scholarly journals Friction Stir Welding of 1Cr11Ni2W2MoV Martensitic Stainless Steel: Numerical Simulation Based on Coupled Eulerian Lagrangian Approach Supported with Experimental Work

2021 ◽  
Vol 11 (7) ◽  
pp. 3049
Author(s):  
Mohamed Ragab ◽  
Hong Liu ◽  
Guan-Jun Yang ◽  
Mohamed M. Z. Ahmed
Keyword(s):  
Numerical Simulation ◽  
Stainless Steel ◽  
Friction Stir Welding ◽  
Rotation Rate ◽  
Cost Effective ◽  
Element Model ◽  
Fusion Welding ◽  
Friction Stir ◽  
Tool Rotation Rate ◽  
Tool Rotation

1Cr11Ni2W2MoV is a new martensitic heat-resistant stainless steel utilized in the manufacturing of aero-engine high-temperature bearing components. Welding of this type of steel using fusion welding techniques causes many defects. Friction stir welding (FSW) is a valuable alternative. However, few investigations have been performed on the FSW of steels because of the high melting point and the costly tools. Numerical simulation in this regard is a cost-effective solution for the FSW of this steel in order to optimize the parameters and to reduce the number of experiments for obtaining high-quality joints. In this study, a 3D thermo-mechanical finite element model based on the Coupled Eulerian Lagrangian (CEL) approach was developed to study the FSW of 1Cr11Ni2W2MoV steel. Numerical results of metallurgical zones’ shape and weld appearance at different tool rotation rates of 250, 350, 450 and 550 rpm are in good agreement with the experimental results. The results revealed that the peak temperature, plastic strain, surface roughness and flash size increased with an increase in the tool rotation rate. Lack-of-fill defect was produced at the highest tool rotation rate of 650 rpm. Moreover, an asymmetrical stir zone was produced at a high tool rotation rate.

scholarly journals Study on the Joining of Titanium and Aluminum Dissimilar Alloys by Friction Stir Welding

2011 ◽  
Vol 5 (1) ◽  
pp. 256-261 ◽  
Author(s):  
Yuhua Chen ◽  
Changhua Liu ◽  
Geping Liu
Keyword(s):  
Titanium Alloy ◽  
Shear Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotation Rate ◽  
Influence Of Process Parameters ◽  
Friction Stir ◽  
Tool Rotation Rate ◽  
Tool Rotation

Titanium alloy TC1 and Aluminum alloy LF6 were butt jointed and lap jointed by friction stir welding (FSW), and the influence of process parameters on formation of weld surface, cross-section morphology and strength were studied. The results show that, Titanium and Aluminum dissimilar alloy is difficult to be butt joined by FSW, and some defects such as cracks and grooves are easy to occur. When the tool rotation rate is 950 r/min and the welding speed is 118 mm/min, the tensile strength of the butt joint is 131MPa which is the highest. FSW is suitable for lap joining of TC1 Titanium alloy and LF6 Aluminum alloy dissimilar materials, an excellent surface appearance is easy to obtain, but the shear strength of the lap welding joint is not high. At the welding speed of 60 mm/min and the tool rotation rate of 1500 r/min, the lap joint has the largest shear strength of 48 MPa. At the welding speed of 150 mm/min and the tool rotation rate of 1500 r/min, crack like a groove occurs on the interface and the shear strength is zero.

scholarly journals Design and Fabrication of Friction Stir Welding End-Effector for an ABB IRB1410 Robot

2016 ◽  
Vol 5 (2) ◽  
pp. 98
Author(s):  
Santosh Vanama
Keyword(s):  
Friction Stir Welding ◽  
High Strength ◽  
Fusion Welding ◽  
Fusion Temperature ◽  
End Effector ◽  
Friction Stir ◽  
Aluminum Sheets ◽  
Operation Pressure ◽  
Welding Processes ◽  
Tool Rotation

<p>The paper propose modelling and fabrication of friction stir welding end-effector for ABB IRB1410 robot. A dynamically developing version of pressure welding processes, join material without reaching the fusion temperature called friction stir welding. As friction stir welding occurs in solid state, no solidification structures are created thereby eliminating the brittle and eutectic phase’s common to fusion welding of high strength aluminium alloys. In this paper, Friction stir welding is applied to aluminum sheets of 2 mm thickness. A prototype setup is developed to monitor the evolution of main forces and tool temperature during the operation. Pressure of a gripper plays a major role for tool rotation and developing torque.  Fabrication of the tool has done. Force calculations are done by placing the sensors on the outer surface of gripper. Methods of evaluating weld quality are surveyed as well.</p>

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.

scholarly journals Friction Stir Welding and Preliminary Characterization of Irradiated 304 Stainless Steel

2019 ◽  
Author(s):  
Wei Tang ◽  
Maxim Gussev ◽  
Zhili Feng ◽  
Brian Gibson ◽  
Roger Miller ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Base Metal ◽  
Nuclear Power ◽  
Power Plants ◽  
Nuclear Power Plants ◽  
Weld Zone ◽  
Fusion Welding ◽  
Friction Stir

Abstract The mitigation of helium induced cracking in the heat affected zone (HAZ), a transition metallurgical zone between the weld zone and base metal, during repair welding is a great challenge in nuclear industry. Successful traditional fusion welding repairs are limited to metals with a maximum of a couple of atomic parts per million (appm) helium, and structural materials helium levels in operating nuclear power plants are generally exceed a couple of appm after years of operations. Therefore, fusion welding is very limited in nuclear power plants structural materials repairing. Friction stir welding (FSW) is a solid-state joining technology that reduces the drivers (temperature and tensile residual stress) for helium-induced cracking. This paper will detail initial procedural development of FSW weld trials on irradiated 304L stainless steel (304L SS) coupons utilizing a unique welding facility located at one of Oak Ridge National Laboratory’s hot cell facilities. The successful early results of FSW of an irradiated 304L SS coupon containing high helium are discussed. Helium induced cracking was not observed by scanning electron microscopy in the friction stir weld zone and the metallurgical zones between the weld zone and base metal, i.e. thermal mechanical affected zone (TMAZ) and HAZ. Characterization of the weld, TMAZ and HAZ regions are detailed in this paper.

Effect of Welding Parameters on Microstructure and Tensile Properties of Friction Stir Welded 6061 AL Joints

2009 ◽  
Vol 618-619 ◽  
pp. 41-44 ◽  
Author(s):  
Ai Han Feng ◽  
Dao Lun Chen ◽  
Zong Yi Ma
Keyword(s):  
Tensile Properties ◽  
Welding Speed ◽  
Rotation Rate ◽  
Welding Parameters ◽  
Nugget Zone ◽  
Fine Needle ◽  
Friction Stir ◽  
Tool Rotation Rate ◽  
The Relationship ◽  
Tool Rotation

The present investigation is aimed at evaluating the influence of tool rotation rate and welding speed on the microstructure, tensile properties, and fracture mode of 6061 Al-T651 alloy after friction stir welding (FSW). TEM results revealed that in the nugget zone (NZ), FSW resulted in the dissolution of fine needle-shaped precipitates that previously existed in the base metal. At a given rotation rate of 1400rpm, the yield strength (YS) and ultimate tensile strength (UTS) of the welded joints increased with increasing welding speed from 200 to 600mm/min. However, the UTS of the joints was nearly independent of the rotation rate. Furthermore, the relationship between the hardness distribution and fracture location has also been identified.

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