scholarly journals Mechanical and Microstructure Properties on Al-Cu Joint processed by Friction Stir Welding: The effect of Tilt Angle Tool

2019 ◽  
Vol 16 (1) ◽  
pp. 56-61
Author(s):  
Jupri Jupri ◽  
Jon Affi ◽  
Devi Chandra ◽  
Mochamad Asrofi
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Fracture Surface ◽  
Tensile Test ◽  
Tilt Angle ◽  
Rotation Speed ◽  
Metal Flow ◽  
Friction Stir ◽  
Microstructure Observation

The tilt angle tool on Aluminum A5083 and Copper C11000 joint processed by Friction Stir Welding (FSW) was observed in this study. The rotation speed and transverse speed were used as a parameter process for 2500 rpm and 30 mm/min, respectively. The tensile test and microstructure observation were carried out to determine the tensile strength and metal flow on Al-Cu joint, respectively. The result shows that the highest tensile strength was in 2o tilt angle tool for 105 MPa. Its fracture surface was more close to Al and formed brittle formation.The metal flows of Al-Cu with 0o and 2o were not homogeneous and formed an agglomeration of Cu particle to Al surface.

Effect of Taper Pin Ratio on AA7075 Aluminium Alloy Friction Stir Welding

2016 ◽  
Vol 701 ◽  
pp. 154-158
Author(s):  
Nurul Hidayah Othman ◽  
Norsyahfiana Abdul Razak ◽  
Luqman Hakim Ahmad Shah ◽  
Mahadzir Ishak
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tensile Test ◽  
Optical Microscope ◽  
Milling Machine ◽  
Friction Stir ◽  
Microstructure Observation ◽  
Optimum Parameters ◽  
Shoulder Diameter

This study focuses on the effect of pin taper tool ratio on friction stir welding of aluminum AA7075. Two pieces of AA7075 alloy with thickness of 6 mm were friction stir welded by using conventional milling machine. The shoulder diameter used in this experiment is fix 18mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2,and 6:1. The rotational speeds that were used in this study were 1000 rpm, 1200 rpm and 1400 rpm, respectively. The welding speeds used are 60 mm/min, 80 mm/min and 100 mm/min. Microstructure observation of welded area was studied by using optical microscope. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:2 shows higher tensile strength compared to other taper pin ratio up to 197 MPa. Moreover, taper pin ratio 6:1 showed better tensile test compared to taper pin ratio above 6:3. The optimum parameters were found to be taper pin ratio 6:2 with 1000 rpm of rotational speed and 60mm/min welding speed.

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.

Studies on Friction Stir Welding of AA2014, AA6082 and AA7075 Simillar and Dissimillar Joints

2020 ◽  
Vol 37 ◽  
pp. 15-24
Author(s):  
P. Gunasekaran ◽  
K.T. Thilagham ◽  
D. Noorullah
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotation Speed ◽  
Hardness Distribution ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Profile ◽  
Tool Rotation

The joining of similar and dissimilar AA2014, AA6068 and AA7075 aluminium plates of 6mm thickness was carried out by friction stir welding (FSW) technique. FSW of Aluminium to Aluminium has caught significant consideration from assembling industries, such as Shipbuilding, Automotive, Railway and Aircraft generation. Here, the chosen process parameters are tilt angle (2º), tool rotation speed (900rpm) and transverse feed of (80mm/min) at constant axial force 2kN. An attempt was made to join the similar and dissimilar aluminium plate of 6 mm thickness with a conical tapered tool profile. Then, the effect of welding speed on microstructures, hardness distribution and tensile properties of the welded similar and dissimilar joints AA2014, AA6068 and AA7075 were investigated.

scholarly journals Effect of Tool Rotation Speed on Mechanical Properties and Microstructure as the Results of Friction Stir Welding Method on Aluminium 5083-7075

2016 ◽  
Vol 27 (1) ◽  
pp. 9-17
Author(s):  
Maryati Maryati ◽  
Bambang Soegijono ◽  
M Yudi Masduky ◽  
Tarmizi Tarmizi
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Incomplete Fusion ◽  
Connection Form ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Speed Rotation ◽  
Tool Rotation

Friction Stir Welding (FSW) is a new method of welding process which is affordable and provide good quality. Aluminium 5083-7075 has been connected successfully by using friction stir welding (FSW) method into butt joint connection form. Tool rotation speed is one of the important parameters in FSW. The changes of rotation speed will affect the characteristics of mechanical properties and microstructure. The parameters of welding being used are welding speed of 29 mm/minutes by varying the speed rotation of 525 rpm, 680 rpm, 910 rpm, and 1555 rpm. In order to find out the mechanical strength of welds, tensile strength and hardness testing is done while finding out the microstructure will be done by using optical microscope and Scanning Electron Microscope (SEM). The result of the research showed that the highest tensile strength obtained at 910 rpm speed rotation about 244.85 MPa and the greatest hardness values was found on aluminium 5083 around the wheel zone area about 96 HV with rotary speed of 525 rpm. Then, the result of testing the macro and microstructure on all samples indicated defect which is seen as incomplete fusion and penetration causing the formation of onion rings. In other words, it is which showed that the result of stirring and tacking in the welding area is less than perfect.

Considerations on the Ultimate Tensile Strength of Butt Welds of the EN AW 5754 Aluminium Alloy, Made by Friction Stir Welding (FSW)

2020 ◽  
Vol 1157 ◽  
pp. 38-46
Author(s):  
Victor Verbiţchi ◽  
Radu Cojocaru ◽  
Lia Nicoleta Boțilă ◽  
Cristian Ciucă ◽  
Ion Aurel Perianu
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Tensile Test ◽  
Aluminium Alloy ◽  
Hazardous Substances ◽  
Parent Metal ◽  
Friction Stir ◽  
Test Pieces ◽  
Fsw Parameters

Experiments have been performed for the butt welding of 160 mm x 90 mm x 2 mm sheets of EN AW 5754 aluminium alloy, where the friction stir welding (FSW) has been used.Referring to the parent metal, the chemical composition and the form of wrought products of the aluminium alloy EN AW 5754 is presented, according to the standard EN 573-1:2005, respectively EN 573-3:2013. The mechanical properties of EN AW-5754 (Al Mg3) sheets are presented, according to EN 485-2:2016. The experiments have been conducted on the own equipment for friction stir welding, type FSW-4kW-10kN, to execute 8 (eight) FSW test pieces, according to EN ISO 25239-4. A quenched FSW tool, own-made of C 45 grade steel, EN 10083, has been used. The parameters of the FSW tests are shown. As main parameters, the rotational speed of the FSW tool was in the range n = 800 – 1200 rev/min, respectively the travel speed was in the range v = 50 – 200 mm/min. The run of the joining experiments is described and the joining test pieces are presented in figures. The ultimate tensile strength of the parent metal (σmin,pm) is based on the specified minimum tensile strength of the ”O” condition of the parent material, respectively this value is also required for the weld, that is σmin,w = 190 MPa. The specimens T1.0, T1.1, T2.1, T2.2, T3.1, T3.2, T4.1, T4.2, T5.1, T5.2 și T6.1 are adequate and accepted by this tensile test. The specimens T1.2, T6.2, T7.1, T72. and T8.1 can be accepted, if higher properties are achieved with a full postweld treatment. Another possibility is a lower extent of the minimum tensile strength of the weld that shall be in accordance with another design specification, for example σmin,w = 145 MPa. By the correlation of the FSW parameters with the results of the tensile test, the ranges for the main parameters with adequate values of the ultimate tensile strength are established: n = 800 – 1000 rev/min and v = 50 – 100 mm/min. By the conclusions, the main aspects of the execution of the FSW test pieces, as well as the results of the tensile tests are selected. The involved industrial areas of the applications are: electro-technique, electronics, manufacturing, shipbuilding and automotive industries. The FSW process is ecological, because it neither uses, nor produces hazardous substances. The references consist of 12 titles.

The Effect of Top Surface Lubrication on the Friction Stir Welding of Polycarbonate Sheets

2021 ◽  
Vol 36 (1) ◽  
pp. 94-102
Author(s):  
M. M. Z. Ahmed ◽  
A. Elnaml ◽  
M. Shazly ◽  
M. M. El-Sayed Seleman
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Transverse Cross Section ◽  
Joint Zone ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Fsw Parameters ◽  
Spherulitic Structure

Abstract In this work, top surface lubrication during friction stir welding of polycarbonate sheets was applied. A homogenous layer of Paraffin wax has been placed on the top surface of the joint area with a width that ensures to cover the shoulder diameter. Then FSW was applied using conventional FSW tool with rotating pin and shoulder at different FSW parameters (Rotation speeds of 1 000, 1500, 2 000 min–1 and welding speeds of 25, 50, 75,100 mm/min). The main objective of using the wax is to act as a lubricant that reduces the friction between the shoulder and the polycarbonate surface. The joints produced were investigated in terms of surface quality, internal defects, and mechanical properties. During FSW the wax is melted and played as lubricant between the tool shoulder and the polycarbonate surface and resulted in defect-free surface with no thickness reduction of the original plate. The transverse cross-section showed defect-free joints for the majority of the FSW parameters investigated. Tensile testing results showed a reduction of the tensile strength after FSW, and an enhancement in the tensile strength with the increase of welding speed or rotation speed. The fracture occurs at the joint zone and the fracture surface investigation using SEM showed the existence of spherulitic structure in the weld joint.

scholarly journals Comparison of Corner-Butt 45 (Cb-45) and Corner-Lap (Cl) joints in friction stir welding

2018 ◽  
Vol 154 ◽  
pp. 01106
Author(s):  
Widia Setiawan ◽  
Djarot B. Darmadi ◽  
Wahyono Suprapto ◽  
Rudy Soenoko
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Experimental Method ◽  
Feed Rate ◽  
Lap Joints ◽  
Nugget Zone ◽  
Rotating Speed ◽  
Friction Stir ◽  
Microstructure Observation ◽  
Independent Parameters

The 10 mm thick Aluminum 6061 plates have been corner joined using varied design and those were 45° Corner Butt and Corner Lap Joints (CB-45 & CL). Friction tool was hardened EMS 45. True experimental method was used with independent parameters is feed rate which varied at 10 mm/min, 15 mm/min and 30 mm/min respectively. Other parameter such as rotating speed was kept constant. Experiment results show that, CB-45 yields better properties than CL. The tensile strength of CB-45 reaches 163.7 MPa for 10 mm/min feed rate. Whilst CL produces joint with tensile strength equal 120 MPa for equal parameters. Microstructure observation showed that CB-45 produces fine and homogenous appearance of MgO compared to CL. This phenomenon is caused by the pin of CB-45 joint which fully penetrates the nugget zone which is not found in CL design. This microstructure in turn promotes higher tensile strength of CB-45.

Friction Stir Welding on Corner Joint with New Surface Preparation Design

2016 ◽  
Vol 836 ◽  
pp. 208-213
Author(s):  
Widia Setiawan ◽  
Djarot B. Darmadi ◽  
Wahyono Suprapto ◽  
Rudy Sunoko
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tensile Test ◽  
Surface Preparation ◽  
Travel Speed ◽  
Welding Parameters ◽  
Micro Hardness ◽  
Micro Structure ◽  
Friction Stir ◽  
Preparation Design

Aluminium 6061 was joined by friction stir welding (FSW) with new surface preparation on corner design. The distribution micro structure in Corner-joints was tool welded rotation (rpm), and travel speed (mm/mnt) observed and analyzed. The welding parameters observing the tensile strength, micro structure and micro hardness it can be said. The result structure micro are homogen whilst from tensile test the strength joint is quilt good even better from preview publihsed papers. The obtained with the transverse speed 15 mm/menit, and 1500 rpm.

Dissimilar Materials Joining between SSM 356-T6 and AA6061-T651 by Friction Stir Welding

2013 ◽  
Vol 372 ◽  
pp. 478-485 ◽  
Author(s):  
Chaiyoot Meengam ◽  
Muhamad Tehyo ◽  
Prapas Muangjunburee ◽  
Jessada Wannasin
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotation Speed ◽  
Stir Zone ◽  
Weld Nugget ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Base Materials ◽  
Tool Rotation

The aim of this research is to study the influence of welding parameters on the metallurgical and mechanical properties of friction stir welded butt joints of dissimilar aluminum alloy sheets between Semi-Solid Metal (SSM) 356-T6 and AA6061-T651 by Friction Stir Welding (FSW). The base materials of SSM 356-T6 and AA6061-T651 were located on the advancing side (AS) and on the retreating side (RS) respectively. The base materials were joined under different tool rotation speeds and welding speeds. The material flows from SSM 356 and AA6061-T651 were clearly visible in the weld nugget. In addition, the mixtures of fine equiaxed grain were observed in the stir zone. The increase in tool rotation speed results in the increase in tensile strength of the joints. As for welding speed associated with various tool rotation speeds, an increase in the welding speed affected lesser the base materials tensile strength up to an optimum value; after which its effect increased. Tensile elongation was generally greater at greater tool rotation speed. An averaged maximum tensile strength of 206.3 MPa was derived for a welded specimen produced at the tool rotation speed of 2,000 rpm associated with the welding speed of 80 mm/min. In the weld nugget, higher hardness was observed in the stir zone than in the thermo-mechanically affected zone. Away from the weld nugget, hardness levels increased back to the levels of the base materials.

scholarly journals Correlating Tensile Strength & Peak Temperatures for Magnesium Alloy AZ91 during Friction Stir Welding Using Varied Tool Geometries & FEA Tool

10.29007/6xnv ◽  
2018 ◽  
Author(s):  
Kamlesh Dhansukhlal Bhatt ◽  
Nikul Patel ◽  
Vishal Mehta
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Rotation Speed ◽  
Welding Process ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Alloy Az91 ◽  
Magnesium Alloy Az91 ◽  
Tool Rotation

Magnesium & its alloys are flammable for conventional fusion welding process. This adverse effect can be eliminated by a non-fusion solid state welding process, established by The Welding Institute (TWI) in 1991, called friction stir welding (FSW). This is applied in this investigation for joining two plates together by using non-consumable tools (three pin profiles) between two abutting plates of magnesium alloy AZ91 having 6 mm thickness. FSW process joins the plates with certain advantages such as low distortion, no shielding gas required, fine recrystallized microstructure, no fumes liberated during the process, etc. In Friction stir welding, process parameters such as welding speed, tool rotation speed, tool dimensions and axial force play an important role during the process. In the present work, the 6 mm thick plates of the said alloy are welded at traverse speed of 28 mm/min to 56 mm/min with tool rotation speed ranging from 710 rpm to 1400 rpm. Tensile strength testing & simulation of peak temperatures has been carried out for establishing correlationship between best parameters from the selected ones with temperature profiles obtained by those parameters for giving optimum structure-property relationship using different pin profiles.

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