The Concept of Electrically Assisted Friction Stir Welding (EAFSW) and Application to the Processing of Various Metals

2008 ◽  
Author(s):  
William A. Ferrando
Keyword(s):  
Friction Stir Welding ◽  
Friction Stir ◽  
Electrically Assisted

Comparison of Electrically-Assisted and Conventional Friction Stir Welding Processes by Feed Force and Torque

2013 ◽  
Author(s):  
Hemanth Potluri ◽  
Joshua J. Jones ◽  
Laine Mears
Keyword(s):  
Friction Stir Welding ◽  
Large Scale ◽  
Welding Process ◽  
Electrical Current ◽  
Ultra Sound ◽  
Friction Stir ◽  
Direct Electrical Current ◽  
Electrically Assisted ◽  
Feed Force ◽  
Welding Processes

The process of friction stir welding involves high tool forces and requires robust machinery; the forces involved make tool wear a predominant problem. As a result, many alternatives have been proposed in decreasing tool forces such as laser assisted friction stir welding and ultra-sound assisted friction stir welding. However, these alternatives are not commercially successful on a large scale due to scalability and capital/maintenance costs. In an attempt to reduce forces in a cost-feasible manner, electrically-assisted friction stir welding (EAFSW) is studied in this work. EAFSW is a result of applying the concept of electrically-assisted manufacturing (i.e., passing high direct electrical current through a workpiece during processing) to the conventional friction stir welding process. The concept of EAFSW is a relatively new adaptation of conventional frictional stir welding, which is well established. The expected benefits are reduction in the feed force and torque, which allow for improved processing productivity as well as the possibility for deeper penetration of the weld.

Utilization of XSYTIN-1 Tool in Electrically-Assisted Friction Stir Welding of Dissimilar Metals - Al 6061-T651 to Mild Steel

2019 ◽  
Vol 1152 ◽  
pp. 31-41 ◽  
Author(s):  
Derek Shaffer ◽  
Tyler J. Grimm ◽  
Ihab Ragai ◽  
John Roth
Keyword(s):  
Friction Stir Welding ◽  
Mild Steel ◽  
Material Flow ◽  
Electrical Current ◽  
Dissimilar Metals ◽  
Friction Stir ◽  
Al 6061 ◽  
Conventional Steel ◽  
Electrically Assisted ◽  
Part Distortion

Friction stir welding (FSW) is a solid-state metal fusion process that is characterized by several benefits over comparable processes such as a reduction in energy input and low part distortion. This process has been shown to hold great potential in the fusion of dissimilar metals, a technology highly sought after in the aerospace and automotive industries for its promising weight-reduction capabilities. Furthermore, electrically-assisted FSW (EAFSW) is the supplementation of the FSW process with an electrical current. This modification has been shown to improve many parameters; however, the current literature related to this subject is scarce. Herein, the fusion of Al 6061-T651 to mild steel is performed using EAFSW methods. A novel tool constructed a proprietary ceramic, XSYTIN-1, is also tested in this application. It was found that EAFSW improved material flow between the constituent materials; however, was unable to increase the joint strength of the weld. Additionally, it was found that the XSYTIN-1 tool did not exhibit any significant differences when compared to a conventional steel tool.

Microstructural and Mechanical Behaviour Evaluation of Mg-Al-Zn Alloy Friction Stir Welded Joint

2020 ◽  
Vol 17 (3) ◽  
pp. 8150-8159
Author(s):  
Kulwant Singh ◽  
Gurbhinder Singh ◽  
Harmeet Singh
Keyword(s):  
Heat Treatment ◽  
Friction Stir Welding ◽  
Magnesium Alloys ◽  
Mechanical Performance ◽  
Fuel Efficiency ◽  
Research Work ◽  
Grain Structure ◽  
Tensile Fracture ◽  
Friction Stir ◽  
The Impact

The weight reduction concept is most effective to reduce the emissions of greenhouse gases from vehicles, which also improves fuel efficiency. Amongst lightweight materials, magnesium alloys are attractive to the automotive sector as a structural material. Welding feasibility of magnesium alloys acts as an influential role in its usage for lightweight prospects. Friction stir welding (FSW) is an appropriate technique as compared to other welding techniques to join magnesium alloys. Field of friction stir welding is emerging in the current scenario. The friction stir welding technique has been selected to weld AZ91 magnesium alloys in the current research work. The microstructure and mechanical characteristics of the produced FSW butt joints have been investigated. Further, the influence of post welding heat treatment (at 260 °C for 1 h) on these properties has also been examined. Post welding heat treatment (PWHT) resulted in the improvement of the grain structure of weld zones which affected the mechanical performance of the joints. After heat treatment, the tensile strength and elongation of the joint increased by 12.6 % and 31.9 % respectively. It is proven that after PWHT, the microhardness of the stir zone reduced and a comparatively smoothened microhardness profile of the FSW joint obtained. No considerable variation in the location of the tensile fracture was witnessed after PWHT. The results show that the impact toughness of the weld joints further decreases after post welding heat treatment.

Friction stir welding

2010 ◽  
Author(s):  
Daniela Lohwasser ◽  
Zhan Chen
Keyword(s):  
Friction Stir Welding ◽  
Friction Stir
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