scholarly journals On the Friction Stir Welding of Al 7075 Thin Sheets

Metals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 57
Author(s):  
Andreas Dimopoulos ◽  
Achilles Vairis ◽  
Nectarios Vidakis ◽  
Markos Petousis
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mechanical Strength ◽  
Parent Material ◽  
Thin Plates ◽  
Tool Geometry ◽  
Optimum Process ◽  
Thin Sheets ◽  
Friction Stir ◽  
Al 7075

The aim of this work was to weld thin sheets (2 mm) of Al 7075 in a butt joint configuration using friction stir welding and to identify the appropriate tool geometry and optimum process parameters. Two tools were produced with heat treatable low alloy steel WNr 1.6582/DIN 34CrNiMo6 with a different pin diameter (3 mm and 4 mm). Welding was performed at a range of rotation speeds 1000–2500 rpm and various welding speeds 80–800 mm/min. The tensile strength was measured to evaluate mechanical properties. Results showed that despite the difficulties in friction stir welding thin plates, sound joints can be produced in a repeatable manner, without visible wear on the welding tool. The mechanical strength of the welds showed a decrease (33.75%) over that of the parent material. The mechanical strength was less affected by rotation speed than welding speed and there was a significant decrease in tensile strength compared to the parent material.

scholarly journals Investigations on force generation and joint properties of dissimilar thickness friction stir corner welded AA 5086 alloy

2020 ◽  
Vol 40 (1) ◽  
pp. 67-74
Author(s):  
Manigandan Krishnan ◽  
Senthilkumar Subramaniam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Welding Process ◽  
Spindle Motor ◽  
Parent Material ◽  
Force Generation ◽  
Friction Stir ◽  
Current Consumption ◽  
Spindle Motor Current

The force generation, joint mechanical and metallurgical properties of friction stir corner welded non-heat treatable AA 5086 aluminum alloy are investigated in this paper. The friction stir welding process is carried out with the plate thicknesses of 6 mm and 4 mm. The welding speed, tool rotational speed and tool plunge depth were considered as the process parameters to conduct the welding experiments. The machine spindle motor current consumption and tool down force generation during friction stir welding were analyzed. The microstructures of various joint regions were observed. The tensile samples revealed the tensile strength of 197 MPa with tool rotational and welding speeds of 1,000 rev/min and 150 mm/min respectively, which is 78 % of parent material tensile strength. A maximum micro hardness of 98 HV was observed at thermomechanically joint affected zone, which was welded with tool rotation of 1,000 rev/min and welding speed of 190 mm/min.

Optimizing Friction Stir Welding of Al 6061 Alloy Using Statistical Analysis

2014 ◽  
Vol 18 (5) ◽  
pp. 752-754
Author(s):  
Dae Min Kang ◽  
◽  
Kyoung Do Park ◽  
Dai Yeal Lee ◽  
◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Condition ◽  
Travel Speed ◽  
Optimum Process ◽  
Friction Stir ◽  
Al 6061 ◽  
Control Factors ◽  
Shoulder Diameter ◽  
Strength Tests

In this study, a three-way factorial design is used to optimize the friction stir welding (FSW) process of Al 6061 alloy. Control factors are shoulder diameter, travel speed, and rotation speed of tool, and each factor has three levels. Tensile strength tests are also carried out to measure the mechanical properties under various FSW conditions. In this work, travel speed, shoulder diameter, and tool speed are shown to individually be meaningful factors in the tensile strength of the alloy, but interactions among the weld factors are not detected. The result of the study is that the optimum process condition for maximum tensile strength is estimated to be A3B3C3. In addition, the presumed range of tensile strength under the optimal conditions is estimated to be 257±23 (Mpa) with 95% reliability.

Estimation and Comparison of Welding Responses Using MRA, GMDH and ANN Technique of Al6061 and Al7075 Material in FSW

2019 ◽  
Author(s):  
Ugrasen Gonchikar ◽  
Holalu Venkatadasu Ravindra ◽  
Prathik Jain Sudhir ◽  
Umeshgowda Bettahally Mahadevegowda ◽  
Shankarnarayan Maskibail Suresh
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Solid State ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Alloying Elements ◽  
Friction Stir ◽  
Al 6061 ◽  
Al 7075

Abstract Friction Stir Welding (FSW) is a solid state welding which uses non-consumable steel rod to weld two materials. Friction stir welding is an emerging process which is based on frictional heat generated through contact between a non-consumable rotating tool and work piece. Friction stir welding technique possesses several advantages over other conventional types of welding due to the fact that process is carried out in solid state. Removal of melting helps in minimizing porosity and eliminates oxide inclusion. In this study, we focus on the optimization of the process parameters in friction stir welding of two different aluminium alloys (6061, 7075) using Taguchi method of experimental design. Al 6061 and Al 7075 are the two different alloys of aluminium. Among these Al 7075 has mechanical properties nearly double than that of Al 6061, but Al 6061 is used more extensively than Al 7075 because of its low cost. Al 6061 and Al 7075 being alloys of aluminium varies in the composition of alloying elements used in their manufacturing. Al 6061 has magnesium and silicon as its major alloying elements whereas Al 7075 has zinc as its primary alloying element. Al 6061 comes with medium to high strength, exhibit good toughness and surface finish, excellent resistance to corrosion at environmental conditions and another important property is its good weldability. Al 7075 being stronger than Al 6061 lacks in its resistance to corrosion and has poor weldability. Al 6061 is readily weldable but Al 7075 is not, because it is prone to micro-cracking during welding. This study also describes the relation between process parameters and their response of friction stir weld on ultimate tensile strength and hardness of composite materials using mathematical models. The process parameters considered are rotational speed, welding speed and number of passes. Different methodologies are used to develop the models to predict the responses and mechanical properties such as ultimate tensile strength and hardness. The objective of Multiple Regression Analysis (MRA) is to construct a model that explains as much as possible, the variability in a dependent variable, using several independent variables. Group Method of data Handling Technique (GMDH) is a family of inductive algorithms for computer-based mathematical modelling of multi-parametric datasets that features fully automatic structural and parametric optimization of models. GMDH is used in such fields as data mining, knowledge discovery, prediction, complex systems modelling, optimization and pattern recognition. As the machining process is non-linear and time dependent, it is difficult for the traditional identification methods to provide an accurate model. Compared to traditional computing methods, the Artificial Neural Network’s (ANN) are robust and global. Estimation and comparison of machining responses were carried out by MRA, GMDH and ANN.

Optimization of Process Parameters of Friction Stir Welding by Taguchi Method

2019 ◽  
Vol 7 (1) ◽  
pp. 17-23
Author(s):  
Azzam Sabah Albunduqee ◽  
Hussein R Al-Bugharbee
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Taguchi Method ◽  
Process Parameters ◽  
Rotational Velocity ◽  
Welding Parameters ◽  
Optimum Process ◽  
Friction Stir ◽  
Optimization Of Process Parameters

Friction Stir Welding is one of the technologies of joining solid states, which still attracts the researchers’ interest.  In welded joints the mechanical properties are affected by a number of mechanical properties of the joined materials and by the process parameters as well. In the present study, the effect of a number of friction stir welding parameters on the tensile strength of the welded joint have been investigated using the Taguchi method and the analysis of variance (ANOVA). The study considers different levels of friction stir welding variables; namely, different rotational speeds of (2000, 1600, 1250 rpm), different welding speeds (12.5, 16, 20 mm / min), and different welding tilt angles (0, 1, 2 degrees).  The optimum process parameters and their contribution rate were selected based on the Taguchi method for test design and by using the Minitab 16 program. In this study, the best results (i.e, higher tensile strength) were obtained at a rotational velocity of 1600 rpm, linear velocity of 16 mm / min, and welding angle, 1o. The highest tensile strength was obtained under these conditions.                                                                                       

Tool Geometry in Friction Stir Welding of Magnesium Alloy Sheets

2009 ◽  
Vol 410-411 ◽  
pp. 555-562 ◽  
Author(s):  
Carlo Bruni ◽  
Gianluca Buffa ◽  
L. d’Apolito ◽  
Archimede Forcellese ◽  
Livan Fratini
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Tool Geometry ◽  
Micro Hardness ◽  
Friction Stir ◽  
New Material ◽  
Full Optimization ◽  
Hardness Values

Friction Stir Welding (FSW) has been arousing a continuously increasing interest among joining processes since its invention in 1991. Although mainly used for aluminum alloys, it can also be applied to other light alloys. In the present work, experimental and numerical campaigns have been performed with the aim to study the effect of the tool geometry on the mechanical properties of FSW-ed AZ31 magnesium alloy sheets. The results, presented in terms of tensile strength, ductility, micro-hardness values and numerical field variables distributions, allow to reach a deeper knowledge on the behaviour of such relatively new material when FSW-ed, and can be used for a full optimization of the joints.

Parameter Optimization for Friction Stir Welding AA1100

2015 ◽  
Vol 813-814 ◽  
pp. 462-466 ◽  
Author(s):  
R Padmanaban ◽  
V. Muthukumaran ◽  
A. Vighnesh
Keyword(s):  
Genetic Algorithm ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Joint Strength ◽  
Rotation Speed ◽  
Optimum Process ◽  
Friction Stir ◽  
Shoulder Diameter ◽  
Tool Rotation

Friction stir welding (FSW) has become a potential solid state joining technique with considerable advantages over conventional joining process. Defect-free friction stir welded joints with high joint strength are obtained when optimum process parameters are used. Although a large number of parameters govern the FSW process, the tool rotation speed, Welding speed and tool geometry are key parameters that influence the joint strength. In this work, a statistical model relating process parameters and the tensile strength (TS) of friction stir welded AA1100 joints is build using response surface methodology. The four independent variables are tool rotational speed (TRS), welding speed (WS), shoulder diameter (SD) and pin diameter (PD). Central Composite design is used and Analysis of Variance at 95% confidence level was applied to assess the adequacy of the developed model. Genetic algorithm is used for optimizing the parameters. The optimum process parameter values predicted using the genetic algorithm are as follows. Tool rotation speed: 1001.9 rpm; welding speed: 62 mm/min; shoulder diameter: 17.8 mm and pin diameter: 6.5 mm. The corresponding tensile strength of the joints is 73.1556 MPa

Friction Stir Welding of Magnesium Alloys under Different Process Parameters

2010 ◽  
Vol 638-642 ◽  
pp. 3954-3959 ◽  
Author(s):  
Carlo Bruni ◽  
Gianluca Buffa ◽  
Livan Fratini ◽  
M. Simoncini
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Magnesium Alloys ◽  
Process Parameters ◽  
Az31 Magnesium Alloy ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Friction Stir ◽  
Numerical Investigations

Experimental and numerical investigations have been performed in order to study the effect of welding parameters on properties of FSW-ed AZ31 magnesium alloy sheets. The results, presented in terms of tensile strength and numerical field variables distributions, allow to understand the behaviour of such material when FSW-ed using different rotational and welding speeds for a given tool geometry.

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.

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