scholarly journals Effects of the FSW Parameters on Microstructure and Electrical Properties in Al 6061-T6- Cu C11000 Plate Joints

Crystals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 21
Author(s):  
Daniel García-Navarro ◽  
Juan Carlos Ortiz-Cuellar ◽  
Jesús Salvador Galindo-Valdés ◽  
Josué Gómez-Casas ◽  
Carlos Rodrigo Muñiz-Valdez ◽  
...  
Keyword(s):  
Electrical Resistivity ◽  
Friction Stir Welding ◽  
Electrical Properties ◽  
Weld Zone ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Traverse Speed ◽  
Friction Stir ◽  
Fsw Parameters ◽  
Pure Cu

Friction Stir Welding (FSW) is a feasible welding process to join dissimilar materials due to its solid-state nature. In this study the FSW of 6061-T6 aluminum with pure Cu plates was performed with the objective of evaluating the effects of the FSW parameters on the microstructure and electrical properties. The processing parameters (rotational and traverse speeds) were established to reduce the common defects in the friction-stir welding process. Therefore, the obtained results validated the better mechanical properties and a smaller increase of the electrical resistivity. The rotational speeds used were of 1000, 1150, and 1300 rpm, and the traverse speeds of 20, 40, and 60 mm/min, with the purpose of varying the heat input of the process. The microstructural characterization revealed the presence of a mixture of aluminum and copper into the weld zone, along with copper particles and the formation of intermetallic compounds. It was found that the electrical resistivity of the joints ranged from 0.029 to 0.036 μΩ. The highest electrical resistivity values were obtained at the lowest traverse speed (20 mm/min) and the lowest resistivity values were obtained at highest traverse speed (60 mm/min).

Influence of Friction Stir Welding Process on the Weld Formation and Tensile Strength of Titanium and Aluminum Dissimilar Alloys Welded Joint

2011 ◽  
Vol 189-193 ◽  
pp. 3266-3269 ◽  
Author(s):  
Yu Hua Chen ◽  
Peng Wei ◽  
Quan Ni ◽  
Li Ming Ke
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Welded Joint ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Influence Of Process Parameters ◽  
Friction Stir ◽  
Dissimilar Alloys ◽  
Titanium Aluminum

Titanium alloy TC1 and Aluminum alloy LF6 were jointed by friction stir welding (FSW), and the influence of process parameters on formation of weld surface, cross-section morphology and tensile strength were studied. The results show that, Titanium and Aluminum dissimilar alloy is difficult to be joined by FSW, and some defects such as cracks and grooves are easy to occur. When the rotational speed of stir head(n) is 750r/min and 950r/min, the welding speed(v) is 118mm/min or 150mm/min, a good formation of weld surface can be obtained, but the bonding of titanium/aluminum interface in the cross-section of weld joint is bad when n is 750r/min which results in a low strength joint. When n is 950r/min and v is 118mm/min，the strength of the FSW joint of Titanium/Aluminum dissimilar materials is 131MPa which is the highest．

scholarly journals Analysis of the influence of position of welding materials on the FSW seams properties for three dissimilar aluminium alloy

2018 ◽  
Vol 178 ◽  
pp. 03003 ◽  
Author(s):  
Ana Bosneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Monica Iordache
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Workpiece Material ◽  
Friction Stir ◽  
Welding Joints ◽  
Welding Materials

Friction Stir Welding, abbreviated FSW is a new and innovative welding process. This welding process is increasingly required, more than traditional arc welding, in industrial environment such us: aeronautics, shipbuilding, aerospace, automotive, railways, general fabrication, nuclear, military, robotics and computers. FSW, more than traditional arc welding, have a lot of advantages, such us the following: it uses a non-consumable tool, realise the welding process without melting the workpiece material, can be realised in all positions (no weld pool), results of good mechanical properties, can use dissimilar materials and have a low environmental impact. This paper presents the results of experimental investigation of friction stir welding joints to three dissimilar aluminium alloy AA2024, AA6061 and AA7075. For experimenting the value of the input process parameters, the rotation speed and advancing speed were kept the same and the position of plates was variable. The exit date recorded in the time of process and after this, will be compared between them and the influence of position of plate will be identified on the welding seams properties and the best position of plates for this process parameters and materials.

scholarly journals Influence of Mx-Trivex, A-Skew, Three Flat Threaded and Concave Shouldered Mx-Triflute Tool Pin Profiles on Tensile Properties and Fractural Behaviour of Aa 6082-T6 Weldments During Friction Stir Welding

2020 ◽  
Vol 9 (4) ◽  
pp. 1376-1384
Keyword(s):  
Friction Stir Welding ◽  
Tensile Test ◽  
Weld Zone ◽  
Base Material ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Pin ◽  
Solid State Joining ◽  
Joining Process ◽  
Brass Wire

Friction Stir Welding (FSW) is a topical and propitious solid-state joining process producing economical and strengthened joints of age-hardened and heat-treatable Aluminium Alloy AA 6082-T6. Mechanical and fractural behaviour of weldments were investigated in order to find crack initiation and necking on the weld zone thereby perceiving the complete behaviour of fracture occurred near the weld zone. Weldments are fabricated by employing four tool pin profiles namely MX-TRIVEX, A-SKEW, Three flat threaded and Concave shouldered MX-TRIFLUTE tools at various rotational speeds 1000 rpm, 1200 rpm and 1400 rpm at single traverse speed 25 mm/min. EXCETEX-EX-40 CNC wire cut EDM with 0.25 mm brass wire diameter has been employed to perform the extraction of tensile test specimens from the weldments according to ASTM E8M-04 standard. Tensile test was performed on elctromechanically servo controlled TUE-C-200 (UTM machine) according to ASTM B557-16 standards Maximum Ultimate Tensile Strength (UTS) of 172.33 MPa (55.5% of base material) and 0.2% Yield Stress (YS) of 134.10 MPa (51.5% of base material) were obtained by using A-SKEW at 1400 rpm, 25 mm/min and maximum % Elongation (%El) of 11.33 (113.3% of base material) was obtained at MX-TRIVEX at 1000 rpm, 25 mm/min. Minimum UTS of 131.16 MPa (42.30% of base material) and 0.2% YS of 105.207 MPa (40.46% of base material )were obtained by using Concave shouldered MX-TRIFLUTE at 1400 rpm, 25 mm/min. Minimum % El of 5.42 ( 54.2% of base material) was obtained by using A-SKEW at 1000 rpm, 25 mm/min.

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

Optimization of Friction Stir Welding Process Parameters to Join Al 5052 and Al 6061 Alloy Plates Using Grey-Taguchi Technique

2017 ◽  
Author(s):  
R. Sandeep ◽  
D. Sudhakara ◽  
G. Prasanthi
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Fusion Welding ◽  
Optimum Process ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Grey Analysis ◽  
Grey Taguchi

Friction stir welding (FSW) is a solid state welding process used for welding similar and dissimilar materials. The process is widely used because it does not have common problems such as solidification and liquefaction cracking associated with the fusion welding techniques. The objective of the present research is to find the best combination of friction stir welding process parameters to join aluminium 5052 and 6061 alloy materials. The combination of process parameters is helpful to improve ultimate tensile strength, yield strength, percentage of elongation and hardness of welded joint. To achieve the research objective taguchi based grey analysis was used. The optimum process parameters were found be at rotational speed is 1400 rpm, transverse speed of 100 mm/min and axial force is at 11 KN.

Numerical Modeling of Thermal Field Distribution during Friction Stir Welding (FSW) of Dissimilar Materials

2016 ◽  
Vol 254 ◽  
pp. 261-266
Author(s):  
Bogdan Radu ◽  
Cosmin Codrean ◽  
Radu Cojocaru ◽  
Cristian Ciucă
Keyword(s):  
Numerical Modeling ◽  
Friction Stir Welding ◽  
Solid State ◽  
Thermal Field ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Dissimilar Joints ◽  
Element Analysis ◽  
Friction Stir ◽  
The Cost

Friction Stir Welding (FSW) is an innovative solid state welding process, relatively new in industry, which allow welding of two or more materials which have very different properties, particularly thermal properties as fusion temperature, thermal expansion coefficient, specific heat and thermal conduction and have a predisposition to form intermetallic brittle phases, neither one of the components to be weld reach to the melting point. Being a solid state welding process temperature field is very important for the quality of the welded joint, and a lot of researches focused on this topic. This paper presents some results in modeling and estimation of thermal field developed during FSW of dissimilar joints, using Finite Element Analysis. Numerical modeling of thermal field allows engineers to predict, in advance, the evolution of temperature and to estimate the behavior of the welded materials during the welding process. This will reduce significantly the time and number of experiments that have to be carried out, in the process of establishing a good FSW technology, as well as reducing significantly the cost of the tests.

scholarly journals Characterization of Brass/Steel Plates Joined by Friction Stir Welding

2018 ◽  
Vol 7 (3.34) ◽  
pp. 366
Author(s):  
Mariyappan. K ◽  
Praveen K ◽  
Suresh Kumar.S ◽  
Kadambanathan. K ◽  
Rajamanickam. S ◽  
...  
Keyword(s):  
Electron Microscopy ◽  
Scanning Electron Microscopy ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Weld Zone ◽  
Steel Plates ◽  
Micro Hardness ◽  
Friction Stir ◽  
Fsw Parameters ◽  
Scanning Electron

The aim of this study is to show the feasibility for butt joining dissimilar brass to austenitic stainless steel plates by Friction Stir Welding. In this study, the limited FSW parameters were employed. Metallurgical characterization like Scanning Electron Microscopy and Mechanical characterization like tensile test, Micro hardness is done to investigate the joint performance and the weld zone of dissimilar brass/steel joints. The tensile strength and micro hardness values are 20 MPa, 122 MPa and 157 MPa and 175 Hv, 196 Hv and 199 Hv for the table traverse speeds of 40 mm/min, 50 mm/min and 60 mm/min respectively. The tensile strength of dissimilar brass/steel joint was found to be lower than that of parent metals. The defect free brass/steel interfaces were seen by Scanning Electron Microscopy. It was illustrated that the stirred zone exposed to two main structures namely, recrystallized grains of brass and intercalated swirl and vortex-like structure which can be characterized both the recrystallized brass grains and steel layers. This work is one of the preliminary studies on the detailed examinations of the dissimilar brass/steel joined by Friction stir welding. 

scholarly journals Parametric Optimization of Friction Stir Welding Factors (FSWF) for Yellow Brass 405-20

2021 ◽  
Author(s):  
Syed Farhan Raza ◽  
Sarmad Ali Khan ◽  
Muhammad Salman Habib ◽  
Naveed Ahmed ◽  
Kashif Ishfaq ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotational Speed ◽  
Weld Zone ◽  
Tool Material ◽  
Traverse Speed ◽  
Weld Strength ◽  
Friction Stir Weld ◽  
Friction Stir ◽  
Wide Range ◽  
Percent Contribution

Abstract Friction stir welding (FSW) is a green, environmentally amicable, and solid-state joining technology. Industries are really interested in adopting FSW in its various applications e.g., automobile, aerospace, marine, construction, etc. FSW can successfully weld a wide range of materials (similar/dissimilar parent materials) including aluminum, copper, steel, different alloys from these materials, plastics, composites, and this material range is subjected to extension if FSW research efforts develop further in future. FSW of brass has already been accomplished by fewer researchers. In this research, yellow brass 405-20 is, therefore, welded with FSW that was never welded before. In this study, tool material utilized was M2 HSS that was also novel. Effect of two friction stir weld factors (FSWF), rotational speed (RS) and traverse speed (TS), was found on three output parameters i.e., weld temperature, weld strength and weld hardness. Weld temperature was found to be 63.72% of melting point of base metal. A significant improvement in friction stir weld strength (FSWS) was also measured that was found to be 82.78% of the base brass strength. Finally, weld hardness was measured which was found to be 87.80% of original brass hardness. Based on main effects of Anova Analysis, optimal FSW factors were found to be 1450 rpm and 60 mm/min resulting interestingly in maximum (max.)/optimal temperature, max./optimal weld strength, and minimum/optimal hardness. Rotational speed (RS) was found to be significant to affect the weld temperature only at the friction stir weld zone (FSWZ) with the highest percent contribution (PCR) of 65.69%. Transverse speed (TS) was found to be overall insignificant for affecting weld temperature, weld strength and hardness. However, PCR of transverse speed was found to be maximum for affecting weld strength as compared to its PCR towards both weld temperature and weld hardness. Error PCR was found to be the lowest for weld zone temperature, then for weld strength, and finally the highest for weld hardness. Interaction Plots (IPs) were also made for those FSWF which were found to be insignificant and to investigate any combined effect of FSWF on output parameters causing increased error PCR towards weld temperature, weld strength, and weld hardness.

scholarly journals Micro Friction Stir Welding Process: State of the Art

2018 ◽  
Vol 8 (02) ◽  
Author(s):  
Akshansh Mishra
Keyword(s):  
Friction Stir Welding ◽  
Copper Alloys ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Zinc Alloys ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Thin Walled Structures ◽  
Current State ◽  
Mechanical Assemblies

IMicro friction stir welding (µFSW) process is mainly adapted from the Friction Stir Welding Process. This process is mainly used for joining dissimilar materials. Micro friction stir welding (µFSW) find its applications in thin walled structures, electrical, electronic and micro-mechanical assemblies. The significant challenges are faced when we downscale to achieve µFSW. This paper addresses the current state of the understanding and development of Micro friction stir welding. This paper further outlines the results achieved after Micro friction stir processing of Aluminium alloys, Copper alloys and Zinc alloys.

scholarly journals An Experimental Test and Optimization of Friction Stir Welding Process for AA6082 By using GRA

2020 ◽  
Vol 9 (6) ◽  
pp. 740-744
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Axial Force ◽  
Welding Process ◽  
Traverse Speed ◽  
Test Plate ◽  
Friction Stir ◽  
Fourth Sample ◽  
Grey Relational Grade ◽  
Grey Relational

Friction stir welding (FSW) is a type of joining process, it uses solid state welding method, also it is widely used in same type and different types of welding like Al, Mg, Cu, Ti, and their alloys. In this study, friction stir welding of two aluminum alloys AA6082 is done with many sets of tool rotation speed, feed and axial force. In this experimental work FSW process was carried out for AA 6082 and optimization of that FSW process parameters were find out for maximum tensile strength values. Taguchi’s L4 orthogonal array was utilized for three parameters – tool rotational speed (TRS), traverse speed (TS), and axial force (AXF) with two levels. Several optimization was carried out with Taguchi method of grey relational tests. During the investigation obtained highest tensile strength value fourth sample 60.887 N/mm2 and lowest hardness strength value second sample 31HRB and bead appearance found very best surface occurred fourth test plates at the same time angle distortion observed very fine in the fourth test plate. The result was calculated for both ultimate tensile strength and hardness value. The expected grey relational grade was shifted from 0.704 to 0.792, it was the highest value received throughout this experimental results. It was mentioned that the multi-responses of FSW process was improved with this method.

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