Effect of friction stir welding parameters on defect formation

2015 ◽  
Author(s):  
S. Yu. Tarasov ◽  
V. E. Rubtsov ◽  
A. A. Eliseev ◽  
E. A. Kolubaev ◽  
A. V. Filippov ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Defect Formation ◽  
Welding Parameters ◽  
Friction Stir

Investigation of material flow and thermomechanical behavior during friction stir welding of an AZ31B alloy for threaded and unthreaded pin geometries using computational solid mechanics simulation

2020 ◽  
pp. 095440622096254
Author(s):  
RAR Giorjao ◽  
EB Fonseca ◽  
JA Avila ◽  
EF Monlevade ◽  
AP Tschiptschin
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Solid Mechanics ◽  
Defect Formation ◽  
Welding Process ◽  
High Sensitivity ◽  
Thermomechanical Behavior ◽  
Welding Parameters ◽  
Arbitrary Lagrangian Eulerian ◽  
Friction Stir

In the friction stir welding process, the tool role in the material flow and its thermomechanical behavior is still not entirely understood. Several modeling approaches attempted to explain the material and tool relationship, but to this date, insufficient results were provided in this matter. Regarding this issue and the urgent need for trustful friction stir welding models, a computational solid mechanic's model capable of simulating material flow and defect formation is presented. This model uses an Arbitrary Lagrangian-Eulerian code comparing a threaded and unthread pin profile. The model was able to reproduce the tool's torque, temperatures, and material flow along the entire process, including the underreported downward flow effect promoted by threaded pin's. A point tracking analysis revealed that threads increase the material velocity and strain rate to almost 30% compared to unthreaded conditions, promoting a temperature increment during the process, which improved the material flow and avoided filling defects. The presented results showed the model's capability to reproduce the defects observed in real welded joints, material thermomechanical characteristics and high sensitivity to welding parameters and tool geometries. Nevertheless, the outcomes of this work contribute to essential guidelines for future friction stir welding modeling and development, tool design, and defect prediction.

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.

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