scholarly journals Springback of Friction Stir Welded Sheets Made of Aluminium Grades during V-Bending: An Experimental Study

2014 ◽  
Vol 2014 ◽  
pp. 1-15 ◽  
Author(s):  
B. Durga Rao ◽  
R. Ganesh Narayanan
Keyword(s):  
Yield Strength ◽  
Young’S Modulus ◽  
Welding Speed ◽  
Rotational Speed ◽  
Young's Modulus ◽  
Weld Zone ◽  
Base Material ◽  
Strain Hardening Exponent ◽  
Friction Stir ◽  
Shoulder Diameter

The main aim of the present work is to study the effect of shoulder diameter, rotational speed, and welding speed on the springback performance of friction stir welded sheets. The friction stir welded sheets are made by welding 6061T6 to 5052H32, and 6061T6 to 6061T6. The springback has been evaluated after V-bending of welded sheets, involving pure bending. The relation between springback and weld zone properties like yield strength, Young’s modulus, yield strength to Young’s modulus ratio, and strain hardening exponent is identified. It is found that, with increase in shoulder diameter, rotational speed, and welding speed, the springback of friction stir welded sheets has reduced, and is independent of the material combinations. The relation between springback and weld properties change coincides with existing knowledge about springback. The friction stir welded sheets show better springback performance as compared to 6061T6 base material, but inferior to 5052H32 base material. By reducing the punch nose radius, the springback of friction stir welded sheets can be minimized. It is also concluded that, by proper tailoring of Al grades, and by alteration of weld zone properties through friction stir welding, the springback of friction stir welded sheets can be reduced considerably.

In-Plane Plane-Strain Formability Investigation of Friction Stir Welded Sheets Made of Dissimilar Aluminium Alloys

2013 ◽  
Vol 446-447 ◽  
pp. 301-305
Author(s):  
Mukesh Kumar ◽  
Satish V. Kailas ◽  
R. Ganesh Narayanan
Keyword(s):  
Plane Strain ◽  
Heat Input ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Traverse Speed ◽  
Al Alloys ◽  
Welding Parameters ◽  
Strain Hardening Exponent ◽  
Friction Stir ◽  
Shoulder Diameter

In the present work, the influence of shoulder diameter, traverse speed, and rotational speed on the formability of friction stir welded sheets made between sheets of AA6061T6 and AA5052H32 Al alloys has been studied. In-Plane Plane-Strain formability tests are conducted for this purpose. It is understood from the results that the formability of welded sheets can be improved by optimizing the welding and tool parameters. A larger shoulder diameter, higher traverse speed, and lower rotational speed are favorable for improved formability, and strain hardening exponent of weld region. This is due to the fact that the heat input and subsequent microstructure evolved depends on the heat input, which depends on the welding parameters.

scholarly journals Mechanical properties and microstructural characteristics of friction stir welded AA2014-T6 aluminium alloy joints

2019 ◽  
Vol 28 (1) ◽  
pp. 169-185 ◽  
Author(s):  
Chinnasamy Rajendran ◽  
Kasi Srinivasan ◽  
Visvalingam Balasubramanian ◽  
Haridasu Balaji ◽  
Ponnumuthu Selvaraj
Keyword(s):  
Aluminium Alloy ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Welding Parameters ◽  
Microstructural Characteristics ◽  
Friction Stir ◽  
Shoulder Diameter ◽  
Working Parameters

AbstractThe quality of friction stir welded joints depends upon the working parameters such as rotational speed, welding speed, shoulder diameter, tilt angle; etc. Each process parameter has a significant effect on the formation of joint strength. This investigation attempts to understand the effect of friction stir welding parameters on microstructural characteristics and tensile strength of AA2014-T6 aluminium alloy. This is performed by changing any one of the process parameters from minimum to maximum and keeping others constant. The joint fabricated from a rotational speed of 1500 rpm, welding speed of 40 mm/min, shoulder diameter of 6 mm and tilt angle of 1.5∘ yielded superior tensile properties compared to their counter joints. Due to the formation of defect-free weld, balanced material flow and uniform distribution of strengthening precipitates in the stir zone is achieved.

scholarly journals Parametric optimization of friction stir welding of Al-Mg-Si alloy: A case study

2021 ◽  
pp. 7-7
Author(s):  
Nasir Khan ◽  
Sandeep Rathee ◽  
Manu Srivastav
Keyword(s):  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Automobile Construction ◽  
Input Variables

Al-Mg-Si alloys have wide applications in industries such as aerospace, marine, automobile, construction. In this work, newly developed friction stir welding (FSW) was utilized for joining of AA6082-T6 alloy. The effect of major FSW process variables like rotational speed, traverse speed, and shoulder diameter of tool is studied over microstructural and mechanical characteristics of friction stir welded (FSWed) joints. Experimental design was done using Taguchi method (L9 orthogonal array). Three factors viz. rotational speed, welding speed, and diameter of tool shoulder were taken at three levels each. Mathematical modelling was developed in order to optimize the tensile strength of weld joints. Analysis of variance (ANOVA) was utilized to determine the percentage contribution of input variables. The results of present study exhibits that shoulder diameter, rotation, and welding speed of tool significantly affect the mechanical strength of FSWed joints.

Study of optimum welding performance in friction stir welding of dissimilar Mg alloys using integrated RSM-TLBO algorithm

2021 ◽  
pp. 095440892110581
Author(s):  
Umesh Kumar Singh ◽  
Avanish Kumar Dubey
Keyword(s):  
Surface Roughness ◽  
Friction Stir Welding ◽  
Magnesium Alloys ◽  
Optimization Algorithm ◽  
Welding Speed ◽  
Rotational Speed ◽  
Friction Stir ◽  
Shoulder Diameter ◽  
Teaching Learning Based Optimization ◽  
Teaching Learning

Lightweight with excellent strength of magnesium alloys has attracted its use in transportation industries but difficulty in fusion welding of magnesium alloys restricts its application. The present research investigates solid state friction stir welding of dissimilar AZ31-AZ91 magnesium alloys with aim to achieve optimum quality welds. Surface roughness, microstructure and mechanical properties of these joints have been investigated at different tool rotational speed, welding speed and tool shoulder diameter. Maximum joint strength obtained is 89.71% (as compare to AZ31) which is more than the previously reported joint strengths of dissimilar magnesium alloys. Further, mathematical relations for responses have been developed and utilised for multi-objective optimization using teaching-learning-based optimization algorithm. Eventually, teaching-learning-based optimization algorithm results suggest that the optimum value of surface roughness (3.3925 µm), grain size (12.6869 µm), tensile strength (237.9621 MPa), microhardness (69.3652 Hv) and flexural strength (333.2285 MPa) can be achieved at 921 rpm rotational speed, 30 mm/min welding speed and 15 mm shoulder diameter with overall improvement in multiple responses.

Multi-response optimization of friction stir welding process of dissimilar AA3003-H12 and C12200-H01 alloys using full factorial method

2021 ◽  
pp. 095440892110082
Author(s):  
Gurunath V Shinde ◽  
Rachayya R Arakerimath
Keyword(s):  
Grain Size ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Microstructural Analysis ◽  
Research Work ◽  
Friction Stir ◽  
Shoulder Diameter ◽  
Tool Pin ◽  
Full Factorial

In current research work, an attempt has been made to join dissimilar metals by employing friction stir welding (FSW), i.e., AA3003-H12 (aluminium alloy) and C12200-H01 (copper alloy). The experiments are designed as per full factorial design at different process parameters, namely tool pin profiles, rotational speed, welding speed, and shoulder diameter while the ultimate tensile strength (UTS), yield strength (YS), and percentage elongation (% E) are considered as a performance parameter. Moreover, a statistical tool, i.e., analysis of variance (ANOVA) is also utilized to check the adequacy of the results. It is observed that the higher UTS, % E and YS are obtained by employing a taper pin profile tool at a rotational speed of 1800 rpm, a welding speed of 16 mm/min, and a shoulder diameter of 22.5 mm. The ANOVA results showed that the rotational speed is the most significant factor for current research work. In addition, a scanning electron microscope is utilized for microstructural analysis of welded joints. It is witnessed that the minimum grain size, i.e., 4 microns, is obtained for highest strength specimen and the maximum grain size is obtained for the lowest strength specimen i.e., 31 microns. Besides this, the swirling of cu particle is also observed from advancing side (AS) to the retreating side (RS). Moreover, energy-dispersive X-ray spectroscopy (EDS) indicates the formation of intermetallic compounds i.e. Al2Cu, Al9Cu4 at nugget zone (NZ). The hardness is found to be higher at NZ due to the presence of Al-Cu intermetallic.

Effect of Welding Speeds on Mechanical Properties of Level Compensation Friction Stir Welded 6061-T6 Aluminum Alloy

2016 ◽  
Vol 35 (4) ◽  
pp. 375-379 ◽  
Author(s):  
Quan Wen ◽  
Yumei Yue ◽  
Shude Ji ◽  
Zhengwei Li ◽  
Shuangsheng Gao
Keyword(s):  
Aluminum Alloy ◽  
Welding Speed ◽  
Weld Zone ◽  
Base Material ◽  
Tensile Fracture ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Fracture Position ◽  
Transverse Tensile ◽  
Equal Thickness

AbstractIn order to eliminate the flash, arc corrugation and concave in weld zone, level compensation friction stir welding (LCFSW) was put forward and successfully applied to weld 6061-T6 aluminum alloy with varied welding speed at a constant tool rotational speed of 1,800 rpm in the present study. The glossy joint with equal thickness of base material can be attained, and the shoulder affected zone (SAZ) was obviously reduced. The results of transverse tensile test indicate that the tensile strength and elongation reach the maximum values of 248 MPa and 7.1% when the welding speed is 600 mm/min. The microhardness of weld nugget (WN) is lower than that of base material. The tensile fracture position locates at the heat affected zone (HAZ) of the advancing side (AS), where the microhardness is the minimum. The fracture surface morphology represents the typical ductile fracture.

scholarly journals Experimental Study on Laser-MIG Hybrid Welding of Thick High-Mn Steel Plate for Cryogenic Tank Production

2021 ◽  
Vol 9 (6) ◽  
pp. 604
Author(s):  
Du-Song Kim ◽  
Hee-Keun Lee ◽  
Woo-Jae Seong ◽  
Kwang-Hyeon Lee ◽  
Hee-Seon Bang
Keyword(s):  
Low Temperature ◽  
Yield Strength ◽  
Steel Plate ◽  
Weld Zone ◽  
Base Material ◽  
Hardness Test ◽  
Steel Plates ◽  
Hybrid Welding ◽  
Temperature Impact ◽  
Mn Steel

The International Maritime Organization has recently updated the ship emission standards to reduce atmospheric contamination. One technique for reducing emissions involves using liquefied natural gas (LNG). The tanks used for the transport and storage of LNG must have very low thermal expansion and high cryogenic toughness. For excellent cryogenic properties, high-Mn steel with a complete austenitic structure is used to design these tanks. We aim to determine the optimum welding conditions for performing Laser-MIG (Metal Inert Gas) hybrid welding through the MIG leading and laser following processes. A welding speed of 100 cm/min was used for welding a 15 mm thick high-Mn steel plate. The welding performance was evaluated through mechanical property tests (tensile and yield strength, low-temperature impact, hardness) of the welded joints after performing the experiment. As a result, it was confirmed that the tensile strength was slightly less than 818.4 MPa, and the yield strength was 30% higher than base material. The low-temperature impact values were equal to or greater than 58 J at all locations in the weld zone. The hardness test confirmed that the hardness did not exceed 292 HV. The results of this study indicate that it is possible to use laser-MIG hybrid welding on thick high-Mn steel plates.

scholarly journals Shoulder Related Temperature Thresholds in FSSW of Aluminium Alloys

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4375
Author(s):  
David G. Andrade ◽  
Sree Sabari ◽  
Carlos Leitão ◽  
Dulce M. Rodrigues
Keyword(s):  
Heat Generation ◽  
Process Parameters ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Spot Welding ◽  
Base Material ◽  
Main Process ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Diameter

Friction Stir Spot Welding (FSSW) is assumed as an environment-friendly technique, suitable for the spot welding of several materials. Nevertheless, it is consensual that the temperature control during the process is not feasible, since the exact heat generation mechanisms are still unknown. In current work, the heat generation in FSSW of aluminium alloys, was assessed by producing bead-on-plate spot welds using pinless tools. Coated and uncoated tools, with varied diameters and rotational speeds, were tested. Heat treatable (AA2017, AA6082 and AA7075) and non-heat treatable (AA5083) aluminium alloys were welded to assess any possible influence of the base material properties on heat generation. A parametric analysis enabled to establish a relationship between the process parameters and the heat generation. It was found that for rotational speeds higher than 600 rpm, the main process parameter governing the heat generation is the tool diameter. For each tool diameter, a threshold in the welding temperature was identified, which is independent of the rotational speed and of the aluminium alloy being welded. It is demonstrated that, for aluminium alloys, the temperature in FSSW may be controlled using a suitable combination of rotational speed and tool dimensions. The temperature evolution with process parameters was modelled and the model predictions were found to fit satisfactorily the experimental results.

Procedure to find out the optimal ranges of process parameters for friction stir welding

2021 ◽  
pp. 146442072199314
Author(s):  
Shubham Verma ◽  
Joy Prakash Misra ◽  
Meenu Gupta
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Optical Microscope ◽  
Graphical Analysis ◽  
Friction Stir ◽  
Steepest Ascent ◽  
Vertical Milling Machine

The present study deals with the application of sequential procedure (i.e. steepest ascent) to obtain the optimum values of process parameters for conducting friction stir welding (FSW) experiments. A vertical milling machine is modified by fabricating fixture and tool ( H13 material) for performing FSW operation to join AA7039 plates. The steepest ascent technique is employed to design the experiments at different rotational speed, welding speed, and tilt angle. The ultimate tensile strength is considered as a performance characteristic for deciding the optimal levels. The mechanical and metallurgical characteristics of the joints are studied by executing tensile and microhardness tests. It is concluded from the graphical analysis of the steepest ascent technique that the optimal maximum and minimum values are 1812–1325 r/min for rotational speed, 43–26 mm/min for welding speed, and 2°–1.3° for tilt angle, respectively. Besides, optical microscope and scanning electron microscope are utilized for microstructural and fractographic analyses for a better understanding of the process.

Sign in / Sign up

Export Citation Format

Share Document