scholarly journals Process Parameters Effect on Mechanical Properties and Fatigue Behavior of Friction Stir Weld AA6060 Joints

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
M. Longo ◽  
G. D’Urso ◽  
C. Giardini ◽  
E. Ceretti
Keyword(s):  
Mechanical Properties ◽  
High Performance ◽  
Fatigue Behavior ◽  
Welding Process ◽  
Fusion Welding ◽  
Fatigue Properties ◽  
Friction Stir Weld ◽  
Welding Parameters ◽  
Rotating Speed ◽  
Friction Stir

Friction stir welding (FSW) is the most remarkable welding technology that has been invented and developed in the last decade. It is a solid-state welding process in which a rotating tool is driven into the material and translated along the interface of two or more plates. This technology has been successfully used to join materials that are considered difficult to be welded by fusion welding methods. FSW has potentially significant applications in many industrial fields such as aerospace, automotive, and naval industry. Anyway, FSW technology requires a meticulous understanding of the process and consequent mechanical properties of the welds in order to be used in the production of high performance components. The present work deals with an experimental campaign aimed at the evaluation of the mechanical properties of AA6060 T6 friction stir welded joints. The butt joints obtained using two different tool geometries (standard and threaded) were performed by varying the welding parameters, namely, tool rotating speed and feed rate. The standard tool was a very simple device fabricated using AISI 1040 steel, with a flat shoulder and a cylindrical pin. The threaded tool was a more complex device based on two main components: a tool holder, with a flat shoulder, and a threaded probe obtained using a commercial thread forming tap. The quality of the joints was evaluated in terms of both tensile strength (UTS) and fatigue behavior. The study of axial pulsing fatigue properties required the fabrication of a specific testing device able to avoid parasite bending moments. In order to estimate the more efficient and effective tool type, the welding forces (axial and longitudinal) were also measured.

Influence of Tool Rotational Speed on the Mechanical Properties of Friction Stir Welded Al-Cu-Li Alloy

2016 ◽  
Vol 857 ◽  
pp. 228-231
Author(s):  
Ho Sung Lee ◽  
Ye Rim Lee ◽  
Kyung Ju Min
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Space Shuttle ◽  
Welding Process ◽  
High Strength ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Mechanical And Microstructural Properties ◽  
Tool Rotation

Aluminum-Lithium alloys have been found to exhibit superior mechanical properties as compared to the conventional aerospace aluminum alloys in terms of high strength, high modulus, low density, good corrosion resistance and fracture toughness at cryogenic temperatures. Even though they do not form low-melting eutectics during fusion welding, there are still problems like porosity, solidification cracking, and loss of lithium. This is why solid state friction stir welding is important in this alloy. It is known that using Al-Cu-Li alloy and friction stir welding to super lightweight external tank for space shuttle, significant weight reduction has been achieved. The objective of this paper is to investigate the effect of friction stir tool rotation speed on mechanical and microstructural properties of Al-Cu-Li alloy. The plates were joined with friction stir welding process using different tool rotation speeds (300-800 rpm) and welding speeds (120-420 mm/min), which are the two prime welding parameters in this process.

Experimental Investigations on Characteristics and Welding Forces in Friction Stir Welding of AA 6061-T6 Aluminum Alloy

2012 ◽  
Vol 249-250 ◽  
pp. 295-302
Author(s):  
Qing Xia Wang ◽  
Jian Guo Yang ◽  
Ling Long Ding
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
High Performance ◽  
Experimental Investigations ◽  
Welding Parameters ◽  
Rotating Speed ◽  
Friction Stir ◽  
Welding Forces ◽  
Hot Work Die ◽  
And Control

Friction stir welding (FSW) technology requires a meticulous understanding of the process and consequent mechanical properties of the welds in order to be used in the production of high performance components. This paper deals with an experimental campaign aimed at the evaluation of the mechanical properties of AA6061-T6 friction stir welded joints. The joints are obtained by varying the welding parameters, namely, tool rotating speed and feed rate. The non-threaded tool is made of hot work die steel H13. The quality of the joints is evaluated in terms of both hardness and tensile strength. Moreover, for going a step further to study and control welding heat input in FSW process, a piezoelectric load cell is installed between the fixture table and the machine tool workbench in order to measure the welding forces in different directions.

On the role of input welding parameters on the microstructure and mechanical properties of Al6061-T6 alloy during the friction stir welding: Experimental and numerical investigation

2021 ◽  
pp. 146442072110444
Author(s):  
Behrouz Bagheri ◽  
Farzaneh Sharifi ◽  
Mahmoud Abbasi ◽  
Amin Abdollahzadeh
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Welding Parameters ◽  
Optimal Parameters ◽  
Rotating Speed ◽  
Friction Stir ◽  
Microstructure And Mechanical Properties ◽  
Material Element

The Taguchi method was employed to find the optimum values of friction stir welding parameters including welding speed, rotating speed, and tilt angle for joining AA6061-T6 aluminum alloys. The combined influences of these parameters were entirely analyzed. Statistical outcomes were investigated by the study of variances and signal-to-noise ratios. A Coupled Eulerian and Lagrangian technique is implemented to simulate and verify the optimal parameters during the friction stir welding. To verify results, a comparison between the welding process under optimized parameters with experimental and non-optimized parameters was simulated for the friction stir welding process. The material flow, strain rate, thermal behaviors, and mechanical properties of samples fabricated with optimal welding parameters are higher than those produced from the non-optimal parameters. It was also concluded that the grain size of the stir zone under optimal welding parameters (6–8 µm) is finer than that of non-optimal welding parameters (11–13 µm). Low uniform distribution of material element and coarse microstructure were some of the results of welding with non-optimized parameters. Based on residual stress analysis, the application of optimal joining conditions can decrease the peak tensile residual stress by about 38.3%. The much desirable results obtained in terms of microstructure and mechanical properties could be of great significance to the welding industry.

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 The Effects of In-Process Cooling during Friction Stir Welding of 7475 Aluminium Alloy

2021 ◽  
Vol 50 (9) ◽  
pp. 2743-2754
Author(s):  
Ashish Jacob ◽  
Sachin Maheshwari ◽  
Arshad Noor Siddiquee ◽  
Abdulrahman Al-Ahmari ◽  
Mustufa Haider Abidi ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welded Joints ◽  
Positive Impact ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir ◽  
Cooling Conditions ◽  
Zero Degree ◽  
Welding Technique

Certain age hardenable alloys such as AA7475 cannot be joined with perfection using fusion welding techniques. This requires non-conventional welding technique such as friction stir welding process to join these ‘difficult to weld’ alloys. In this study, three different cooling conditions i.e. cryogenic, sub-zero, and zero-degree Celsius temperature conditions have been analyzed to understand its impact on the welding process. In-process cooling was found to behave effectively and also enhanced the mechanical properties of the welded joints. A stable microstructure was clearly seen in the images observed under the metallurgical microscope. The weld efficiencies were found to be good in each of the samples which are indicative of a strong metallic joint. The effective cooling conditions employed had an overall positive impact on the joint.

Studying Mechanical Properties Specially Fatigue Behavior of (Polyether Ether Ketone)/Glass Fiber Composites in Aerospace Applications

2014 ◽  
Vol 666 ◽  
pp. 8-16
Author(s):  
A. Saad Najim ◽  
Mohammed Adwaa
Keyword(s):  
Mechanical Properties ◽  
Glass Fiber ◽  
High Performance ◽  
Fatigue Behavior ◽  
Fatigue Properties ◽  
Glass Fiber Composites ◽  
Aerospace Applications ◽  
Polyether Ether Ketone ◽  
High Performance Composite ◽  
Ether Ketone

This work deals with studying the mechanical properties specially fatigue behavior for high performance composite materials of poly ether ether ketone (PEEK)/glass fiber, which are used in Aircraft Industry. Two materials have been used: (PEEK natural) and (PEEK+30% glass fiber).To identify the type of (PEEK), infrared (FTIR) test has been conducted. X-ray test has been used to measure the (PEEK) crystalline ,also the tensile properties, impact strength and the fatigue test are performed.The results show that FTIR test peaks are for standard PEEK polymer and that GFRP increases the crystalline of (PEEK) material , while the tensile , impact and fatigue properties of (PEEK) decreases by adding GF to PEEK .

Mechanical Characterization of AA2024-T3 FSWed Butt Joints

2013 ◽  
Vol 753-755 ◽  
pp. 431-434 ◽  
Author(s):  
Pierpaolo Carlone ◽  
Gaetano S. Palazzo
Keyword(s):  
Mechanical Properties ◽  
Mechanical Characterization ◽  
Base Material ◽  
Welding Process ◽  
Butt Joints ◽  
Influence Of Process Parameters ◽  
Rotating Speed ◽  
Friction Stir ◽  
Process Heat

In recent years friction stir welding process has received a great deal of attention from the transport industry. During the process, heat generation and material stirring induce significant microstructural alteration in the base material, affecting the properties of the welded assembly. In this paper the influence of process parameters, namely rotating speed and welding speed, on mechanical properties of AA2024-T3 friction stir butt welds is experimentally investigated. An increase of the yield stress has been found decreasing the heat input, while an opposite variation was measured for the elongation.

Influence of Heating Friction Stir Spot Welding Process Parameters on Steel Aluminum Forming Quality

2018 ◽  
Vol 917 ◽  
pp. 246-251
Author(s):  
Kai Xu ◽  
Shu Quan Zhang
Keyword(s):  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
Joint Line ◽  
Welding Parameters ◽  
Forming Quality ◽  
Rotating Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Pressure

A lap welding experiment of DP590 steel and 6061 aluminum plate is carried out by using Heating Friction Stir Spot Welding (HFSSW) to study the influence of welding parameters on the forming quality. The results show that a lap joint with better forming can be obtained for the dissimilar metal of steel and aluminum. Under the condition that the rotating speed of the stirring tool is 1000r/min, the penetration depth, 0.2mm, the dwell time, 90s, the welding pressure, 0.2Mp, and the flow rate of cooling air, 20L/min, the forming quality of the surface of the joint line is good & bright, and the exit hole is also smaller. The mechanism of heat production is revealed in the following: the main heat is produced by the friction between the stirring tool shoulder and the welded part & between the probe and the welded part as well as by the latent heat resulted from the plastic deformation of the material in joint line during welding.

scholarly journals Influence of Parameters on Micro Structural and Mechanical Properties of Aluminium Based Alloy (A356) with Friction Stir Welding

2019 ◽  
Vol 9 (2) ◽  
pp. 4802-4805
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Liquid Nitrogen ◽  
Welding Process ◽  
Experimental Investigations ◽  
Air Cooling ◽  
Rotating Speed ◽  
Friction Stir ◽  
Lubrication Oil ◽  
Machining Properties

This study examines the influence of varied conditions of cooling and different rotations of tool on the accuracy of weld of aluminum samples taken out by friction stir welding process. The aim of this study was to check the effects on samples of aluminum alloy of A356 grades that were welded by friction stir welding under various conditions of cooling like cooling by water, cooling by air, cooling by nitrogen gas and cooling by lubrication oil at two varied rotating speed of tool at 900 revolution per minute and 1100 revolution per minute. These readings were being carried by experimental investigations. The influence of these different parameters on micro structural and mechanical properties of these joint are discussed. Cooling the different specimens by lubrication oil or liquid nitrogen showed to reduce the input heat in processing which reduce the improvement of grains in between the process. The reduction in input heat showed in decreasing the microscopic defects in the specimen found to gain in micro hardness and betterment of tensile properties. It was observed that best machining properties was found when the rotational speed is higher and no condition of cooling is used i.e. friction stir welding is applied in air. Also, the better findings found out from all the specimens when cooling by liquid nitrogen under rotating speed of tool at 1100 rpm as it represents higher tensile.

scholarly journals Study on Friction Stir Lap Welding of Aluminium to Steel Sheets

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 498
Author(s):  
Lingfei Meng ◽  
Shujin Chen ◽  
Jiaqi Zhang ◽  
Di Wang ◽  
Hao Zhang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Melting Point ◽  
Welding Process ◽  
Zinc Content ◽  
Galvanized Steel ◽  
Formation Mechanisms ◽  
Friction Stir Lap Welding ◽  
Rotating Speed ◽  
Friction Stir ◽  
Lap Welding

Friction stir lap welding (FSLW) of 6061-T6 aluminium sheet and DX51D galvanized steel sheet was carried out by adding zinc foil to the lap interface and studying the influence of the zinc foil on the formation mechanisms and mechanical properties. The influence of the thickness of zinc foil, the plunge depth of the shoulder and the shape of the tools on the mechanical properties of the weld are discussed. Zinc foil reduced the generation of brittle intermetallic compounds, such as Fe4Al13. During the welding process, the axial force was small due to the high rotating speed. Liquid zinc was retained at the interface, where eutectic Al–Zn with low melting point and an Fe–Zn compound were generated to achieve the metallurgical combination of aluminium and steel. The fracture was located in the heat affected zone (HAZ) of the 6061-T6 base aluminium. The results showed that when the zinc foil was too thin, there was less zinc content at the interface; the resulting Al–Zn eutectic had low melting point, was not fully spread and had poor continuity, resulting in poor mechanical properties. When the zinc foil was too thick, a large amount of zinc-based solid solution was generated at the interface, and most of the fracture occurred in the zinc-rich layer.

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