seen in the micrographs, which indicate that fracture is initiated due to breaking of the brittle inter-metallic bonding.

scholarly journals Realizing a Novel Friction Stir Processing-Enabled FWTPET Process for Strength Enhancement Using Firefly and PSO Methods

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 728
Author(s):  
Senthil Kumaran S ◽  
Jayakumar Kaliappan ◽  
Kathiravan Srinivasan ◽  
Yuh-Chung Hu ◽  
Sanjeevikumar Padmanaban ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Friction Stir Processing ◽  
Power Plants ◽  
Weld Zone ◽  
Industrial Applications ◽  
Tube Plate ◽  
Friction Stir ◽  
Input And Output ◽  
Experimental Values

The friction welding of tube to tube plate using an external tool (FWTPET) is widely deployed in several industrial applications, such as aerospace, automotive, and power plants. Moreover, for achieving a better tensile strength and hardness in the weld zone, the friction stir processing (FSP) technique was incorporated into the FWTPET process for joining aluminum alloys (AA6063 tube, AA6061 tube plate). Furthermore, it has to be noted that FWTPET was applied for joining the AA6063 tube to the AA6061 tube plate, and FSP was deployed for reinforcing the weld zone with carbon nanotube (CNT) and silicon nitride (Si3N4) particles, thereby attaining the desirable mechanical properties. Subsequently, the Taguchi L25 orthogonal array was used for identifying the most influential input and output FWTPET + FSP process parameters. Furthermore, particle swarm optimization (PSO) and the firefly algorithm (FFA) were deployed for determining the optimized input and output FWTPET + FSP process parameters. The input process parameters include CNT, Si3N4, rotational tool speed, and depth. Furthermore, the tensile strength of the welded joint was considered as the output process parameter. The process parameters predicted by PSO and FFA were compared with the experimental values. It was witnessed that deviation between the predicted and experimental values was minimal. Moreover, it was found that FFA provided a superior tensile strength prediction than PSO.

Characterization o Solid-State Vortices Associated with the Friction-Stir Welding of Copper to Aluminum

1998 ◽  
Vol 4 (S2) ◽  
pp. 530-531
Author(s):  
R. D. Flores ◽  
L. E. Murr ◽  
E. A. Trillo
Keyword(s):  
Plastic Deformation ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Weld Zone ◽  
Thick Plates ◽  
6061 Aluminum Alloy ◽  
Friction Stir ◽  
The Past ◽  
Joining Process

Although friction-stir welding has been developing as a viable industrial joining process over the past decade, only little attention has been given to the elucidation of associated microstructures. We have recently produced welds of copper to 6061 aluminum alloy using the technique illustrated in Fig. 1. In this process, a steel tool rod (0.6 cm diameter) or head-pin (HP) traverses the seam of 0.64 cm thick plates of copper butted against 6061-T6 aluminum at a rate (T in Fig. 1) of 1 mm/s; and rotating at a speed (R in Fig. 1) of 650 rpm (Fig. 1). A rather remarkable welding of these two materials results at temperatures measured to be around 400°C for 6061-T6 aluminum welded to itself. Consequently, the metals are stirred into one another by extreme plastic deformation which universally seems to involve dynamic recrystallization in the actual weld zone. There is no melting.

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