Influence of Shoulder Diameter, Plunge Depth, Welding Speed, Rotational Speed on the Tensile Behavior of Friction Stir Welded AA 6061-T6 Sheets

2014 ◽  
Vol 42 (3) ◽  
pp. 20120236 ◽  
Author(s):  
Perumalla Janaki Ramulu ◽  
R. Ganesh Narayanan
Keyword(s):  
Welding Speed ◽  
Rotational Speed ◽  
Tensile Behavior ◽  
Plunge Depth ◽  
Friction Stir ◽  
Shoulder Diameter

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.

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.

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.

A study on the effect of cooling on microstructure and mechanical properties of friction stir-welded AA5086 aluminum butt and lap joints

2017 ◽  
Vol 233 (6) ◽  
pp. 1156-1165 ◽  
Author(s):  
Adel Sedaghati ◽  
Hamed Bouzary
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Feed Rate ◽  
Rotational Speed ◽  
Lap Joints ◽  
Tensile Behavior ◽  
Water Cooling ◽  
Friction Stir ◽  
Microstructural Behavior ◽  
Constant Feed Rate

In this paper, the effect of water cooling on mechanical properties and microstructure of AA5086 aluminum joints during friction stir welding is investigated. For doing so, the mechanical and microstructural behavior of samples welded both in air and in water was analyzed. Tests were performed involving both butt and lap welds and the results were compared. The effect of rotational speed at constant feed rate of 50 mm/min and changing rotational speed ranging from 250 to 1250 r/min was investigated. The results showed a significant change in the tensile behavior of the butt-welded specimens due to water cooling. In addition, welding was performed at constant spindle speed of 800 r/min and various traverse speeds (25 mm/min to 80 mm/min) to determine the effect of feed rate. The strength increases at first, but then decreases dramatically along with the feed rate which is due to the occurrence of a groove defect. Results showed some generally positive impacts of water cooling which are discussed in terms of tensile results, hardness distributions and microstructure analysis.

Mechanical Property of Friction Stir Welded Retardant Magnesium Alloy Joint

2011 ◽  
Vol 295-297 ◽  
pp. 1929-1932
Author(s):  
Yi Min Tu ◽  
Ran Feng Qiu ◽  
Hong Xin Shi ◽  
Xin Zhang ◽  
Ke Ke Zhang
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Welding Speed ◽  
Rotational Speed ◽  
Maximum Strength ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir

In order to obtain better understanding of the friction stir weldability of the magnesium alloy and provide some foundational information for improving mechanical properties of retardant magnesium alloy joints. A retardant magnesium alloy was weld using the method of friction stir welding. The influence of welding parameters on the strength of the joint was investigated. The maximum strength of 230 MPa was obtained from the joint welded at the tool rotational speed of 1000 r/min and welding speed of 750 mm/min.

Crack Repair Using Hybrid Additive Manufacturing and Friction Stir Processing

2019 ◽  
Author(s):  
Fadi Al-Badour ◽  
Ibrahim H. Zainelabdeen ◽  
Rami K. Suleiman ◽  
Akeem Adesina
Keyword(s):  
Additive Manufacturing ◽  
Friction Stir Processing ◽  
Welding Speed ◽  
Rotational Speed ◽  
Hardness Test ◽  
Mechanical Tests ◽  
Friction Stir ◽  
Al 6061 ◽  
The Impact

Abstract A hybrid additive manufacturing (AM) and friction stir processing (FSP) was used to heal a crack in 6 mm thick Al 6061-T6 aluminum alloy. AL-6061 is usually used in H2 high-pressure vessel fabrication as well as aerospace applications. In this work, Al-Si powder was utilized to fill the crack, then FSP was applied to consolidate and stir the powder with the base metal to fill and close the crack zone. Effect of FSP parameters including welding speed and tool rotation speed on the quality of repair was studied. Various mechanical tests, as well as characterization techniques such as hardness test, optical microscopy, scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDS), were employed to study the newly developed hybrid process on the quality of the repair. The investigation revealed that low rotational speed of 800 rpm results in minimum variation in microhardness. Moreover, the impact of welding speed on microhardness is smaller as compared to rotational speed.

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