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Sample records for friction stir process

  1. Friction Stir Welding and Processing

    Energy Technology Data Exchange (ETDEWEB)

    Hovanski, Yuri; Carsley, John; Clarke, Kester D.; Krajewski, Paul E.

    2015-05-01

    With nearly twenty years of international research and collaboration in friction stir welding (FSW) and processing industrial applications have spread into nearly every feasible market. Currently applications exist in aerospace, railway, automotive, personal computers, technology, marine, cutlery, construction, as well as several other markets. Implementation of FSW has demonstrated diverse opportunities ranging from enabling new materials to reducing the production costs of current welding technologies by enabling condensed packaging solutions for traditional fabrication and assembly. TMS has sponsored focused instruction and communication in this technology area for more than fifteen years, with leadership from the Shaping and Forming Committee, which organizes a biannual symposium each odd year at the annual meeting. A focused publication produced from each of these symposia now comprises eight volumes detailing the primary research and development activities in this area over the last two decades. The articles assembled herein focus on both recent developments and technology reviews of several key markets from international experts in this area.

  2. Friction Stir Welding Process: A Green Technology

    OpenAIRE

    Esther T. Akinlabi; Stephen A. Akinlabi

    2012-01-01

    Friction Stir Welding (FSW) is a solid state welding process invented and patented by The Welding Institute (TWI) in the United Kingdom in 1991 for butt and lap welding of metals and plastics. This paper highlights the benefits of friction stir welding process as an energy efficient and a green technology process in the field of welding. Compared to the other conventional welding processes, its benefits, typical applications and its use in joining similar and dissimilar materia...

  3. Engineered Alloy Structures by Friction Stir Reaction Processing, Phase I

    Data.gov (United States)

    National Aeronautics and Space Administration — This SBIR Phase I effort examines the feasibility of an innovative surface modification technology incorporating friction stir reaction processing for producing...

  4. Friction Stir Processing of Cast Superalloys, Phase II

    Data.gov (United States)

    National Aeronautics and Space Administration — This SBIR effort examines the feasibility of an innovative fabrication technology incorporating sand casting and friction stir processing (FSP) for producing...

  5. Applications of Friction Stir Processing during Engraving of Soft Materials

    Directory of Open Access Journals (Sweden)

    V. Kočović

    2015-12-01

    Full Text Available Friction stir processing has extensive application in many technological operations. Application area of friction stir processing can be extended to the processing of non-metallic materials, such as wood. The paper examines the friction stir processing contact between a specially designed hard and temperature-resistant rotating tool and workpiece which is made of wood. Interval of speed slip and temperature level under which the combustion occurs and carbonization layer of soft material was determined. The results of the research can be applied in technological process of wood engraving operations which may have significant technological and aesthetic effects.

  6. Automatic Gap Detection in Friction Stir Welding Processes (Preprint)

    National Research Council Canada - National Science Library

    Yang, Yu; Kalya, Prabhanjana; Landers, Robert G; Krishnamurthy, K

    2006-01-01

    .... This paper develops a monitoring algorithm to detect gaps in Friction Stir Welding (FSW) processes. Experimental studies are conducted to determine how the process parameters and the gap width affect the welding process...

  7. Friction Stir Processing of Cast Superalloys, Phase I

    Data.gov (United States)

    National Aeronautics and Space Administration — This SBIR Phase I effort examines the feasibility of an innovative fabrication technology incorporating sand casting and friction stir processing (FSP) for producing...

  8. Process Model for Friction Stir Welding

    Science.gov (United States)

    Adams, Glynn

    1996-01-01

    Friction stir welding (FSW) is a relatively new process being applied for joining of metal alloys. The process was initially developed by The Welding Institute (TWI) in Cambridge, UK. The FSW process is being investigated at NASA/MSEC as a repair/initial weld procedure for fabrication of the super-light-weight aluminum-lithium shuttle external tank. The FSW investigations at MSFC were conducted on a horizontal mill to produce butt welds of flat plate material. The weldment plates are butted together and fixed to a backing plate on the mill bed. A pin tool is placed into the tool holder of the mill spindle and rotated at approximately 400 rpm. The pin tool is then plunged into the plates such that the center of the probe lies at, one end of the line of contact, between the plates and the shoulder of the pin tool penetrates the top surface of the weldment. The weld is produced by traversing the tool along the line of contact between the plates. A lead angle allows the leading edge of the shoulder to remain above the top surface of the plate. The work presented here is the first attempt at modeling a complex phenomenon. The mechanical aspects of conducting the weld process are easily defined and the process itself is controlled by relatively few input parameters. However, in the region of the weld, plasticizing and forging of the parent material occurs. These are difficult processes to model. The model presented here addresses only variations in the radial dimension outward from the pin tool axis. Examinations of the grain structure of the weld reveal that a considerable amount of material deformation also occurs in the direction parallel to the pin tool axis of rotation, through the material thickness. In addition, measurements of the axial load on the pin tool demonstrate that the forging affect of the pin tool shoulder is an important process phenomenon. Therefore, the model needs to be expanded to account for the deformations through the material thickness and the

  9. Friction stir welding process to repair voids in aluminum alloys

    Science.gov (United States)

    Rosen, Charles D. (Inventor); Litwinski, Edward (Inventor); Valdez, Juan M. (Inventor)

    1999-01-01

    The present invention provides an in-process method to repair voids in an aluminum alloy, particularly a friction stir weld in an aluminum alloy. For repairing a circular void or an in-process exit hole in a weld, the method includes the steps of fabricating filler material of the same composition or compatible with the parent material into a plug form to be fitted into the void, positioning the plug in the void, and friction stir welding over and through the plug. For repairing a longitudinal void (30), the method includes machining the void area to provide a trough (34) that subsumes the void, fabricating filler metal into a strip form (36) to be fitted into the trough, positioning the strip in the trough, and rewelding the void area by traversing a friction stir welding tool longitudinally through the strip. The method is also applicable for repairing welds made by a fusing welding process or voids in aluminum alloy workpieces themselves.

  10. Friction stir processing on high carbon steel U12

    Energy Technology Data Exchange (ETDEWEB)

    Tarasov, S. Yu., E-mail: tsy@ispms.ru; Rubtsov, V. E., E-mail: rvy@ispms.ru [Institute of Strength Physics and Materials Science SB RAS, Tomsk, 634055 (Russian Federation); National Research Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation); Melnikov, A. G., E-mail: melnikov-ag@tpu.ru [National Research Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation)

    2015-10-27

    Friction stir processing (FSP) of high carbon steel (U12) samples has been carried out using a milling machine and tools made of cemented tungsten carbide. The FSP tool has been made in the shape of 5×5×1.5 mm. The microstructural characterization of obtained stir zone and heat affected zone has been carried out. Microhardness at the level of 700 MPa has been obtained in the stir zone with microstructure consisting of large grains and cementitte network. This high-level of microhardness is explained by bainitic reaction developing from decarburization of austenitic grains during cementite network formation.

  11. Simulation of friction stir drilling process

    Science.gov (United States)

    Vijayabaskar, P.; Hynes, N. Rajesh Jesudoss

    2018-05-01

    The project is the study of the thermal drilling process. The process is a hole forming process in the sheet metals using the heat generated by means of friction. The main advantage of the process over the conventional drilling process is that the holes formed using this process does not need any backing arrangements such as weld nuts, rivet nuts etc. Because the extruded bush itself acts as a supporting structure for the fasteners. This eliminates the need for the access to the backside of the work material for fastening operations. The major factors contributing the thermal drilling operation are the spindle speed and the thrust force required for forming a hole. The process of finding out the suitable thrust force and the speed for drilling a particular material with particular thickness is a tedious process. The process can be simplified by forming a mathematical model by combining the empirical formulae from the literature. These formulae were derived in the literature from the experimental trials by following certain assumptions. In this paper a suitable mathematical model is formed by replicating the experiments and tried to be validated by the results from numerical analysis. The numerical analysis of the model is done using the ANSYS software.

  12. Unraveling the Processing Parameters in Friction Stir Welding

    Science.gov (United States)

    Schneider, Judy; Nunes, Arthur C., Jr.

    2005-01-01

    In friction stir welding (FSW), a rotating threaded pin tool is translated along a weld seam, literally stirring the edges of the seam together. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path or paths is required. In this study, various markers are used to trace the flow paths of the metal. X-ray radiographs record the segmentation and position of the wire. Several variations in the trajectories can be differentiated within the weld zone.

  13. Process optimization of friction stir welding based on thermal models

    DEFF Research Database (Denmark)

    Larsen, Anders Astrup

    2010-01-01

    This thesis investigates how to apply optimization methods to numerical models of a friction stir welding process. The work is intended as a proof-of-concept using different methods that are applicable to models of high complexity, possibly with high computational cost, and without the possibility...... information of the high-fidelity model. The optimization schemes are applied to stationary thermal models of differing complexity of the friction stir welding process. The optimization problems considered are based on optimizing the temperature field in the workpiece by finding optimal translational speed....... Also an optimization problem based on a microstructure model is solved, allowing the hardness distribution in the plate to be optimized. The use of purely thermal models represents a simplification of the real process; nonetheless, it shows the applicability of the optimization methods considered...

  14. New Materials Design Through Friction Stir Processing Techniques

    International Nuclear Information System (INIS)

    Buffa, G.; Fratini, L.; Shivpuri, R.

    2007-01-01

    Friction Stir Welding (FSW) has reached a large interest in the scientific community and in the last years also in the industrial environment, due to the advantages of such solid state welding process with respect to the classic ones. The complex material flow occurring during the process plays a fundamental role in such solid state welding process, since it determines dramatic changes in the material microstructure of the so called weld nugget, which affects the effectiveness of the joints. What is more, Friction Stir Processing (FSP) is mainly being considered for producing high-strain-rate-superplastic (HSRS) microstructure in commercial aluminum alloys. The aim of the present research is the development of a locally composite material through the Friction Stir Processing (FSP) of two AA7075-T6 blanks and a different material insert. The results of a preliminary experimental campaign, carried out at the varying of the additional material placed at the sheets interface under different conditions, are presented. Micro and macro observation of the such obtained joints permitted to investigate the effects of such process on the overall joint performance

  15. Sustainability of Welding Process through Bobbin Friction Stir Welding

    Science.gov (United States)

    Sued, M. K.; Samsuri, S. S. M.; Kassim, M. K. A. M.; Nasir, S. N. N. M.

    2018-03-01

    Welding process is in high demand, which required a competitive technology to be adopted. This is important for sustaining the needs of the joining industries without ignoring the impact of the process to the environment. Friction stir welding (FSW) is stated to be benefitting the environment through low energy consumption, which cannot be achieved through traditional arc welding. However, this is not well documented, especially for bobbin friction stir welding (BFSW). Therefore, an investigation is conducted by measuring current consumption of the machine during the BFSW process. From the measurement, different phases of BFSW welding process and its electrical demand are presented. It is found that in general total energy in BFSW is about 130kW inclusive of all identified process phases. The phase that utilise for joint formation is in weld phase that used the highest total energy of 120kWs. The recorded total energy is still far below the traditional welding technology and the conventional friction stir welding (CFSW) energy demand. This indicates that BFSW technology with its vast benefit able to sustain the joining technology in near future.

  16. Friction Stir Processing of ODS and FM Steels

    Energy Technology Data Exchange (ETDEWEB)

    Kang, Suk Hoon; Chun, Young Bum; Noh, Sang Hoon; Jang, Jin Sung; Kim, Tae Kyu [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2013-10-15

    In ODS steels, it is well known that uniform nano-oxide dispersoids act as pinning points to obstruct dislocation and grain boundary motion, however, those advantages will be disappeared while the material is subjected to the high temperature of conventional fusion welding. Rotary friction welding, also referred to as friction stir welding (FSW), has shown great promise as a method for welding traditionally difficult to weld materials such as aluminum alloys. This relatively new technology has more recently been applied to higher melting temperature alloys such as steels, nickel-based and titanium alloys. Friction stir processing (FSP) is a method of changing the properties of a metal through intense, localized plastic deformation. FSW is the precursor of the FSP technique. When ideally implemented, this process mixes the material without changing the phase and creates a microstructure with fine, equiaxed grains. This homogeneous grain structure, separated by high-angle boundaries, allows some alloys to take on superplastic properties. In this study, FSW is used as a substitutive welding process between FMS tube and ODS parts. The dimension of tube is 7.0 OD, 0.5 T. During the FSW, dynamic-recrystallized grains are developed; the uniform oxides dispersion is preserved in the metal matrix. The microstructure and microtexture of the material near the stir zone is found to be influenced by the rotational behavior of the tool. The additive effect from FSP on sample surface is considered. Since the mechanical alloying (MA) and FSP commonly apply extreme shear deformation on materials, the dispersion of oxide particle in ODS steels is very active during both processes. Friction stir welding appears to be a very promising technique for the welding of FMS and ODS steels in the form of sheet and tube. FSW could successfully produce defect-free welds on FMS tubes and ODS ring assembly. FSW produces a fine grain structure consisting of ferrite and martensite, and the oxide

  17. Friction Stir Processing of ODS and FM Steels

    International Nuclear Information System (INIS)

    Kang, Suk Hoon; Chun, Young Bum; Noh, Sang Hoon; Jang, Jin Sung; Kim, Tae Kyu

    2013-01-01

    In ODS steels, it is well known that uniform nano-oxide dispersoids act as pinning points to obstruct dislocation and grain boundary motion, however, those advantages will be disappeared while the material is subjected to the high temperature of conventional fusion welding. Rotary friction welding, also referred to as friction stir welding (FSW), has shown great promise as a method for welding traditionally difficult to weld materials such as aluminum alloys. This relatively new technology has more recently been applied to higher melting temperature alloys such as steels, nickel-based and titanium alloys. Friction stir processing (FSP) is a method of changing the properties of a metal through intense, localized plastic deformation. FSW is the precursor of the FSP technique. When ideally implemented, this process mixes the material without changing the phase and creates a microstructure with fine, equiaxed grains. This homogeneous grain structure, separated by high-angle boundaries, allows some alloys to take on superplastic properties. In this study, FSW is used as a substitutive welding process between FMS tube and ODS parts. The dimension of tube is 7.0 OD, 0.5 T. During the FSW, dynamic-recrystallized grains are developed; the uniform oxides dispersion is preserved in the metal matrix. The microstructure and microtexture of the material near the stir zone is found to be influenced by the rotational behavior of the tool. The additive effect from FSP on sample surface is considered. Since the mechanical alloying (MA) and FSP commonly apply extreme shear deformation on materials, the dispersion of oxide particle in ODS steels is very active during both processes. Friction stir welding appears to be a very promising technique for the welding of FMS and ODS steels in the form of sheet and tube. FSW could successfully produce defect-free welds on FMS tubes and ODS ring assembly. FSW produces a fine grain structure consisting of ferrite and martensite, and the oxide

  18. Friction stir welding tool and process for welding dissimilar materials

    Science.gov (United States)

    Hovanski, Yuri; Grant, Glenn J; Jana, Saumyadeep; Mattlin, Karl F

    2013-05-07

    A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.

  19. Microstructure characterization of the stir zone of submerged friction stir processed aluminum alloy 2219

    International Nuclear Information System (INIS)

    Feng, Xiuli; Liu, Huijie; Lippold, John C.

    2013-01-01

    Aluminum alloy 2219-T6 was friction stir processed using a novel submerged processing technique to facilitate cooling. Processing was conducted at a constant tool traverse speed of 200 mm/min and spindle rotation speeds in the range from 600 to 800 rpm. The microstructural characteristics of the base metal and processed zone, including grain structure and precipitation behavior, were studied using optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Microhardness maps were constructed on polished cross sections of as-processed samples. The effect of tool rotation speed on the microstructure and hardness of the stir zone was investigated. The average grain size of the stir zone was much smaller than that of the base metal, but the hardness was also lower due to the formation of equilibrium θ precipitates from the base metal θ′ precipitates. Stir zone hardness was found to decrease with increasing rotation speed (heat input). The effect of processing conditions on strength (hardness) was rationalized based on the competition between grain refinement strengthening and softening due to precipitate overaging. - Highlights: • SZ grain size (∼ 1 μm) is reduced by over one order of magnitude relative to the BM. • Hardness in the SZ is lower than that of the precipitation strengthened BM. • Metastable θ′ in the base metal transforms to equilibrium θ in the stir zone. • Softening in the SZ results from a decrease of precipitation strengthening

  20. Microstructure characterization of the stir zone of submerged friction stir processed aluminum alloy 2219

    Energy Technology Data Exchange (ETDEWEB)

    Feng, Xiuli, E-mail: feng.97@osu.edu [Welding Engineering Program, Department of Materials Science and Engineering, The Ohio State University, Columbus, OH 43221 (United States); State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001 (China); Liu, Huijie, E-mail: liuhj@hit.edu.cn [State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001 (China); Lippold, John C., E-mail: lippold.1@osu.edu [Welding Engineering Program, Department of Materials Science and Engineering, The Ohio State University, Columbus, OH 43221 (United States)

    2013-08-15

    Aluminum alloy 2219-T6 was friction stir processed using a novel submerged processing technique to facilitate cooling. Processing was conducted at a constant tool traverse speed of 200 mm/min and spindle rotation speeds in the range from 600 to 800 rpm. The microstructural characteristics of the base metal and processed zone, including grain structure and precipitation behavior, were studied using optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Microhardness maps were constructed on polished cross sections of as-processed samples. The effect of tool rotation speed on the microstructure and hardness of the stir zone was investigated. The average grain size of the stir zone was much smaller than that of the base metal, but the hardness was also lower due to the formation of equilibrium θ precipitates from the base metal θ′ precipitates. Stir zone hardness was found to decrease with increasing rotation speed (heat input). The effect of processing conditions on strength (hardness) was rationalized based on the competition between grain refinement strengthening and softening due to precipitate overaging. - Highlights: • SZ grain size (∼ 1 μm) is reduced by over one order of magnitude relative to the BM. • Hardness in the SZ is lower than that of the precipitation strengthened BM. • Metastable θ′ in the base metal transforms to equilibrium θ in the stir zone. • Softening in the SZ results from a decrease of precipitation strengthening.

  1. Grain refinement of Aluminium alloys using friction stir processing

    International Nuclear Information System (INIS)

    Khraisheh, M.

    2004-01-01

    Full text.Friction Stir Processing (FSP) is a new advanced material processing technique used to refine and homogenize the microstructure of sheet metals. FSP is a solid state processing technique that uses a rapidly rotating non-consumable high strength tool steel pin that extends from a cylindrical shoulder. The rotating pin is forced with a predetermined load into the work piece and moved along with the work pieces, while the rotating pin deforms and stirs the locally heated material. It is a hot working process in which a large amount of deformation is imparted to the sheet. FS processed zone is characterized by dynamic recrystallization which results in grain refinement . this promising emerging process needs further investigations to develop optimum process parameters to produce the desired microstructure. In this work, we present preliminary results on the effects of rotational and translational speeds on grain refinement of AA5052. Under certain processing conditions, sub-micron grain structure was produced using this technique

  2. Simulation of Friction Stir Processing in 304L Stainless Steel

    Directory of Open Access Journals (Sweden)

    Miles M.P.

    2016-01-01

    Full Text Available A major dilemma facing the nuclear industry is repair or replacement of stainless steel reactor components that have been exposed to neutron irradiation. When conventional fusion welding is used for weld repair, the high temperatures and thermal stresses inherent in the process enhance the growth of helium bubbles, causing intergranular cracking in the heat-affected zone (HAZ. Friction stir processing (FSP has potential as a weld repair technique for irradiated stainless steel, because it operates at much lower temperatures than fusion welding, and is therefore less likely to cause cracking in the HAZ. Numerical simulation of the FSP process in 304L stainless steel was performed using an Eulerian finite element approach. Model input required flow stresses for the large range of strain rates and temperatures inherent in the FSP process. Temperature predictions in three locations adjacent to the stir zone were accurate to within 4% of experimentally measure values. Prediction of recrystallized grain size at a location about 6mm behind the tool center was less accurate, because the empirical model employed for the prediction did not account for grain growth that occurred after deformation in the experiment was halted.

  3. Characteristics of Friction Stir Processed UHMW Polyethylene Based Composite

    Science.gov (United States)

    Hussain, G.; Khan, I.

    2018-01-01

    Ultra-high molecular weight polyethylene (UHMWPE) based composites are widely used in biomedical and food industries because of their biocompatibility and enhanced properties. The aim of this study was to fabricate UHMWPE / nHA composite through heat assisted Friction Stir Processing. The rotational speed (ω), feed rate (f), volume fraction of nHA (v) and shoulder temperature (T) were selected as the process parameters. Macroscopic and microscopic analysis revealed that these parameters have significant effects on the distribution of reinforcing material, defects formation and material mixing. Defects were observed especially at low levels of (ω, T) and high levels of (f, v). Low level of v with medium levels of other parameters resulted in better mixing and minimum defects. A 10% increase in strength with only 1% reduction in Percent Elongation was observed at the above set of conditions. Moreover, the resulted hardness of the composite was higher than that of the parent material.

  4. Friction stir welding (FSW process of copper alloys

    Directory of Open Access Journals (Sweden)

    M. Miličić

    2016-01-01

    Full Text Available The present paper analyzes the structure of the weld joint of technically pure copper, which is realized using friction stir welding (FSW. The mechanism of thermo-mechanical processes of the FSW method has been identified and a correlation between the weld zone and its microstructure established. Parameters of the FSW welding technology influencing the zone of the seam material and the mechanical properties of the resulting joint were analyzed. The physical joining consists of intense mixing the base material along the joint line in the “doughy” phase. Substantial plastic deformations immediately beneath the frontal surface of tool provide fine-grained structure and a good quality joint. The optimum shape of the tool and the optimum welding regime (pressure force, rotation speed and the traverse speed of the tool in the heat affected zone enable the achievement of the same mechanical properties as those of the basic material, which justifies its use in welding reliable structures.

  5. Role of friction stir processing parameters on microstructure and ...

    Indian Academy of Sciences (India)

    The life of compo- nents depends on surface properties in many applications. ... The modified surface layer is called as surface composite (Attia. 2001). Friction stir .... The optical photomicrograph of as received copper plate is shown in figure 1a. ... It is essential to obtain a smooth crown appearance owing to the fact that ...

  6. Deconvoluting the Friction Stir Weld Process for Optimizing Welds

    Science.gov (United States)

    Schneider, Judy; Nunes, Arthur C.

    2008-01-01

    In the friction stir welding process, the rotating surfaces of the pin and shoulder contact the weld metal and force a rotational flow within the weld metal. Heat, generated by the metal deformation as well as frictional slippage with the contact surface, softens the metal and makes it easier to deform. As in any thermo-mechanical processing of metal, the flow conditions are critical to the quality of the weld. For example, extrusion of metal from under the shoulder of an excessively hot weld may relax local pressure and result in wormhole defects. The trace of the weld joint in the wake of the weld may vary geometrically depending upon the flow streamlines around the tool with some geometry more vulnerable to loss of strength from joint contamination than others. The material flow path around the tool cannot be seen in real time during the weld. By using analytical "tools" based upon the principles of mathematics and physics, a weld model can be created to compute features that can be observed. By comparing the computed observations with actual data, the weld model can be validated or adjusted to get better agreement. Inputs to the model to predict weld structures and properties include: hot working properties ofthe metal, pin tool geometry, travel rate, rotation and plunge force. Since metals record their prior hot working history, the hot working conditions imparted during FSW can be quantified by interpreting the final microstructure. Variations in texture and grain size result from variations in the strain accommodated at a given strain rate and temperature. Microstructural data from a variety of FSWs has been correlated with prior marker studies to contribute to our understanding of the FSW process. Once this stage is reached, the weld modeling process can save significant development costs by reducing costly trial-and-error approaches to obtaining quality welds.

  7. Surface modification of hydroturbine steel using friction stir processing

    Science.gov (United States)

    Grewal, H. S.; Arora, H. S.; Singh, H.; Agrawal, A.

    2013-03-01

    Friction stir processing (FSP) has proved to be a viable tool for enhancing the mechanical properties of materials, however, the major focus has been upon improving the bulk properties of light metals and their alloys. Hydroturbines are susceptible to damage owing to slurry and cavitation erosion. In this study, FSP of a commonly employed hydroturbine steel, 13Cr4Ni was undertaken. Microstructural characterization of the processed steel was conducted using optical microscopy (OM), scanning electron microscopy (SEM) equipped with energy dispersive spectroscopy (EDS), X-ray diffraction (XRD) and electron back scatter diffraction (EBSD) techniques. Mechanical characterization of the steel was undertaken in terms of microhardness and resistance to cavitation erosion (CE). FSP resulted in the refinement of the microstructure with reduction in grain size by a factor of 10. EBSD results confirmed the existence of submicron and ultrafine grained microstructure. The microhardness of the steel was found to enhance by 2.6 times after processing. The processed steel also showed 2.4 times higher resistance against cavitation erosion in comparison to unprocessed steel. The primary erosion mechanism for both the steels was identical in nature, with plastic deformation responsible for the loss of material.

  8. Surface hardening of two cast irons by friction stir processing

    International Nuclear Information System (INIS)

    Fujii, Hidetoshi; Kikuchi, Toshifumi; Nogi, Kiyoshi; Yamaguchi, Yasufumi; Kiguchi, Shoji

    2009-01-01

    The Friction Stir Processing (FSP) was applied to the surface hardening of cast irons. Flake graphite cast iron (FC300) and nodular graphite cast iron (FCD700) were used to investigate the validity of this method. The matrices of the FC300 and FC700 cast irons are pearlite. The rotary tool is a 25mm diameter cylindrical tool, and the travelling speed was varied between 50 and 150mm/min in order to control the heat input at the constant rotation speed of 900rpm. As a result, it has been clarified that a Vickers hardness of about 700HV is obtained for both cast irons. It is considered that a very fine martensite structure is formed because the FSP generates the heat very locally, and a very high cooling rate is constantly obtained. When a tool without an umbo (probe) is used, the domain in which graphite is crushed and striated is minimized. This leads to obtaining a much harder sample. The hardness change depends on the size of the martensite, which can be controlled by the process conditions, such as the tool traveling speed and the load. Based on these results, it was clarified that the FSP has many advantages for cast irons, such as a higher hardness and lower distortion. As a result, no post surface heat treatment and no post machining are required to obtain the required hardness, while these processes are generally required when using the traditional methods.

  9. Friction stir processing (FSP: refining microstructures and improving properties

    Directory of Open Access Journals (Sweden)

    McNelley, T. R.

    2010-12-01

    Full Text Available FSP is reviewed as an allied technology of friction stir welding (FSW and additional considerations such as processing pattern and step over distance are introduced. The application of FSP to continuously cast AA5083 material in the as-cast condition is described and the extent of grain refinement and homogenization of microstructure is documented. The FSP-induced superplastic response of this material is compared to the response of conventionally processed AA5083 and the improved ductility of the FSP material is related to grain refinement and microstructure homogenization.

    Se revisa el procesado por fricción batida (FSP como un aliado tecnológico de la soldadura por fricción batida (FSW y se introducen consideraciones adicionales tales como el patrón de procesado y el paso en función de la distancia. Se describe la aplicación de FSP al material AA5083 por colada continua en la condición de colada y se documenta el grado de afino de grano y homogeneización de la microestructura. La respuesta de superplasticidad inducida por FSP se compara con la respuesta de la aleación AA5083 procesada convencionalmente y la mejora de ductilidad del material FSP se relaciona con el afino de grano y la homogeneización de la microestructura.

  10. Optimization of Friction Stir Welding Tool Advance Speed via Monte-Carlo Simulation of the Friction Stir Welding Process.

    Science.gov (United States)

    Fraser, Kirk A; St-Georges, Lyne; Kiss, Laszlo I

    2014-04-30

    Recognition of the friction stir welding process is growing in the aeronautical and aero-space industries. To make the process more available to the structural fabrication industry (buildings and bridges), being able to model the process to determine the highest speed of advance possible that will not cause unwanted welding defects is desirable. A numerical solution to the transient two-dimensional heat diffusion equation for the friction stir welding process is presented. A non-linear heat generation term based on an arbitrary piecewise linear model of friction as a function of temperature is used. The solution is used to solve for the temperature distribution in the Al 6061-T6 work pieces. The finite difference solution of the non-linear problem is used to perform a Monte-Carlo simulation (MCS). A polynomial response surface (maximum welding temperature as a function of advancing and rotational speed) is constructed from the MCS results. The response surface is used to determine the optimum tool speed of advance and rotational speed. The exterior penalty method is used to find the highest speed of advance and the associated rotational speed of the tool for the FSW process considered. We show that good agreement with experimental optimization work is possible with this simplified model. Using our approach an optimal weld pitch of 0.52 mm/rev is obtained for 3.18 mm thick AA6061-T6 plate. Our method provides an estimate of the optimal welding parameters in less than 30 min of calculation time.

  11. Friction Stir Welding

    Science.gov (United States)

    Nunes, Arthur C., Jr.

    2008-01-01

    Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and promises to be an important welding process for any industries where welds of optimal quality are demanded. This article provides an introduction to the FSW process. The chief concern is the physical effect of the tool on the weld metal: how weld seam bonding takes place, what kind of weld structure is generated, potential problems, possible defects for example, and implications for process parameters and tool design. Weld properties are determined by structure, and the structure of friction stir welds is determined by the weld metal flow field in the vicinity of the weld tool. Metal flow in the vicinity of the weld tool is explained through a simple kinematic flow model that decomposes the flow field into three basic component flows: a uniform translation, a rotating solid cylinder, and a ring vortex encircling the tool. The flow components, superposed to construct the flow model, can be related to particular aspects of weld process parameters and tool design; they provide a bridge to an understanding of a complex-at-first-glance weld structure. Torques and forces are also discussed. Some simple mathematical models of structural aspects, torques, and forces are included.

  12. Effects of tool speeds and corresponding torque/energy on stir zone formation during friction stir welding/processing

    International Nuclear Information System (INIS)

    Cui, S; Chen, Z W

    2009-01-01

    The way processing parameters and the measurable thermomechanical responses relate to the individual and combined flows forming the different processed zones during friction stir welding/processing has been studied. Experimentally, a cast Al-7Si-0.3Mg alloy was used to provide readily identifiable processed zones. A series of friction stir experiments covering a wide range of tool forward and rotation speeds were conducted followed by the measurement of individual and combined stir areas. It has been found that the basic modes of material flow did not change but the relative volume of each flow depended on both forward and rotation speeds. The trends observed in the present data explain how pin rotation relates to the material transportation mechanism and the associated torque required. This data also explains how forward speed, not rotation speed, relates to specific energy and the volume of the total stir zone.

  13. Characterization of Microstructure and Microtexture in Longitudinal Sections from Friction Stir Processed Nickel-Aluminum Bronze

    National Research Council Canada - National Science Library

    Faires, Kenneth B

    2003-01-01

    .... Friction stir processing (FSP) represents a new technology for surface hardening of as-cast NAB by means of severe plastic deformation induced by a rotating tool that is traversed across the surface of a material...

  14. Retractable Pin Tools for the Friction Stir Welding Process

    Science.gov (United States)

    1998-01-01

    Two companies have successfully commercialized a specialized welding tool developed at the Marshall Space Flight Center (MSFC). Friction stir welding uses the high rotational speed of a tool and the resulting frictional heat created from contact to crush, 'stir' together, and forge a bond between two metal alloys. It has had a major drawback, reliance on a single-piece pin tool. The pin is slowly plunged into the joint between two materials to be welded and rotated as high speed. At the end of the weld, the single-piece pin tool is retracted and leaves a 'keyhole,' something which is unacceptable when welding cylindrical objects such as drums, pipes and storage tanks. Another drawback is the requirement for different-length pin tools when welding materials of varying thickness. An engineer at the MSFC helped design an automatic retractable pin tool that uses a computer-controlled motor to automatically retract the pin into the shoulder of the tool at the end of the weld, preventing keyholes. This design allows the pin angle and length to be adjusted for changes in material thickness and results in a smooth hole closure at the end of the weld. Benefits of friction stir welding, using the MSFC retractable pin tool technology, include the following: The ability to weld a wide range of alloys, including previously unweldable and composite materials; provision of twice the fatigue resistance of fusion welds and no keyholes; minimization of material distortion; no creation of hazards such as welding fumes, radiation, high voltage, liquid metals, or arcing; automatic retraction of the pin at the end of the weld; and maintaining full penetration of the pin.

  15. Superplastic forming of 7475 Al sheet after friction stir processing (FSP)

    Energy Technology Data Exchange (ETDEWEB)

    Mahoney, M.; Bingel, W.H.; Fuller, C. [Rockwell Scientific Co., Thousand Oaks, CA (United States); Barnes, A.J. [Superform USA, Riverside, CA (United States)

    2004-07-01

    Since the invention of friction stir welding (FSW) in 1991, an increasing number of successful applications have been found for this unique solid-state welding technique. More recently, attention has been given to utilizing the mechanics of friction stirring to thermo-mechanically modify the microstructure of aluminum alloys to create or enhance superplasticity. Until now, superplasticity induced by friction stir processing (FSP) has only been demonstrated in small samples and evaluated by hot tensile elongation testing. The present work describes what we believe to be the first biaxial testing and full size component superplastic forming of friction stir processed aluminum sheet. The remarkable formability demonstrated in these 'first time' trials is described in detail. (orig.)

  16. Friction stir welding tool

    Science.gov (United States)

    Tolle,; Charles R. , Clark; Denis E. , Barnes; Timothy, A [Ammon, ID

    2008-04-15

    A friction stir welding tool is described and which includes a shank portion; a shoulder portion which is releasably engageable with the shank portion; and a pin which is releasably engageable with the shoulder portion.

  17. Understanding Friction Stir Welding

    Science.gov (United States)

    Nunes, A. C., Jr.

    2018-01-01

    This Technical Memorandum explains the friction stir welding process in terms of two basic concepts: the concentration of deformation in a shear surface enveloping the tool and the composition of the overall plastic flow field around the tool from simple flow field components. It is demonstrated how weld structure may be understood and torque, drag, and lateral tool forces may be estimated using these concepts. Some discrepancies between computations and accompanying empirical data are discussed in the text. This work is intended to be helpful to engineers in diagnosing problems and advancing technology.

  18. Experimental studies of parameters affecting the heat generation in friction stir welding process

    Directory of Open Access Journals (Sweden)

    Mijajlović Miroslav M.

    2012-01-01

    Full Text Available Heat generation is a complex process of transformation of a specific type of energy into heat. During friction stir welding, one part of mechanical energy delivered to the welding tool is consumed in the welding process, another is used for deformational processes etc., and the rest of the energy is transformed into heat. The analytical procedure for the estimation of heat generated during friction stir welding is very complex because it includes a significant number of variables and parameters, and many of them cannot be fully mathematically explained. Because of that, the analytical model for the estimation of heat generated during friction stir welding defines variables and parameters that dominantly affect heat generation. These parameters are numerous and some of them, e. g. loads, friction coefficient, torque, temperature, are estimated experimentally. Due to the complex geometry of the friction stir welding process and requirements of the measuring equipment, adequate measuring configurations and specific constructional solutions that provide adequate measuring positions are necessary. This paper gives an overview of the process of heat generation during friction stir welding, the most influencing parameters on heat generation, constructional solutions for the measuring equipment needed for these experimental researches and examples of measured values.

  19. A framework for shear driven dissolution of thermally stable particles during friction stir welding and processing

    Energy Technology Data Exchange (ETDEWEB)

    Palanivel, S. [Advanced Materials and Manufacturing Processes Institute, Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76203 (United States); Arora, A. [Materials Science and Engineering, Indian Institute of Technology Gandhinagar, Palaj, Gandhinagar 382355, Gujarat (India); Doherty, K.J. [U.S. Army Research Laboratory, Materials and Manufacturing Science Division, Aberdeen Proving Ground, MD 21005 (United States); Mishra, R.S., E-mail: Rajiv.Mishra@unt.edu [Advanced Materials and Manufacturing Processes Institute, Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76203 (United States)

    2016-12-15

    A framework is proposed to explain the dissolution and fragmentation of particles during friction stir welding and processing. Two major mechanisms dissolve the particle during the process: (i) thermally activated diffusion, and (ii) dislocation and grain boundary sweeping of atoms. We use a three-dimensional coupled viscoplastic flow and heat transfer model to quantify these mechanisms. For illustration purposes, calculations were done on a thermally stable Mg{sub 2}Y intermetallic that dissolved during processing. The framework is universal and applies to any second phase dissolution and fragmentation during friction stir welding and processing, thus enabling a science-based approach to tailor microstructures.

  20. Physics-based process model approach for detecting discontinuity during friction stir welding

    Energy Technology Data Exchange (ETDEWEB)

    Shrivastava, Amber; Pfefferkorn, Frank E.; Duffie, Neil A.; Ferrier, Nicola J.; Smith, Christopher B.; Malukhin, Kostya; Zinn, Michael

    2015-02-12

    The goal of this work is to develop a method for detecting the creation of discontinuities during friction stir welding. This in situ weld monitoring method could significantly reduce the need for post-process inspection. A process force model and a discontinuity force model were created based on the state-of-the-art understanding of flow around an friction stir welding (FSW) tool. These models are used to predict the FSW forces and size of discontinuities formed in the weld. Friction stir welds with discontinuities and welds without discontinuities were created, and the differences in force dynamics were observed. In this paper, discontinuities were generated by reducing the tool rotation frequency and increasing the tool traverse speed in order to create "cold" welds. Experimental force data for welds with discontinuities and welds without discontinuities compared favorably with the predicted forces. The model currently overpredicts the discontinuity size.

  1. An analysis to optimize the process parameters of friction stir welded ...

    African Journals Online (AJOL)

    The friction stir welding (FSW) of steel is a challenging task. Experiments are conducted here, with a tool having a conical pin of 0.4mm clearance. The process parameters are optimized by using the Taguchi technique based on Taguchi's L9 orthogonal array. Experiments have been conducted based on three process ...

  2. Optimization of process parameters for friction stir processing (FSP ...

    Indian Academy of Sciences (India)

    Administrator

    al 2005; Yadav and Bauri 2011) as the thermo- mechanical aspect of the process provides enough driving force for occurrence of dynamic recovery (DRV) that precedes DRX leading to an equi-axed fine grain struc- ture. The microstructure evolution is further discussed below with the aid of transmission electron microscopy.

  3. Use of Friction Stir Welding and Friction Stir Processing for Advanced Nuclear Fuels and Materials Joining Applications

    International Nuclear Information System (INIS)

    J. I. Cole; J. F. Jue

    2006-01-01

    Application of the latest developments in materials technology may greatly aid in the successful pursuit of next generation reactor and transmutation technologies. One such area where significant progress is needed is joining of advanced fuels and materials. Rotary friction welding, also referred to as friction stir welding (FSW), has shown great promise as a method for joining traditionally difficult to join materials such as aluminum alloys. This relatively new technology, first developed in 1991, has more recently been applied to higher melting temperature alloys such as steels, nickel-based and titanium alloys. An overview of the FSW technology is provided and two specific nuclear fuels and materials applications where the technique may be used to overcome limitations of conventional joining technologies are highlighted

  4. Ultrasonic Low-Friction Containment Plate for Thermal and Ultrasonic Stir Weld Processes

    Science.gov (United States)

    Graff, Karl; Short, Matt

    2013-01-01

    The thermal stir welding (TSW) process is finding applications in fabrication of space vehicles. In this process, workpieces to be joined by TSW are drawn, by heavy forces, between "containment plates," past the TSW tool that then causes joining of the separate plates. It is believed that the TSW process would be significantly improved by reducing the draw force, and that this could be achieved by reducing the friction forces between the workpieces and containment plates. Based on use of high-power ultrasonics in metal forming processes, where friction reduction in drawing dies has been achieved, it is believed that ultrasonic vibrations of the containment plates could achieve similar friction reduction in the TSW process. By applying ultrasonic vibrations to the containment plates in a longitudinal vibration mode, as well as by mounting and holding the containment plates in a specific manner such as to permit the plates to acoustically float, friction between the metal parts and the containment plates is greatly reduced, and so is the drawing force. The concept was to bring in the ultrasonics from the sides of the plates, permitting the ultrasonic hardware to be placed to the side, away from the equipment that contains the thermal stir tooling and that applies clamping forces to the plates. Tests demonstrated that one of the major objectives of applying ultrasonics to the thermal stir system, that of reducing draw force friction, should be achievable on a scaled-up system.

  5. Deformation During Friction Stir Welding

    Science.gov (United States)

    White, Henry J.

    2002-01-01

    Friction Stir Welding (FSW) is a solid state welding process that exhibits characteristics similar to traditional metal cutting processes. The plastic deformation that occurs during friction stir welding is due to the superposition of three flow fields: a primary rotation of a radially symmetric solid plug of metal surrounding the pin tool, a secondary uniform translation, and a tertiary ring vortex flow (smoke rings) surrounding the tool. If the metal sticks to the tool, the plug surface extends down into the metal from the outer edge of the tool shoulder, decreases in diameter like a funnel, and closes up beneath the pin. Since its invention, ten years have gone by and still very little is known about the physics of the friction stir welding process. In this experiment, an H13 steel weld tool (shoulder diameter, 0.797 in; pin diameter, 0.312 in; and pin length, 0.2506 in) was used to weld three 0.255 in thick plates. The deformation behavior during friction stir welding was investigated by metallographically preparing a plan view sections of the weldment and taking Vickers hardness test in the key-hole region.

  6. Effect of process parameters on microstructure and mechanical properties of friction stir welded joints: A review

    Science.gov (United States)

    Wanare, S. P.; Kalyankar, V. D.

    2018-04-01

    Friction stir welding is emerging as a promising technique for joining of lighter metal alloys due to its several advantages over conventional fusion welding processes such as low thermal distortion, good mechanical properties, fine weld joint microstructure, etc. This review article mainly focuses on analysis of microstructure and mechanical properties of friction stir welded joints. Various microstructure characterization techniques used by previous researchers such as optical microscopes, x-ray diffraction, electron probe microscope, transmission electron microscope, scanning electron microscopes with electron back scattered diffraction, electron dispersive microscopy, etc. are thoroughly overviewed and their results are discussed. The effects of friction stir welding process parameters such as tool rotational speed, welding speed, tool plunge depth, axial force, tool shoulder diameter to tool pin diameter ratio, tool geometry etc. on microstructure and mechanical properties of welded joints are studied and critical observations are noted down. The microstructure examination carried out by previous researchers on various zones of welded joints such as weld zone, heat affected zone and base metal are studied and critical remarks have been presented. Mechanical performances of friction stir welded joints based on tensile test, micro-hardness test, etc. are discussed. This article includes exhaustive literature review of standard research articles which may become ready information for subsequent researchers to establish their line of action.

  7. Multiple pass and multiple layer friction stir welding and material enhancement processes

    Science.gov (United States)

    Feng, Zhili [Knoxville, TN; David, Stan A [Knoxville, TN; Frederick, David Alan [Harriman, TN

    2010-07-27

    Processes for friction stir welding, typically for comparatively thick plate materials using multiple passes and multiple layers of a friction stir welding tool. In some embodiments a first portion of a fabrication preform and a second portion of the fabrication preform are placed adjacent to each other to form a joint, and there may be a groove adjacent the joint. The joint is welded and then, where a groove exists, a filler may be disposed in the groove, and the seams between the filler and the first and second portions of the fabrication preform may be friction stir welded. In some embodiments two portions of a fabrication preform are abutted to form a joint, where the joint may, for example, be a lap joint, a bevel joint or a butt joint. In some embodiments a plurality of passes of a friction stir welding tool may be used, with some passes welding from one side of a fabrication preform and other passes welding from the other side of the fabrication preform.

  8. High strain rate superplasticity in a friction stir processed 7075 Al alloy

    Energy Technology Data Exchange (ETDEWEB)

    Mishra, R.S.; Mahoney, M.W.; McFaden, S.X.; Mara, N.A.; Mukherjee, A.K.

    1999-12-31

    In this paper, the authors report the first results using friction stir processing (FSP). In the last ten years, a new technique of Friction Stir Welding (FSW) has emerged as an exciting solid state joining technique for aluminum alloys. This technique, developed by The Welding Institute (TWI), involves traversing a rotating tool that produces intense plastic deformation through a stirring action. The localized heating is produced by friction between the tool shoulder and the sheet top surface, as well as plastic deformation of the material in contact with the tool. This results in a stirred zone with a very fine grain size in a single pass. Mahoney et al. observed a grain size of 3 {micro}m in a 7075 Al alloy. This process can be easily adopted as a processing technique to obtain fine grain size. FSP of a commercial 7075 Al alloy resulted in significant enhancement of superplastic properties. The optimum superplastic strain rate was 10{sup {minus}2}s{sup {minus}1} at 490 C in the FSP 7075 Al alloy, an improvement of more than an order of magnitude in strain rate. The present results suggest an exciting possibility to use a simple FSP technique to enhance grain size dependent properties.

  9. Solid state crack repair by friction stir processing in 304L stainless steel

    Institute of Scientific and Technical Information of China (English)

    C.Gunter; M.P.Miles; F.C.Liu; T.W Nelson

    2018-01-01

    Friction stir processing (FSP) was investigated as a method of repairing cracks in 12mm thick 304L stainless steel plate.Healing feasibility was demonstrated by processing a tapered crack using a PCBN/WRe tool with a 25 mm diameter shoulder and a pin length of 6.4 mm.The experiment showed that it was possible to heal a crack that begins narrow and then progressively grows up to a width of 2 mm.Bead on plate experiments were used to find the best parameters for creating a consolidated stir zone with the least amount of hardness difference compared to the base metal.Grain refinement in some specimens resulted in much higher stir zone hardness,compared to base metal.A plot of grain size versus microhardness showed a very strong inverse correlation between grain size and hardness,as expected from the HallPetch relationship.Corrosion testing was carried out in order to evaluate the effect of FSP on potential sensitization of the stir zone.After 1000h of intermittent immersion in 3.5% saline solution at room temperature it was found that no corrosion products formed on the base material controls or on any of the friction stir processed specimens.

  10. Surface enhancement of cold work tool steels by friction stir processing with a pinless tool

    Science.gov (United States)

    Costa, M. I.; Verdera, D.; Vieira, M. T.; Rodrigues, D. M.

    2014-03-01

    The microstructure and mechanical properties of enhanced tool steel (AISI D2) surfaces produced using a friction stir welding (FSW) related procedure, called friction stir processing (FSP), are analysed in this work. The surface of the tool steel samples was processed using a WC-Co pinless tool and varying processing conditions. Microstructural analysis revealed that meanwhile the original substrate structure consisted of a heterogeneous distribution of coarse carbides in a ferritic matrix, the transformed surfaces consisted of very small carbides, homogenously distributed in a ferrite- bainite- martensite matrix. The morphology of the surfaces, as well as its mechanical properties, evaluated by hardness and tensile testing, were found to vary with increasing tool rotation speed. Surface hardness was drastically increased, relative to the initial hardness of bulk steel. This was attributed to ferrite and carbide refinement, as well as to martensite formation during solid state processing. At the highest rotation rates, tool sliding during processing deeply compromised the characteristics of the processed surfaces.

  11. Effect of process parameters on mechanical properties of friction stir spot welded magnesium to aluminum alloys

    International Nuclear Information System (INIS)

    Rao, H.M.; Yuan, W.; Badarinarayan, H.

    2015-01-01

    Highlights: • Lap-shear failure load of ∼2.5 kN was achieved in dissimilar Mg to Al spot welds. • Failure load depends on both welding geometrical features and IMCs formation. • Thin and discontinuous IMCs formed in stir zone are beneficial for weld strength. • Low heat input and good material mixing/interlocking is essential for high strength. - Abstract: Friction stir spot welding was applied to dissimilar cast magnesium (Mg) alloy AM60B and wrought aluminum (Al) alloy 6022-T4 under various welding conditions. The influence of tool rotation rate and shoulder plunge depth on lap-shear failure load was examined. Welds were made at four different tool rotation rates of 1000, 1500, 2000 and 2500 revolution per minute (rpm) and various tool shoulder plunge depths from 0 mm to 0.9 mm. The cross section of each weld exhibited the formation of intermetallic compounds (IMCs) in the stir zone. An increase in tool rotation rate decreased the width of the stir zone and resulted in lower lap-shear failure loads. The stir zone width increased and interlocking of IMCs was observed with an increase in tool shoulder plunge depth at 1000 rpm. High lap-shear failure loads were achieved in welds having a large stir zone width with formation of discontinuous IMCs at the tip of the interfacial hook. An average lap-shear failure load of 2.5 kN was achieved for welds made at 1000 rpm and 0.9 mm shoulder plunge. The present study suggests that the mechanical properties of friction stir spot welded dissimilar alloys are greatly influenced by the stir zone width, interfacial hooks and IMCs which are all weld process dependent

  12. Texture analysis of a friction stir processed 6061-T6 aluminum alloy using neutron diffraction

    International Nuclear Information System (INIS)

    Woo, W.; Choo, H.; Brown, D.W.; Vogel, S.C.; Liaw, P.K.; Feng, Z.

    2006-01-01

    Time-of-flight neutron diffraction was used to investigate the texture changes in friction stir-processed (FSP) 6061-T6 aluminum alloy plates. Two different specimens were prepared with the purpose of separating the effects of frictional heating and severe plastic deformation on the changes of the preferred orientation in the as-received rolled plates: a plate processed with both stirring pin and tool shoulder, i.e., a regular FSP plate subjected to both severe plastic deformation and frictional heating (Case 1); and a plate processed only with the tool shoulder, i.e., subjected mainly to frictional heating (Case 2). The diffraction peak intensities provide insights into the texture variations at various locations across the centerline and through the thickness of the FSP plates. Comparison of the texture variations between Cases 1 and 2 clearly shows that the severe plastic deformation from the stirring pin affects the preferred orientation during the FSP, while heating alone from the tool shoulder has little effect

  13. The erosion performance of cold spray deposited metal matrix composite coatings with subsequent friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Peat, Tom, E-mail: tompeat12@gmail.com [Department of Mechanical & Aerospace Engineering, University of Strathclyde, James Weir Building, 75 Montrose Street, Glasgow G1 1XJ (United Kingdom); Galloway, Alexander; Toumpis, Athanasios [Department of Mechanical & Aerospace Engineering, University of Strathclyde, James Weir Building, 75 Montrose Street, Glasgow G1 1XJ (United Kingdom); McNutt, Philip [TWI Ltd., Granta Park, Cambridge CB21 6AL (United Kingdom); Iqbal, Naveed [TWI Technology Centre, Wallis Way, Catcliff, Rotherham, S60 5TZ (United Kingdom)

    2017-02-28

    Highlights: • WC-CoCr, Cr{sub 3}C{sub 2}-NiCr and Al{sub 2}O{sub 3} coatings were cold spray deposited on AA5083 and friction stir processed. • The SprayStirred WC-CoCr demonstrated a hardness increase of 100% over the cold sprayed coating. • As-deposited and SprayStirred coatings were examined under slurry erosion test conditions. • Mass and volume loss was measured following 20-min exposure to the slurry. • The WC-CoCr and Al2O3 demonstrated a reduction in volume loss of approx. 40% over the cold sprayed coating. - Abstract: This study forms an initial investigation into the development of SprayStir, an innovative processing technique for generating erosion resistant surface layers on a chosen substrate material. Tungsten carbide – cobalt chromium, chromium carbide – nickel chromium and aluminium oxide coatings were successfully cold spray deposited on AA5083 grade aluminium. In order to improve the deposition efficiency of the cold spray process, coatings were co-deposited with powdered AA5083 using a twin powder feed system that resulted in thick (>300 μm) composite coatings. The deposited coatings were subsequently friction stir processed to embed the particles in the substrate in order to generate a metal matrix composite (MMC) surface layer. The primary aim of this investigation was to examine the erosion performance of the SprayStirred surfaces and demonstrate the benefits of this novel process as a surface engineering technique. Volumetric analysis of the SprayStirred surfaces highlighted a drop of approx. 40% in the level of material loss when compared with the cold spray deposited coating prior to friction stir processing. Micro-hardness testing revealed that in the case of WC-CoCr reinforced coating, the hardness of the SprayStirred material exhibits an increase of approx. 540% over the unaltered substrate and 120% over the as-deposited composite coating. Microstructural examination demonstrated that the increase in the hardness of the

  14. Microstructural transformations and mechanical properties of cast NiAl bronze: Effects of fusion welding and friction stir processing

    International Nuclear Information System (INIS)

    Fuller, M.D.; Swaminathan, S.; Zhilyaev, A.P.; McNelley, T.R.

    2007-01-01

    A plate of as-cast NiAl bronze (NAB) material was sectioned from a large casting. A six-pass fusion weld overlay was placed in a machined groove; a portion of the weld reinforcement was removed by milling and a single friction stir processing (FSP) pass was conducted in a direction transverse to the axis of and over the weld overlay. A procedure was developed for machining of miniature tensile samples and the distributions of strength and ductility were evaluated for the fusion weld metal; for the stir zone (SZ) produced by the friction stir processing; and for a region wherein friction stir processing had taken place over the fusion weld. A region of low ductility in the heat affected zone (HAZ) of the fusion weld and in the thermomechanically affected zone (TMAZ) of friction stir processed material was attributed to partial reversion of an equilibrium lamellar eutectoid constituent upon local heating above ∼800 deg. C and formation of non-equilibrium transformation products upon subsequent cooling. The adverse effect on ductility is worse in the heat affected zone of the fusion weld than in the thermomechanically affected zone of friction stir processing due to the lower heat input of the latter process. The implications of this work to engineering applications of friction stir processing are discussed

  15. Comparison of corrosion behaviour of friction stir processed and laser melted AA 2219 aluminium alloy

    International Nuclear Information System (INIS)

    Surekha, K.; Murty, B.S.; Prasad Rao, K.

    2011-01-01

    Highlights: → Poor corrosion resistance of AA 2219 can be improved by surface treatments. → FSP and LM leads to dissolution of second phase particles. → No literature available on comparison of corrosion behaviour after FSP and LM. → The study implies FSP is as good as LM in improving the corrosion resistance of AA 2219. -- Abstract: Dissolution of second phase particles (CuAl 2 ) present in AA 2219 aluminium improves the corrosion resistance of the alloy. Two surface treatment techniques, viz., solid state friction stir processing and fusion based laser melting lead to the reduction in CuAl 2 content and the effect of these processes on the corrosion behaviour of the alloy is compared in this study. Potentiodynamic polarization and electrochemical impedance spectroscopy tests were carried out to compare corrosion behaviour. The corrosion resistance achieved by friction stir processing is comparable to that obtained by the laser melting technique.

  16. Microstructure and wear behavior of friction stir processed cast hypereutectic aluminum silicon

    Directory of Open Access Journals (Sweden)

    Ahmad Rosli

    2017-01-01

    Full Text Available Hypereutectic as-cast Al-18Si-Cu-Ni alloy was subjected to friction stir processing (FSP. The resultant effect of FSP on the alloy was evaluated by microstructure analysis and wear tests (dry sliding. A significant microstructural modification and enhancement in wear behavior of Al-18Si-Cu-Ni alloy was recorded after friction stir processing. Wear resistance improvement was related to considerable modification in size, morphology and distribution of silicon particles, and hardness improvement. It was found that lower tool rotation speed was more effective to refine silicon particles and in turn increase wear resistance. Minimum Si particle mean area of about 47.8 µm2, and wear rate of 0.0155 mg/m was achieved.

  17. Characterization of boron carbide particulate reinforced in situ copper surface composites synthesized using friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Sathiskumar, R., E-mail: sathiscit2011@gmail.com [Department of Mechanical Engineering, Coimbatore Institute of Technology, Coimbatore, 641 014 Tamil Nadu (India); Murugan, N., E-mail: murugan@cit.edu.in [Department of Mechanical Engineering, Coimbatore Institute of Technology, Coimbatore, 641 014 Tamil Nadu (India); Dinaharan, I., E-mail: dinaweld2009@gmail.com [Department of Mechanical Engineering, V V College of Engineering, Tisaiyanvilai, 627 657 Tamil Nadu (India); Vijay, S.J., E-mail: vijayjoseph@karunya.edu [Centre for Research in Metallurgy (CRM), School of Mechanical Sciences, Karunya University, Coimbatore, 641 114 Tamil Nadu (India)

    2013-10-15

    Friction stir processing has evolved as a novel solid state technique to fabricate surface composites. The objective of this work is to apply the friction stir processing technique to fabricate boron carbide particulate reinforced copper surface composites and investigate the effect of B{sub 4}C particles and its volume fraction on microstructure and sliding wear behavior of the same. A groove was prepared on 6 mm thick copper plates and packed with B{sub 4}C particles. The dimensions of the groove was varied to result in five different volume fractions of B{sub 4}C particles (0, 6, 12, 18 and 24 vol.%). A single pass friction stir processing was done using a tool rotational speed of 1000 rpm, travel speed of 40 mm/min and an axial force of 10 kN. Metallurgical characterization of the Cu/B{sub 4}C surface composites was carried out using optical microscope and scanning electron microscope. The sliding wear behavior was evaluated using a pin-on-disk apparatus. Results indicated that the B{sub 4}C particles significantly influenced the area, dispersion, grain size, microhardness and sliding wear behavior of the Cu/B{sub 4}C surface composites. When the volume fraction of B{sub 4}C was increased, the wear mode changed from microcutting to abrasive wear and wear debris was found to be finer. Highlights: • Fabrication of Cu/B{sub 4}C surface composite by friction stir processing • Analyzing the effect of B{sub 4}C particles on the properties of Cu/B4C surface composite • Increased volume fraction of B{sub 4}C particles reduced the area of surface composite. • Increased volume fraction of B{sub 4}C particles enhanced the microhardness and wear rate. • B{sub 4}C particles altered the wear mode from microcutting to abrasive.

  18. Characteristic evaluation of process parameters of friction stir welding of aluminium 2024 hybrid composites

    Science.gov (United States)

    Sadashiva, M.; Shivanand, H. K.; Vidyasagar, H. N.

    2018-04-01

    The Current work is aimed to investigate the effect of process parameters in friction stir welding of Aluminium 2024 base alloy and Aluminium 2024 matrix alloy reinforced with E Glass and Silicon Carbide reinforcements. The process involved a set of synthesis techniques incorporating stir casting methodology resulting in fabrication of the composite material. This composite material that is synthesized is then machined to obtain a plate of dimensions 100 mm * 50 mm * 6 mm. The plate is then friction stir welded at different set of parameters viz. the spindle speed of 600 rpm, 900 rpm and 1200 rpm and feed rate of 40 mm/min, 80 mm/min and 120 mm/min for analyzing the process capability. The study of the given set of parameters is predominantly important to understand the physics of the process that may lead to better properties of the joint, which is very much important in perspective to its use in advanced engineering applications, especially in aerospace domain that uses Aluminium 2024 alloy for wing and fuselage structures under tension.

  19. Influence of Processing Parameters on the Flow Path in Friction Stir Welding

    Science.gov (United States)

    Schneider, J. A.; Nunes, A. C., Jr.

    2006-01-01

    Friction stir welding (FSW) is a solid phase welding process that unites thermal and mechanical aspects to produce a high quality joint. The process variables are rpm, translational weld speed, and downward plunge force. The strain-temperature history of a metal element at each point on the cross-section of the weld is determined by the individual flow path taken by the particular filament of metal flowing around the tool as influenced by the process variables. The resulting properties of the weld are determined by the strain-temperature history. Thus to control FSW properties, improved understanding of the processing parameters on the metal flow path is necessary.

  20. Thermal analysis of friction stir welding process and investigation into affective parameters using simulation

    Energy Technology Data Exchange (ETDEWEB)

    Abbasi, Mahmoud [University of Kashan, Kashan (Iran, Islamic Republic of); Bagheri, Behrouz [Amirkabir University of Technology, Tehran (Iran, Islamic Republic of); Keivani, Rasoul [Islamic Azad University, Tehran (Iran, Islamic Republic of)

    2015-02-15

    Friction stir welding (FSW) as an efficient solid state joining process has numerous applications in industries. Temperature distribution analysis through simulation not only brings the possibility to characterize the microstructure of different zones, but also enables one to save cost and energy as optimum welding variables are obtained with less concern. In the present study, the temperature distribution during the friction stir welding (FSW) process of AA6061-T6 was evaluated using finite element method (FEM). Since experimental measurements cannot be readily made in the weld region, it is difficult to understand physics in the stir zone of the welds without simulation. Abaqus software was applied to model the parts and simulate the process of welding, while Johnson-Cook law utilized to evaluate the effect of strain rate and generated heat. FE-results were verified by experimental results. The comparisons revealed a good compatibility between the results. The effect of probe shape on temperature distribution was also studied. It was found that spherical pins result in the highest temperatures at workpieces with respect to cylindrical and tapered pins. Additionally, it was concluded that more heat is generated in workpieces as pin angle increases.

  1. Thermal analysis of friction stir welding process and investigation into affective parameters using simulation

    International Nuclear Information System (INIS)

    Abbasi, Mahmoud; Bagheri, Behrouz; Keivani, Rasoul

    2015-01-01

    Friction stir welding (FSW) as an efficient solid state joining process has numerous applications in industries. Temperature distribution analysis through simulation not only brings the possibility to characterize the microstructure of different zones, but also enables one to save cost and energy as optimum welding variables are obtained with less concern. In the present study, the temperature distribution during the friction stir welding (FSW) process of AA6061-T6 was evaluated using finite element method (FEM). Since experimental measurements cannot be readily made in the weld region, it is difficult to understand physics in the stir zone of the welds without simulation. Abaqus software was applied to model the parts and simulate the process of welding, while Johnson-Cook law utilized to evaluate the effect of strain rate and generated heat. FE-results were verified by experimental results. The comparisons revealed a good compatibility between the results. The effect of probe shape on temperature distribution was also studied. It was found that spherical pins result in the highest temperatures at workpieces with respect to cylindrical and tapered pins. Additionally, it was concluded that more heat is generated in workpieces as pin angle increases.

  2. Optimization of the Process Parameters for Controlling Residual Stress and Distortion in Friction Stir Welding

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Schmidt, Henrik Nikolaj Blicher; Hattel, Jesper Henri

    2008-01-01

    In the present paper, numerical optimization of the process parameters, i.e. tool rotation speed and traverse speed, aiming minimization of the two conflicting objectives, i.e. the residual stresses and welding time, subjected to process-specific thermal constraints in friction stir welding......, is investigated. The welding process is simulated in 2-dimensions with a sequentially coupled transient thermo-mechanical model using ANSYS. The numerical optimization problem is implemented in modeFRONTIER and solved using the Multi-Objective Genetic Algorithm (MOGA-II). An engineering-wise evaluation or ranking...

  3. Microstructural characteristics and effects of TC4 titanium alloy processed by using friction stir welding

    Directory of Open Access Journals (Sweden)

    Bo LI

    2016-02-01

    Full Text Available Friction stir welding technique is used for the processing of TC4 titanium alloy under protective atmosphere, and it results with good formability. The research focues on the evolution mechanisms of α+β dual phase microstructure in stirred zone and the effects of processing parameters on structures hardness. The results show that with optimized technological parameters, stir zone structure experiences the α/β transformation, and finally changes to the α+β duplex structure which is based on the β phase. After mixing head leaves and the structure cools, the precipitated lamellar α phase is among and/or within-regions. Grain refining of α+β dual phase is obvious. The shortened α/β lamellar spacing distance may improve the strengthening effect of the α+β duplex phase and enhance the hardness of the stir zone. The increasing of the tool rotation speed could coarsen β-regions, while the increasing of the travel speed could help reduce the α phase ratio and generate needle-type Martensites.

  4. Effect of process control mode on weld quality of friction stir welded plates

    Energy Technology Data Exchange (ETDEWEB)

    Shazly, Mostafa; Sorour, Sherif; Alian, Ahmed R. [Faculty of Engineering, The British University in Egypt, Cairo (Egypt)

    2016-01-15

    Friction stir welding (FSW) is a solid state welding process which requires no filler material where the heat input is generated by frictional energy between the tool and workpiece. The objective of the present work is to conduct a fully coupled thermomechanical finite element analysis based on Arbitrary Lagrangian Eulerian (ALE) formulation for both 'Force-Controlled' and 'Displacement-Controlled' FSW process to provide more detailed insight of their effect on the resulting joint quality. The developed finite element models use Johnson- Cook material model and temperature dependent physical properties for the welded plates. Efforts on proper modeling of the underlying process physics are done focusing on the heat generation of the tool/workpiece interface to overcome the shortcomings of previous investigations. Finite elements results show that 'Force-Controlled' FSW process provides better joint quality especially at higher traveling speed of the tool which comes to an agreement with published experimental results.

  5. Multi-objective Optimization of Process Parameters in Friction Stir Welding

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Hattel, Jesper Henri

    The objective of this paper is to investigate optimum process parameters in Friction Stir Welding (FSW) to minimize residual stresses in the work piece and maximize production efficiency meanwhile satisfying process specific constraints as well. More specifically, the choices of tool rotational...... speed and traverse welding speed have been sought in order to achieve the goals mentioned above using an evolutionary multi-objective optimization (MOO) algorithm, i.e. non-dominated sorting genetic algorithm (NSGA-II), integrated with a transient, 2- dimensional sequentially coupled thermo...

  6. Microstructure and optical appearance of anodized friction stir processed Al - Metal oxide surface composites

    DEFF Research Database (Denmark)

    Gudla, Visweswara Chakravarthy; Jensen, Flemming; Bordo, Kirill

    2014-01-01

    Multiple-pass friction stir processing (FSP) was employed to impregnate Ti, Y and Ce oxide powders into the surface of an Aluminium alloy. The FSP processed surface composite was subsequently anodized with an aim to develop optical effects in the anodized layer owing to the presence of incorporated...... oxide particles which will influence the scattering of light. This paper presents the investigations on relation between microstructure of the FSP zone and optical appearance of the anodized layer due to incorporation of metal oxide particles and modification of the oxide particles due to the anodizing...

  7. Friction stir processed Al - Metal oxide surface composites: Anodization and optical appearance

    DEFF Research Database (Denmark)

    Gudla, Visweswara Chakravarthy; Jensen, Flemming; Canulescu, Stela

    2014-01-01

    Multiple-pass friction stir processing (FSP) was employed to impregnate metal oxide (TiO2, Y2O3 and CeO2) particles into the surface of an Aluminium alloy. The surface composites were then anodized in a sulphuric acid electrolyte. The effect of anodizing parameters on the resulting optical...... dark to greyish white. This is attributed to the localized microstructural and morphological differences around the metal oxide particles incorporated into the anodic alumina matrix. The metal oxide particles in the FSP zone electrochemically shadowed the underlying Al matrix and modified the local...

  8. Influence of Stored Strain on Fabricating of Al/SiC Nanocomposite by Friction Stir Processing

    Science.gov (United States)

    Khorrami, M. Sarkari; Kazeminezhad, M.; Kokabi, A. H.

    2015-05-01

    In this work, 1050 aluminum (Al) sheets were annealed and severely deformed by 1, 2, and 3 passes of constrained groove pressing process to obtain the various initial stored strain values of 0, 1.16, 2.32, and 3.48, respectively. Friction stir processing (FSP) was then applied using SiC nanoparticles to fabricate Al/SiC nanocomposite with approximately 1.5 vol pct reinforced particles. Microstructural examinations revealed that an increase in the initial stored strain of the base metal led to the formation of finer grain structure after 1 pass of FSP. The finer grain structure occurred in the stir zone where a sufficient amount of nanoparticles with a relatively proper distribution existed. However, the initial stored strain value had a contrary influence in the regions with low volume fraction of nanoparticles. In fact, more stored strain in the base metal provided more driving force for both nucleation and grain growth of newly recrystallized grains at the stir zone. Pinning effect of well-distributed nanoparticles could effectively retard grain growth leading to the formation of very fine grain structure. Also it was observed that the initial stored strain values did not have impressive rule in the microstructural evolutions at the stir zone during the second and third FSP passes signifying that all of the stored energy in the base metal would be released after 1 pass of FSP. The results obtained with microhardness measurement at the stir zone were fairly in agreement with those achieved by the microstructure assessments.

  9. Development of a process envelope for friction stir welding of DH36 steel – A step change

    International Nuclear Information System (INIS)

    Toumpis, Athanasios; Galloway, Alexander; Cater, Stephen; McPherson, Norman

    2014-01-01

    Highlights: • The friction stir welding speed on DH36 steel has been substantially increased. • Excellent quality welds offering potential economic advantages are obtained. • Friction stir welding of steel generates a very complex metallurgical system. • Slow and intermediate welding speed tensile samples fractured in the parent material. • Increasing traverse speed is seen to improve the impact toughness of the weld. - Abstract: Friction stir welding of steel presents an array of advantages across many industrial sectors compared to conventional fusion welding techniques. However, the fundamental knowledge of the friction stir welding process in relation to steel remains relatively limited. A microstructure and property evaluation of friction stir welded low alloy steel grade DH36 plate, commonly used in ship and marine applications has been undertaken. In this comprehensive study, plates of 2000 × 200 × 6 mm were butt welded together at varying rotational and traverse speeds. Samples were examined microscopically and by transverse tensile tests. In addition, the work was complemented by Charpy impact testing and micro-hardness testing in various regions of the weld. The study examined a wide range of process parameters; from this, a preliminary process parameter envelope has been developed and initial process parameter sets established that produce commercially attractive excellent quality welds through a substantial increase in the conventionally recognised weld traverse speed

  10. Improvement in cavitation erosion resistance of AISI 316L stainless steel by friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Hajian, M. [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of); Abdollah-zadeh, A., E-mail: zadeh@modares.ac.ir [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of); Rezaei-Nejad, S.S.; Assadi, H. [Department of Materials Engineering, Tarbiat Modares University, P.O. Box 14115-143, Tehran (Iran, Islamic Republic of); Hadavi, S.M.M. [Department of Materials Science and Engineering, MA University of Technology, Tehran (Iran, Islamic Republic of); Chung, K. [Department of Materials Science and Engineering, Research Institute of Advanced Materials, Engineering Research Institute, Seoul National University, Seoul (Korea, Republic of); Shokouhimehr, M. [Department of Chemical Engineering, College of Engineering, Seoul National University, Seoul 151-742 (Korea, Republic of)

    2014-07-01

    Commercial AISI 316L plates with the initial grain size of 14.8 μm were friction stir processed (FSP) with different processing parameters, resulting in two fine-grained microstructures with the grain sizes of 4.6 and 1.7 μm. The cavitation erosion behavior, before and after FSP, was evaluated in terms of incubation time, cumulative mass loss and mean depth of erosion. A separate cavitation erosion test was performed on the transverse cross section of a FSP sample to reveal the effect of grain structure. It was observed that FSP samples, depending on their grain size, are at least 3–6 times more resistant than the base material against cavitation erosion. The improvement in cavitation erosion resistance is attributed to smaller grain structure, lower fraction of twin boundaries, and favorable crystallographic orientation of grains in FSP samples. The finer the grain size, the more cavitation erosion resistance was achieved. Moreover, the microstructures of eroded surfaces were studied using a scanning electron microscope equipped with EBSD, and an atomic force microscope. The mechanisms controlling the cavitation erosion damage in friction stir processed AISI 316L are also discussed.

  11. Microstructure, Mechanical and Corrosion Properties of Friction Stir-Processed AISI D2 Tool Steel

    Science.gov (United States)

    Yasavol, Noushin; Jafari, Hassan

    2015-05-01

    In this study, AISI D2 tool steel underwent friction stir processing (FSP). The microstructure, mechanical properties, and corrosion resistance of the FSPed materials were then evaluated. A flat WC-Co tool was used; the rotation rate of the tool varied from 400 to 800 rpm, and the travel speed was maintained constant at 385 mm/s during the process. FSP improved mechanical properties and produced ultrafine-grained surface layers in the tool steel. Mechanical properties improvement is attributed to the homogenous distribution of two types of fine (0.2-0.3 μm) and coarse (1.6 μm) carbides in duplex ferrite-martensite matrix. In addition to the refinement of the carbides, the homogenous dispersion of the particles was found to be more effective in enhancing mechanical properties at 500 rpm tool rotation rate. The improved corrosion resistance was observed and is attributed to the volume fraction of low-angle grain boundaries produced after friction stir process of the AISI D2 steel.

  12. Friction stir processing: a new grain refinement technique to achieve high strain rate superplasticity in commercial alloys

    Energy Technology Data Exchange (ETDEWEB)

    Mishra, R.S. [Missouri Univ., Rolla, MO (United States). Dept. of Metallurgical Engineering; Mahoney, M.W. [Rockwell International Corp., Thousand Oaks, CA (United States). Science Center

    2001-07-01

    Friction stir processing is a new thermo-mechanical processing technique that leads to a microstructure amenable for high strain rate superplasticity in commercial aluminum alloys. Friction stirring produces a combination of very fine grain size and high grain boundary misorientation angles. Preliminary results on a 7075 Al demonstrate high strain rate superplasticity in the temperature range of 430-510 C. For example, an elongation of >1000% was observed at 490 C and 1 x 10{sup -2} s{sup -1}. This demonstrates a new possibility to economically obtain a superplastic microstructure in commercial aluminum alloys. Based on these results, a three-step manufacturing process to fabricate complex shaped components can be envisaged: cast sheet or hot-pressed powder metallurgy sheet + friction stir processing + superplastic forging or forming. (orig.)

  13. Friction Stir Processing of Copper-Coated SiC Particulate-Reinforced Aluminum Matrix Composite

    Directory of Open Access Journals (Sweden)

    Chih-Wei Huang

    2018-04-01

    Full Text Available In the present work, we proposed a novel friction stir processing (FSP to produce a locally reinforced aluminum matrix composite (AMC by stirring copper-coated SiC particulate reinforcement into Al6061 alloy matrix. Electroless-plating process was applied to deposit the copper surface coating on the SiC particulate reinforcement for the purpose of improving the interfacial adhesion between SiC particles and Al matrix. The core-shell SiC structure provides a layer for the atomic diffusion between aluminum and copper to enhance the cohesion between reinforcing particles and matrix on one hand, the dispersion of fine copper in the Al matrix during FSP provides further dispersive strengthening and solid solution strengthening, on the other hand. Hardness distribution and tensile results across the stir zone validated the novel concept in improving the mechanical properties of AMC that was realized via FSP. Optical microscope (OM and Transmission Electron Microscopy (TEM investigations were conducted to investigate the microstructure. Energy dispersive spectrometer (EDS, electron probe micro-analyzer (EPMA, and X-ray diffraction (XRD were explored to analyze the atomic inter-diffusion and the formation of intermetallic at interface. The possible strengthening mechanisms of the AMC containing Cu-coated SiC particulate reinforcement were interpreted. The concept of strengthening developed in this work may open a new way of fabricating of particulate reinforced metal matrix composites.

  14. Surface Modification by Friction Stir Processing of Low-Carbon Steel: Microstructure Investigation and Wear Performance

    Science.gov (United States)

    Sattari, Behnoosh; Shamanian, Morteza; Salimijazi, Farshid; Salehi, Mehdi

    2018-02-01

    A low-carbon steel sheet with a thickness of 5 mm was subjected to friction stir processing (FSP) by one to four different passes. The microstructures of different regions were characterized using the optical microscopy and electron backscatter diffraction. The Vickers micro-harness was measured at the distance of 200 μm below the processed surfaces. The influence of pass numbers (PNs) on wear resistance was studied in terms of coefficients of friction (CoFs), weight losses and wear rates. SEM topographies of the worn surfaces were also studied to evaluate the wear mechanisms. Microstructure observations showed that Widmänstatten ferrite plates were formed in stir zones (SZs) and heat affected zones. As PN increased, these grains were widened due to the increment of the carbon diffusivity and lengthened because of the high heat input and microstructure anisotropy. Besides, increasing the PN causes increasing of the hardness and wear resistance, simultaneously. Specifically, the wear rate in the SZ was reduced from 2.8 × 10-2 mm3 m-1 in base metal to 0.3 × 10-2 mm3 m-1 in sample which was subjected to 4 FSP passes. However, variation in PN had no considerable effect on CoFs. Oxidative wear mechanism was observed on the worn surface of the steel and the FSPed samples while more debris was formed by increasing the PNs.

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

    National Research Council Canada - National Science Library

    Ferrando, William A

    2008-01-01

    This report introduces a novel variant of conventional friction stir welding (FSW). Since 1991, friction stir welding provides an alternative to arc welding as a metal joining method in numerous applications...

  16. Flexible Friction Stir Joining Technology

    Energy Technology Data Exchange (ETDEWEB)

    Feng, Zhili [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lim, Yong Chae [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Mahoney, Murray [MegaStir Technologies LLC, Orem, UT (United States); Sanderson, Samuel [MegaStir Technologies LLC, Orem, UT (United States); Larsen, Steve [MegaStir Technologies LLC, Orem, UT (United States); Steel, Russel [MegaStir Technologies LLC, Orem, UT (United States); Fleck, Dale [MegaStir Technologies LLC, Orem, UT (United States); Fairchild, Doug P [ExxonMobil, Upstream Research Company (URC), Houston, TX (United States); Wasson, Andrew J [ExxonMobil, Upstream Research Company (URC), Houston, TX (United States); Babb, Jon [MegaStir Technologies LLC, Orem, UT (United States); Higgins, Paul [MegaStir Technologies LLC, Orem, UT (United States)

    2015-07-23

    Reported herein is the final report on a U.S. Department of Energy (DOE) Advanced Manufacturing Office (AMO) project with industry cost-share that was jointly carried out by Oak Ridge National Laboratory (ORNL), ExxonMobil Upstream Research Company (ExxonMobil), and MegaStir Technologies (MegaStir). The project was aimed to advance the state of the art of friction stir welding (FSW) technology, a highly energy-efficient solid-state joining process, for field deployable, on-site fabrications of large, complex and thick-sectioned structures of high-performance and high-temperature materials. The technology innovations developed herein attempted to address two fundamental shortcomings of FSW: 1) the inability for on-site welding and 2) the inability to weld thick section steels, both of which have impeded widespread use of FSW in manufacturing. Through this work, major advance has been made toward transforming FSW technology from a “specialty” process to a mainstream materials joining technology to realize its pervasive energy, environmental, and economic benefits across industry.

  17. Modelling of peak temperature during friction stir processing of magnesium alloy AZ91

    Science.gov (United States)

    Vaira Vignesh, R.; Padmanaban, R.

    2018-02-01

    Friction stir processing (FSP) is a solid state processing technique with potential to modify the properties of the material through microstructural modification. The study of heat transfer in FSP aids in the identification of defects like flash, inadequate heat input, poor material flow and mixing etc. In this paper, transient temperature distribution during FSP of magnesium alloy AZ91 was simulated using finite element modelling. The numerical model results were validated using the experimental results from the published literature. The model was used to predict the peak temperature obtained during FSP for various process parameter combinations. The simulated peak temperature results were used to develop a statistical model. The effect of process parameters namely tool rotation speed, tool traverse speed and shoulder diameter of the tool on the peak temperature was investigated using the developed statistical model. It was found that peak temperature was directly proportional to tool rotation speed and shoulder diameter and inversely proportional to tool traverse speed.

  18. Optimisation of process parameters in friction stir welding based on residual stress analysis: a feasibility study

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Hattel, Jesper Henri

    2010-01-01

    The present paper considers the optimisation of process parameters in friction stir welding (FSW). More specifically, the choices of rotational speed and traverse welding speed have been investigated using genetic algorithms. The welding process is simulated in a transient, two......-dimensional sequentially coupled thermomechanical model in ANSYS. This model is then used in an optimisation case where the two objectives are the minimisation of the peak residual stresses and the maximisation of the welding speed. The results indicate that the objectives for the considered case are conflicting......, and this is presented as a Pareto optimal front. Moreover, a higher welding speed for a fixed rotational speed results, in general, in slightly higher stress levels in the tension zone, whereas a higher rotational speed for a fixed welding speed yields somewhat lower peak residual stress, however, a wider tension zone...

  19. Hybrid Search for Faster Production and Safer Process Conditions in Friction Stir Welding

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Deb, Kalyanmoy; Hattel, Jesper Henri

    2011-01-01

    The objective of this paper is to investigate optimum process parameters and tool geometries in Friction Stir Welding (FSW) to minimize temperature difference between the leading edge of the tool probe and the work piece material in front of the tool shoulder, and simultaneously maximize traverse...... welding speed, which conflicts with the former objective. An evolutionary multi-objective optimization algorithm (i.e. NSGA-II), is applied to find multiple trade-off solutions followed by a gradient-based local search (i.e. SQP) to improve the convergence of the obtained Pareto-optimal front. In order...... choices have been offered based on several process specific performance and cost related criteria....

  20. Fabrication of novel fiber reinforced aluminum composites by friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Arab, Seyyed Mohammad; Karimi, Saeed; Jahromi, Seyyed Ahmad Jenabali, E-mail: jahromi@shirazu.ac.ir; Javadpour, Sirus; Zebarjad, Seyyed Mojtaba

    2015-04-24

    In this study, chopped and attrition milled high strength carbon, E-glass, and S-glass fibers have been used as the reinforcing agents in an aluminum alloy (Al1100) considered as the matrix. The Surface Metal Matrix Composites (SMMCs) then are produced by Friction Stir Processing (FSP). Tensile and micro-hardness examinations represent a magnificent improvement in the hardness, strength, ductility and toughness for all of the processed samples. Scanning Electron Micrographs reveal a proper distribution of the reinforcements in the matrix and a change in the fracture behavior of the FSPed specimens. The synergetic effects of reinforcing by fibers and Severe Plastic Deformation (SPD) lead to an extra ordinary improvement in the mechanical properties.

  1. Friction stir welding and processing of oxide dispersion strengthened (ODS) alloys

    Science.gov (United States)

    Ren, Weiju

    2014-11-11

    A method of welding including forming a filler material of a first oxide dispersoid metal, the first oxide dispersoid material having first strengthening particles that compensate for decreases in weld strength of friction stir welded oxide dispersoid metals; positioning the filler material between a first metal structure and a second metal structure each being comprised of at least a second oxide dispersoid metal; and friction welding the filler material, the first metal structure and the second metal structure to provide a weld.

  2. Effect of process parameters on the residual stresses in AA5083-H321 friction stir welds

    Energy Technology Data Exchange (ETDEWEB)

    Lombard, H. [NMMU, Gardham Avenue, PO Box 77000, 6031 Port Elizabeth (South Africa); University of Plymouth, Drake Circus, Plymouth PL4 8AA (United Kingdom); Hattingh, D.G. [NMMU, Gardham Avenue, PO Box 77000, 6031 Port Elizabeth (South Africa); Steuwer, A. [NMMU, Gardham Avenue, PO Box 77000, 6031 Port Elizabeth (South Africa); FaME38 at the ILL-ESRF, 6 rue J Horowitz, 38042 Grenoble (France); University of Plymouth, Drake Circus, Plymouth PL4 8AA (United Kingdom)], E-mail: steuwer@ill.fr; James, M.N. [NMMU, Gardham Avenue, PO Box 77000, 6031 Port Elizabeth (South Africa); University of Plymouth, Drake Circus, Plymouth PL4 8AA (United Kingdom)

    2009-02-15

    This paper investigates the effect of varying welding parameters on the residual stress profiles in friction stir welds of aluminium alloy AA5083-H321, which were created on a fully instrumented friction welding machine. The residual stresses were determined non-destructively using synchrotron X-ray diffraction. The width and maximum of the residual stress profile show clear correlation with the heat input, and in particular feed rate, which was found to be the dominant parameter.

  3. Microstructure evolution and texture development in a friction stir-processed AISI D2 tool steel

    Science.gov (United States)

    Yasavol, N.; Abdollah-zadeh, A.; Vieira, M. T.; Jafarian, H. R.

    2014-02-01

    Crystallographic texture developments during friction stir processing (FSP) of AISI D2 tool were studied with respect to grain sizes in different tool rotation rates. Comparison of the grain sizes in various rotation rates confirmed that grain refinement occurred progressively in higher rotation rates by severe plastic deformation. It was found that the predominant mechanism during FSP should be dynamic recovery (DRV) happened concurrently with continuous dynamic recrystallization (CDRX) caused by particle-stimulated nucleation (PSN). The developed shear texture relates to the ideal shear textures of D1 and D2 in bcc metals. The prevalence of highly dense arrangement of close-packed planes of bcc and the lowest Taylor factor showed the lowest compressive residual stress which is responsible for better mechanical properties compared with the grain-precipitate refinement.

  4. Microstructure and hardness performance of AA6061 aluminium composite using friction stir processing

    Science.gov (United States)

    Marini, C. D.; Fatchurrohman, N.

    2018-04-01

    Rice husk ash (RHA) is an industrial waste that has become a potential reinforced material for aluminium matrix composite (AMCs) due to low cost and abundantly available resources. Friction stir processing (FSP) has been introduced as a method to modify surface properties of the metal and alloy including theirs composite as well. The present work reports the production and characterization of AA6061 and AA6061/5 vol% RHA using FSP using parameters rotation speed 1000 rpm and traversed speed 25 mm/min. The microstructure was studied using optical microscopy (OM). A homogenous dispersion of RHA particles was obtained in the composite. No agglomeration or segregation was observed. The produced composite exhibited a fine grain structure. An improvement in hardness profile was observed as AA6061/5 vol% RHA improves in hardness compared to FSPed of AA6061 without reinforcement.

  5. Impacts of friction stir processing on irradiation effects in vacuum-plasma-spray coated tungsten

    Energy Technology Data Exchange (ETDEWEB)

    Ozawa, Kazumi, E-mail: ozawa.kazumi@jaea.go.jp [Fusion Research and Development Directorate, Japan Atomic Energy Agency, 2-166 Obuchi-Omotedate, Rokkasho, Aomori 039-3212 (Japan); Tanigawa, Hiroyasu [Fusion Research and Development Directorate, Japan Atomic Energy Agency, 2-166 Obuchi-Omotedate, Rokkasho, Aomori 039-3212 (Japan); Morisada, Yoshiaki; Fujii, Hidetoshi [Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047 (Japan)

    2015-10-15

    In order to examine the impacts of friction stir processing (FSP) on irradiation effects in vacuum-plasma-spray (VPS) coated tungsten (W), nano indentation hardness was evaluated of three kinds of W materials after self-ion-irradiation to 5.0–5.4 dpa at 500 and 800 °C. The VPS-FSP clearly got grains refined and isotropic compared to bulk-W and the as-VPS-W. Nano indentation hardness remains unchanged for the as-VPS-W and VPS-FSP × 2-W irradiated to 5.4 dpa at 500 °C and it decreased from 1 dpa at 800 °C, while typical irradiation induced hardening was observed for the bulk-W irradiated at 500 °C.

  6. Development of quartz particulate reinforced AA6063 aluminum matrix composites via friction stir processing

    Directory of Open Access Journals (Sweden)

    S. Joyson Abraham

    2016-12-01

    Full Text Available Friction stir processing (FSP has been accepted as a potential method to produce aluminum matrix composites (AMCs without the drawbacks of liquid metallurgy methods. The present work focuses on the development of AMCs reinforced with quartz (SiO2 particles using FSP. Grooves with various dimensions were machined on AA6063 plates and compacted with quartz particles. A single pass FSP was carried out using a combination of optimized process parameters. The volume fraction of quartz particles in the AMCs was varied from 0 to 18 vol.% in steps of 6 vol.%. The developed AA6063/Quartz AMCs were characterized using optical, scanning and transmission electron microscopy. The quartz particles were distributed uniformly in the aluminum matrix irrespective of the location within the stir zone. The grains of the AA6063 were extensively refined by the combination of thermomechanical effect of FSP and the pinning effect of quartz particles. The dispersion of the quartz particles improved the microhardness and wear resistance of the AMCs. The role of quartz particles on the worn surface and wear debris is reported.

  7. Generated forces and heat during the critical stages of friction stir welding and processing

    Energy Technology Data Exchange (ETDEWEB)

    Hussein, Sadiq Aziz; Tahir, Abd Salam Md; Izamshah, R. [University Teknikal Malaysia Melaka, Malacca (Malaysia)

    2015-10-15

    The solid-state behavior of friction stir welding process results in violent mechanical forces that should be mitigated, if not eliminated. Plunging and dwell time are the two critical stages of this welding process in terms of the generated forces and the related heat. In this study, several combinations of pre-decided penetration speeds, rotational speeds, tool designs, and dwell time periods were used to investigate these two critical stages. Moreover, a coupled-field thermal-structural finite element model was developed to validate the experimental results and the induced stresses. The experimental results revealed the relatively large changes in force and temperature during the first two stages compared with those during the translational tool movement stage. An important procedure to mitigate the undesired forces was then suggested. The model prediction of temperature values and their distribution were in good agreement with the experimental prediction. Therefore, the thermal history of this non-uniform heat distribution was used to estimate the induced thermal stresses. Despite the 37% increase in these stresses when 40 s dwell time was used instead of 5 s, these stresses showed no effect on the axial force values because of the soft material incidence and stir effects.

  8. Generated forces and heat during the critical stages of friction stir welding and processing

    International Nuclear Information System (INIS)

    Hussein, Sadiq Aziz; Tahir, Abd Salam Md; Izamshah, R.

    2015-01-01

    The solid-state behavior of friction stir welding process results in violent mechanical forces that should be mitigated, if not eliminated. Plunging and dwell time are the two critical stages of this welding process in terms of the generated forces and the related heat. In this study, several combinations of pre-decided penetration speeds, rotational speeds, tool designs, and dwell time periods were used to investigate these two critical stages. Moreover, a coupled-field thermal-structural finite element model was developed to validate the experimental results and the induced stresses. The experimental results revealed the relatively large changes in force and temperature during the first two stages compared with those during the translational tool movement stage. An important procedure to mitigate the undesired forces was then suggested. The model prediction of temperature values and their distribution were in good agreement with the experimental prediction. Therefore, the thermal history of this non-uniform heat distribution was used to estimate the induced thermal stresses. Despite the 37% increase in these stresses when 40 s dwell time was used instead of 5 s, these stresses showed no effect on the axial force values because of the soft material incidence and stir effects

  9. Effect of process parameters on optimum welding condition of DP590 steel by friction stir welding

    International Nuclear Information System (INIS)

    Kim, Young Gon; Kim, Ji Sun; Kim, In Ju

    2014-01-01

    In the automotive industry, vehicle weight reduction techniques have been actively studied to improve the rate of fuel consumption and to cope with the regulation restricting exhaust gas. For this reason, advanced high-strength steel (AHSS) is preferred in the automobile industry as its tensile strength is 590 MPa and over. In this study, to obtain the optimum welding condition, the friction stir welding (FSW) process applied to AHSS was considered. The FSW experiment was performed on a stir plate using a Si 3 N 4 tool and a 1.4-mm thick DP590 steel sheet manufactured by cold rolling. In addition, to investigate the temperature distribution of the advancing and retreating sides in the welding state, the tool rotation speed of 800 rpm, and the welding speed of 180 mm/min, a K-type thermocouple was inserted in the backing plate, and the peak temperature was evaluated at each point. Especially, the correlation between the heat input per unit length and the formation of the FSW zone was minutely analyzed.

  10. Effect of process parameters on optimum welding condition of DP590 steel by friction stir welding

    Energy Technology Data Exchange (ETDEWEB)

    Kim, Young Gon; Kim, Ji Sun; Kim, In Ju [Korea Institute of Industrial Technology, Gwangju (Korea, Republic of)

    2014-12-15

    In the automotive industry, vehicle weight reduction techniques have been actively studied to improve the rate of fuel consumption and to cope with the regulation restricting exhaust gas. For this reason, advanced high-strength steel (AHSS) is preferred in the automobile industry as its tensile strength is 590 MPa and over. In this study, to obtain the optimum welding condition, the friction stir welding (FSW) process applied to AHSS was considered. The FSW experiment was performed on a stir plate using a Si{sub 3}N{sub 4} tool and a 1.4-mm thick DP590 steel sheet manufactured by cold rolling. In addition, to investigate the temperature distribution of the advancing and retreating sides in the welding state, the tool rotation speed of 800 rpm, and the welding speed of 180 mm/min, a K-type thermocouple was inserted in the backing plate, and the peak temperature was evaluated at each point. Especially, the correlation between the heat input per unit length and the formation of the FSW zone was minutely analyzed.

  11. Microstructure Characterization of Al-TiC Surface Composite Fabricated by Friction Stir Processing

    Science.gov (United States)

    Shiva, Apireddi; Cheepu, Muralimohan; Charan Kantumuchu, Venkata; Kumar, K. Ravi; Venkateswarlu, D.; Srinivas, B.; Jerome, S.

    2018-03-01

    Titanium carbide (TiC) is an exceedingly hard and wear refractory ceramic material. The surface properties of the material are very important and the corrosion, wear and fatigue resistance behaviour determines its ability and applications. It is necessary to modify the surface properties of the materials to enhance their performance. The present work aims on developing a new surface composite using commercially pure aluminum and TiC reinforcement powder with a significant fabrication technique called friction stir processing (FSP). The metal matrix composite of Al/TiC has been developed without any defects formation to investigate the particles distribution in the composite, microstructural changes and mechanical properties of the material. The microstructural observations exhibited that the grain refinement in the nugget compared to the base metal and FSP without TiC particles. The developed composite properties showed substantial improvement in micro-hardness, friction factor, wear resistance and microstructural characteristics in comparison to parent metal. On the other side, the ductility of the composite specimens was diminished over the substrate. The FSPed specimens were characterised using X-ray diffraction technique and revealed that the formation of AlTi compounds and the presence of Ti phases in the matrix. The microstructures of the samples illustrated the uniform distribution of particles in the newly developed metal matrix composite.

  12. Wear Resistance Increase by Friction Stir Processing for Partial Magnesium Replacement in Aluminium Alloys

    Science.gov (United States)

    Balos, Sebastian; Labus Zlatanovic, Danka; Janjatovic, Petar; Dramicanin, Miroslav; Rajnovic, Dragan; Sidjanin, Leposava

    2018-03-01

    In this paper, the influence of friction stir processing (FSP) was evaluated as a way of increasing mechanical properties and a way of replacing the magnesium content in aluminium alloys. FSP was done on AA5754 H111 aluminium alloy, containing 3 % Mg, by using various types of tools and different welding speeds, rotational speeds and tilt angles. Wear test was done against SiC abrasive papers. SiC was used to simulate extreme abrasive wear conditions. The wear test was done on untreated AA5754 specimens, processed AA5754 specimens and untreated AA5083 H111 specimens, the latter containing 4.5 % Mg. AA5083 was chosen as an alternative to AA5754, but with a significantly higher Mg content. Base material microhardness was 60 HV1 and 80 HV1 for AA5754 and AA5083 alloys respectively. To find the effect of FSP on AA5754 alloy, microstructures were studied, mainly grain size in the stir zone. It was found, that an elevated processing and rotational speed, without tilt angle and the tool without a reservoir resulted in an increase in hardness of the AA5754 to 70 HV1, but with the occurrence of tunneling defect and the wear rate of 79.3 mg. Lower FSP parameters and a tilted tool with a reservoir resulted in microhardness of 68 HV1 and wear rate of 68.2 mg without tunneling. These wear values are lower than those obtained with unmodified Al-alloys: AA5754 97.2 mg and AA5083 86.3 mg. An increased wear resistance can be attributed to the combined effect of grain boundary strengthening mechanism and solid solution strengthening, versus only the latter in untreated alloys.

  13. Influential Parameters and Numerical Simulation of Heat Generated in the Process of Friction Stir Welding

    Directory of Open Access Journals (Sweden)

    Ilija KOVACEVIC

    2016-09-01

    Full Text Available The paper analyzes the problem of friction stir welding (FSW technology. The mechanism of thermo-mechanical process of the FSW method has been identified and a correlation between the weld zone and its microstructure established. Presented are the basic analytical formulations for the definition of temperature fields. Analysis of influential parameters of welding FSW technology at the zone of the weld material and mechanical properties of the realized joint was performed. Influential welding parameters were defined based on tool geometry, technological parameters of processing and the axial load of tool. Specific problems with the FSW process are related to gaps (holes left behind by a tool at the end of the process and inflexibility of welding regarding the degree of variation of material thickness. Numerical simulation of process welding FSW proceeding was carried out on the example of Aluminum Alloy (AA 2219 using the ANSYS Mechanical ADPL (Transient Thermal software package. The defined was the temperature field in the welding process at specified time intervals.DOI: http://dx.doi.org/10.5755/j01.ms.22.3.10022

  14. Optimization of friction stir welding process parameters to maximize tensile strength of stir cast AA6061-T6/AlNp composite

    International Nuclear Information System (INIS)

    Ashok Kumar, B.; Murugan, N.

    2014-01-01

    Highlights: • AA6061/AlN p cast composite was welded by FSW process. • Regression models were developed to predict UTS and elongation of the FS welded joint. • FS welded joint using the optimized parameters exhibited maximum UTS and joint efficiency. • Defect free weld joint was obtained with optimized parameters value. - Abstract: Aluminium Matrix Composites (AMCs) reinforced with particulate form of reinforcement has replaced monolithic alloys in many engineering industries due to its superior mechanical properties and tailorable thermal and electrical properties. As aluminium nitride (AlN) has high specific strength, high thermal conductivity, high electrical resistivity, low dielectric constant, low coefficient of thermal expansion and good compatibility with aluminium alloy, Al/AlN composite is extensively used in electronic packaging industries. Joining of AMCs is unavoidable in many engineering applications. Friction Stir Welding (FSW) is one of the most suitable welding process to weld the AMCs reinforced with particulate form of ceramics without deteriorating its superior mechanical properties. An attempt has been made to develop regression models to predict the Ultimate Tensile Strength (UTS) and Percent Elongation (PE) of the friction stir welded AA6061 matrix composite reinforced with aluminium nitride particles (AlN p ) by correlating the significant parameters such as tool rotational speed, welding speed, axial force and percentage of AlN p reinforcement in the AA6061 matrix. Statistical software SYSTAT 12 and statistical tools such as analysis of variance (ANOVA) and student’s t test, have been used to validate the developed models. It was observed from the investigation that these factors independently influenced the UTS and PE of the friction stir welded composite joints. The developed regression models were optimized to maximize UTS of friction stir welded AA6061/AlN p composite joints

  15. Fabrication of Surface Level Cu/Si Cp Nano composites by Friction Stir Processing Route

    International Nuclear Information System (INIS)

    Srinivasan, R. C.; Karunanithi, M.

    2015-01-01

    Friction stir processing (FSP) technique has been successfully employed as low energy consumption route to prepare copper based surface level nano composites reinforced with nano sized silicon carbide particles (Si Cp). The effect of FSP parameters such as tool rotational speed, processing speed, and tool tilt angle on microstructure and microhardness was investigated. Single pass FSP was performed based on Box-Behnken design at three factors in three levels. A cluster of blind holes 2 mm in diameter and 3 mm in depth was used as particulate deposition technique in order to reduce the agglomeration problem during composite fabrication. K-type thermocouples were used to measure temperature histories during FSP. The results suggest that the heat generation during FSP plays a significant role in deciding the microstructure and microhardness of the surface composites. Microstructural observations revealed a uniform dispersion of nano sized Si Cp without any agglomeration problem and well bonded with copper matrix at different process parameter combinations. X-ray diffraction study shows that no intermetallic compound was produced after processing. The microhardness of nano composites was remarkably enhanced and about 95% more than that of copper matrix

  16. Fabrication of Surface Level Cu/SiCp Nanocomposites by Friction Stir Processing Route

    Directory of Open Access Journals (Sweden)

    Cartigueyen Srinivasan

    2015-01-01

    Full Text Available Friction stir processing (FSP technique has been successfully employed as low energy consumption route to prepare copper based surface level nanocomposites reinforced with nanosized silicon carbide particles (SiCp. The effect of FSP parameters such as tool rotational speed, processing speed, and tool tilt angle on microstructure and microhardness was investigated. Single pass FSP was performed based on Box-Behnken design at three factors in three levels. A cluster of blind holes 2 mm in diameter and 3 mm in depth was used as particulate deposition technique in order to reduce the agglomeration problem during composite fabrication. K-type thermocouples were used to measure temperature histories during FSP. The results suggest that the heat generation during FSP plays a significant role in deciding the microstructure and microhardness of the surface composites. Microstructural observations revealed a uniform dispersion of nanosized SiCp without any agglomeration problem and well bonded with copper matrix at different process parameter combinations. X-ray diffraction study shows that no intermetallic compound was produced after processing. The microhardness of nanocomposites was remarkably enhanced and about 95% more than that of copper matrix.

  17. Influence of friction stir welding process and tool parameters on strength properties of AA7075-T6 aluminium alloy joints

    International Nuclear Information System (INIS)

    Rajakumar, S.; Muralidharan, C.; Balasubramanian, V.

    2011-01-01

    The aircraft aluminium alloys generally present low weldability by traditional fusion welding process. The development of the friction stir welding has provided an alternative improved way of satisfactorily producing aluminium joints, in a faster and reliable manner. In this present work, the influence of process and tool parameters on tensile strength properties of AA7075-T 6 joints produced by friction stir welding was analysed. Square butt joints were fabricated by varying process parameters and tool parameters. Strength properties of the joints were evaluated and correlated with the microstructure, microhardness of weld nugget. From this investigation it is found that the joint fabricated at a tool rotational speed of 1400 rpm, welding speed of 60 mm/min, axial force of 8 kN, using the tool with 15 mm shoulder diameter, 5 mm pin diameter, 45 HRc tool hardness yielded higher strength properties compared to other joints.

  18. Multi-Track Friction Stir Lap Welding of 2024 Aluminum Alloy: Processing, Microstructure and Mechanical Properties

    Directory of Open Access Journals (Sweden)

    Shengke Zou

    2016-12-01

    Full Text Available Friction stir lap welding (FSLW raises the possibility of fabricating high-performance aluminum components at low cost and high efficiency. In this study, we mainly applied FSLW to fabricate multi-track 2024 aluminum alloy without using tool tilt angle, which is important for obtaining defect-free joint but significantly increases equipment cost. Firstly, systematic single-track FSLW experiments were conducted to attain appropriate processing parameters, and we found that defect-free single-track could also be obtained by the application of two-pass processing at a rotation speed of 1000 rpm and a traverse speed of 300 mm/min. Then, multi-track FSLW experiments were conducted and full density multi-track samples were fabricated at an overlapping rate of 20%. Finally, the microstructure and mechanical properties of the full density multi-track samples were investigated. The results indicated that ultrafine equiaxed grains with the grain diameter about 9.4 μm could be obtained in FSLW samples due to the dynamic recrystallization during FSLW, which leads to a yield strength of 117.2 MPa (17.55% higher than the rolled 2024-O alloy substrate and an elongation rate of 31.05% (113.84% higher than the substrate.

  19. Corrosion behavior of Al6061 alloy weldment produced by friction stir welding process

    Directory of Open Access Journals (Sweden)

    Farhad Gharavi

    2015-07-01

    Full Text Available In this work, the corrosion behavior of welded lap joints of AA6061-T6 aluminum alloy produced by friction stir welding process has been investigated. Corrosion properties of welded lap joints were studied by cyclic polarization and electrochemical impedance spectroscopy tests. All tests were performed in an aerated 0.6 mol L−1 NaCl aqueous solution with pH = 6.5 at a temperature of 30 °C to characterize corrosion morphology and realize corrosion features of weld regions as opposed to the parent alloy. The microstructure of weld nugget (WN, heated affected zone (HAZ, and parent alloy were analyzed using scanning electron microscopy and energy dispersive spectroscopy. The experimental results indicated that the welding process has a major effect on the corrosion resistance, which possibly associated to the break-down and dissolution of intermetallic particles. It is supposed that an increasing in intermetallic distributed throughout the matrix of weld regions increases the galvanic corrosion couples. Furthermore, by decreasing the grain size in the weld regions, the susceptibility to corrosion is enhanced. The pitting corrosion and intergranular attack are the dominant corrosion types in the weld regions and the parent alloy.

  20. Analysis and Modeling of Friction Stir Processing-Based Crack Repairing in 2024 Aluminum Alloy

    Institute of Scientific and Technical Information of China (English)

    Jun-Gang Ren; Lei Wang; Dao-Kui Xu; Li-Yang Xie; Zhan-Chang Zhang

    2017-01-01

    A friction stir processing-based method was used to repair cracks in the 2024 aluminum alloy plates.The temperature field and plastic material flow pattern were analyzed on the basis of experimental and finite element simulation results.Microstructure and tensile properties of the repaired specimens were studied.The results showed that the entire crack repairing was a solid-phase process and plastic materials tended to flow toward the shoulder center and then resulted in the repairing of cracks.Meanwhile,the coarse grain structures were refined in repaired zone (RZ),while the grains in thermal-mechanically affected zone and heat-affected zone were elongated and driven to grow up.Meanwhile,large phases are crushed into small particles and dispersed inside the RZ.Finally,the strength of the repaired specimens can be restored dramatically and their ductility can be partially restored.After heat treatment,the tensile properties of the repaired specimens can be further enhanced.

  1. Effect of friction stir processing on erosion–corrosion behavior of nickel–aluminum bronze

    International Nuclear Information System (INIS)

    Lotfollahi, M.; Shamanian, M.; Saatchi, A.

    2014-01-01

    Highlights: • The average hardness value of the FSP samples was higher than cast sample. • Erosion–corrosion rate of the FSP samples was higher than cast sample. • The gravimetric analysis showed a negative synergy. - Abstract: In the present investigation, effects of Friction Stir Processing (FSP) on Erosion–Corrosion (E–C) behavior of Nickel–Aluminum Bronze (NAB) were studied by weight-loss measurements and surface characterization using an impingement jet test system. After FSP, the initial coarse microstructure of the cast NAB was transformed to a fine structure, and the porosity defects were eliminated. In addition, different FSP structures were produced by each rotation rate. Microhardness measurements showed a marked increase in FSP samples depending upon the FSP parameters. E–C tests were carried out by erodent at kinetic energies about 0.45 μJ and in 30°, 60° and 90° impact angles to simulate actual service conditions. The maximum weight-loss was observed in FSP samples and Scanning Electron Microscopy (SEM) results showed signs of brittle fracture mechanism in FSP samples. By gravimetric analysis, the degree of synergy was evaluated at 0.45 μJ kinetic energy at normal impact angle and negative synergy result implies the presence of a protective film on all sample surfaces

  2. Application of laser ultrasonic method for on-line monitoring of friction stir spot welding process.

    Science.gov (United States)

    Zhang, Kuanshuang; Zhou, Zhenggan; Zhou, Jianghua

    2015-09-01

    Application of a laser ultrasonic method is developed for on-line monitoring of the friction stir spot welding (FSSW) process. Based on the technology of FSSW, laser-generated ultrasonic waves in a good weld and nonweld area are simulated by a finite element method. The reflected and transmitted waves are analyzed to disclose the properties of the welded interface. The noncontact-laser ultrasonic-inspection system was established to verify the numerical results. The reflected waves in the good-weld and nonweld area can be distinguished by time-of-flight. The transmitted waves evidently attenuate in the nonweld area in contrast to signal amplitude in the good weld area because of interfacial impedance difference. Laser ultrasonic C-scan images can sufficiently evaluate the intrinsic character of the weld area in comparison with traditional water-immersion ultrasonic testing results. The research results confirm that laser ultrasonics would be an effective method to realize the characterization of FSSW defects.

  3. Enhancement of wear and ballistic resistance of armour grade AA7075 aluminium alloy using friction stir processing

    Directory of Open Access Journals (Sweden)

    I. Sudhakar

    2015-03-01

    Full Text Available Industrial applications of aluminium and its alloys are restricted because of their poor tribological properties. Thermal spraying, laser surfacing, electron beam welding are the most widely used techniques to alter the surface morphology of base metal. Preliminary studies reveal that the coating and layering of aluminium alloys with ceramic particles enhance the ballistic resistance. Furthermore, among aluminium alloys, 7075 aluminium alloy exhibits high strength which can be compared to that of steels and has profound applications in the designing of lightweight fortification structures and integrated protection systems. Having limitations such as poor bond integrity, formation of detrimental phases and interfacial reaction between reinforcement and substrate using fusion route to deposit hard particles paves the way to adopt friction stir processing for fabricating surface composites using different sizes of boron carbide particles as reinforcement on armour grade 7075 aluminium alloy as matrix in the present investigation. Wear and ballistic tests were carried out to assess the performance of friction stir processed AA7075 alloy. Significant improvement in wear resistance of friction stir processed surface composites is attributed to the change in wear mechanism from abrasion to adhesion. It has also been observed that the surface metal matrix composites have shown better ballistic resistance compared to the substrate AA7075 alloy. Addition of solid lubricant MoS2 has reduced the depth of penetration of the projectile to half that of base metal AA7075 alloy. For the first time, the friction stir processing technique was successfully used to improve the wear and ballistic resistances of armour grade high strength AA7075 alloy.

  4. Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

    Science.gov (United States)

    McGill, Preston; Burkholder, Jonathan

    2012-01-01

    Friction stir welding is a solid state welding process used in the fabrication of various aerospace structures. Self-reacting and conventional friction stir welding are variations of the friction stir weld process employed in the fabrication of cryogenic propellant tanks which are classified as pressurized structure in many spaceflight vehicle architectures. In order to address damage tolerance behavior associated with friction stir welds in these safety critical structures, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data describing fracture behavior, residual strength capability, and cyclic mission life capability of friction stir welds at ambient and cryogenic temperatures have been generated and will be presented in this paper. Fracture behavior will include fracture toughness and tearing (R-curve) response of the friction stir welds. Residual strength behavior will include an evaluation of the effects of lack of penetration on conventional friction stir welds, the effects of internal defects (wormholes) on self-reacting friction stir welds, and an evaluation of the effects of fatigue cycled surface cracks on both conventional and selfreacting welds. Cyclic mission life capability will demonstrate the effects of surface crack defects on service load cycle capability. The fracture data will be used to evaluate nondestructive inspection and proof test requirements for the welds.

  5. Gimbaled-shoulder friction stir welding tool

    Science.gov (United States)

    Carter, Robert W. (Inventor); Lawless, Kirby G. (Inventor)

    2010-01-01

    A gimbaled-shoulder friction stir welding tool includes a pin and first and second annular shoulders coupled to the pin. At least one of the annular shoulders is coupled to the pin for gimbaled motion with respect thereto as the tool is rotated by a friction stir welding apparatus.

  6. Experimental investigation on the effect of process environment on the mechanical properties of AA5083/Al2O3 nanocomposite fabricated via friction stir processing

    International Nuclear Information System (INIS)

    Ashjari, M.; Mostafapour Asl, A.; Rouhi, S.

    2015-01-01

    Friction stir processing, a lately devised grain refining and also microstructure homogenizing technique, has extensively been used on aluminum alloys. Significance of limiting the grain growth during the process, has made lots of researchers make endeavor to keep, as one of the ways of controlling grain growth, the process temperature low; one way of doing so, is performing the friction stir process under water, which keeps the peak temperature low and increases the cooling rate as well. In the present work, research has been done to make known the effects of doing submerged friction stir processing on mechanical properties of AA5083/Al 2 O 3p composite. The process was completed on each sample without changing the rotation and traverse speed of the tool. The pin of the tool was a threaded cylindrical one. Tensile and micro-hardness tests were used to evaluate the effect of the process on these properties of the samples. Also to study the microstructure of the samples, optical microscopy (OM) and scanning electron microscopy (SEM) micrographs were used. The results show that, underwater friction stir process is capable of producing defect-free AA5083/Al 2 O 3p nanocomposite. Analyzing the properties of the processed samples showed that, by significantly reducing the grain size, water environment has positive impact on the mechanical properties of the alloy; And that, Hall–Petch effect is more powerful than Orowan mechanism in enhancing the mechanical properties of the samples

  7. Microstructure and wear characterization of aluminum matrix composites reinforced with industrial waste fly ash particulates synthesized by friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Dinaharan, I., E-mail: dinaweld2009@gmail.com [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park Kingsway Campus, Johannesburg 2006 (South Africa); Nelson, R., E-mail: nelson.90.mech@gmail.com [Department of Mechanical Engineering, Karunya University, Coimbatore 641114, Tamil Nadu (India); Vijay, S.J., E-mail: vijayjoseph.2001@gmail.com [Center for Research in Metallurgy, School of Mechanical Sciences, Karunya University, Coimbatore 641114, Tamil Nadu (India); Akinlabi, E.T., E-mail: etakinlabi@uj.ac.za [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park Kingsway Campus, Johannesburg 2006 (South Africa)

    2016-08-15

    Fly ash (FA) is a waste product of coal combustion in thermal power plants which is available in massive quantities all over the world causing land pollution. This paper reports the characterization of AA6061 aluminum matrix composites (AMCs) reinforced with FA particles synthesized using friction stir processing (FSP). The volume fraction of FA particles was varied from 0 to 18 in steps of 6. The prepared AMCs were characterized using optical microscopy (OM), scanning electron microscopy (SEM) and electron backscattered diagram (EBSD). The wear rate was estimated using a pin-on-disc wear apparatus. FA particles were observed to be distributed homogeneously in the AMC irrespective of the location within the stir zone. The EBSD micrographs revealed remarkable grain refinement in the AMC. The incorporation of FA particles enhanced the microhardness and wear resistance of the AMC. The strengthening mechanisms of the AMC were discussed and correlated to the observed microstructures. The wear mechanisms were identified by characterizing the wear debris and worn surfaces. - Highlights: •Industrial waste fly ash was used to produce aluminum matrix composites. •Friction stir processing was used to produce AA6061/Fly Ash composite. •Fly ash particles refined the grains of aluminum matrix. •Fly ash particles enhanced the hardness and wear resistance. •Successful utilization of fly ash to make aluminum composites reduces land pollution.

  8. Friction-stir processing of a high-damping Mn-Cu alloy used for marine propellers

    Energy Technology Data Exchange (ETDEWEB)

    Lynch, S.P.; Edwards, D.P.; Majumdar, A. [Defence Science and Technology Organisation, Melbourne (Australia); Moutsos, S. [Centre for Advanced Materials Technology, Monash Univ. (Australia); Mahoney, M.W. [Rockwell Scientific, Thousand Oaks (United States)

    2003-07-01

    Mn-Cu alloys are used for specialised applications, such as marine propellers, where high noise-damping characteristics are required. These alloys tend to have more severe shrinkage porosity than conventional propeller alloys, and the corrosion resistance (including stress-corrosion and corrosion-fatigue resistance) of the alloys is not as high as desirable. Friction-stir processing (FSP) trials on one such alloy (tradename Sonoston) have shown that near-surface porosity can be eliminated and that the coarse, as-cast microstructure can be significantly refined. The corrosion resistance of processed material is substantially improved provided a heat treatment to relieve residual stress is carried out after FSP. (orig.)

  9. Effect of the Preheating Temperature on Process Time in Friction Stir Welding of Al 6061-T6

    DEFF Research Database (Denmark)

    Jabbari, Masoud

    2013-01-01

    This paper presents the results obtained and the deductions made from an analytical modeling involving friction stir welding of Al 6061-T6. A new database was developed to simulate the contact temperature between the tool and the workpiece. A second-order equation is proposed for simulating...... the temperature in the contact boundary and the thermal history during the plunge phase. The effect of the preheating temperature on the process time was investigated with the proposed model. The results show that an increase of the preheating time leads to a decrease in the process time up to the plunge...

  10. Investigation of effects of process parameters on properties of friction stir welded joints

    Science.gov (United States)

    Chauhan, Atul; Soota, Tarun; Rajput, S. K.

    2018-03-01

    This work deals with application of friction stir welding (FSW) using application of Taguchi orthogonal array. FSW procedure is used for joining the aluminium alloy AA6063-T0 plates in butt configuration with orthogonal combination of factors and their levels. The combination of factors involving tool rotation speed, tool travel speed and tool pin profile are used in three levels. Grey relational analysis (GRA) has been applied to select optimum level of factors for optimising UTS, ductility and hardness of joint. Experiments have been conducted with two different tool materials (HSS and HCHCr steel) with various factors level combinations for joining AA6063-T0. On the basis of grey relational grades at different levels of factors and analysis of variance (ANOVA) ideal combination of factors are determined. The influence of tool material is also studied.

  11. Effect of Multipass Friction Stir Processing on Mechanical and Corrosion Behavior of 2507 Super Duplex Stainless Steel

    Science.gov (United States)

    Mishra, M. K.; Gunasekaran, G.; Rao, A. G.; Kashyap, B. P.; Prabhu, N.

    2017-02-01

    The microstructure, mechanical properties, and corrosion behavior of 2507 super duplex stainless steel after multipass friction stir processing (FSP) were examined. A significant refinement in grain size of both ferrite and austenite was observed in stir zone resulting in improved yield and tensile strength. Electrochemical impedance spectroscopy and anodic polarization studies in 3.5 wt.% NaCl solution showed nobler corrosion characteristics with increasing number of FSP passes. This was evident from the decrease in corrosion current density, decrease in passive current density, and increase in polarization resistance. Also, the decrease in density of defects, based on Mott-Schottky analysis, further confirms the improvement in corrosion resistance of 2507 super duplex stainless steel after multipass FSP.

  12. Numerical simulation of temperature distribution using finite difference equations and estimation of the grain size during friction stir processing

    International Nuclear Information System (INIS)

    Arora, H.S.; Singh, H.; Dhindaw, B.K.

    2012-01-01

    Highlights: ► Magnesium alloy AE42 was friction stir processed under different cooling conditions. ► Heat flow model was developed using finite difference heat equations. ► Generalized MATLAB code was developed for solving heat flow model. ► Regression equation for estimation of grain size was developed. - Abstract: The present investigation is aimed at developing a heat flow model to simulate temperature history during friction stir processing (FSP). A new approach of developing implicit form of finite difference heat equations solved using MATLAB code was used. A magnesium based alloy AE42 was friction stir processed (FSPed) at different FSP parameters and cooling conditions. Temperature history was continuously recorded in the nugget zone during FSP using data acquisition system and k type thermocouples. The developed code was validated at different FSP parameters and cooling conditions during FSP experimentation. The temperature history at different locations in the nugget zone at different instants of time was further utilized for the estimation of grain growth rate and final average grain size of the FSPed specimen. A regression equation relating the final grain size, maximum temperature during FSP and the cooling rate was developed. The metallurgical characterization was done using optical microscopy, SEM, and FIB-SIM analysis. The simulated temperature profiles and final average grain size were found to be in good agreement with the experimental results. The presence of fine precipitate particles generated in situ in the investigated magnesium alloy also contributed in the evolution of fine grain structure through Zener pining effect at the grain boundaries.

  13. Molecular dynamics modeling of bonding two materials by atomic scale friction stir welding at different process parameters

    Science.gov (United States)

    Konovalenko S., Iv.; Psakhie, S. G.

    2017-12-01

    Using the molecular dynamics method, we simulated the atomic scale butt friction stir welding on two crystallites and varied the onset FSW tool plunge depth. The effects of the plunge depth value on the thermomechanical evolution of nanosized crystallites and mass transfer in the course of FSW have been studied. The increase of plunge depth values resulted in more intense heating and reducing the plasticized metal resistance to the tool movement. The mass transfer intensity was hardly dependent on the plunge depth value. The plunge depth was recommended to be used as a FSW process control parameter in addition to the commonly used ones.

  14. Effects of nanometric inclusions on the microstructural characteristics and strengthening of a friction-stir processed aluminum–magnesium alloy

    Energy Technology Data Exchange (ETDEWEB)

    Khodabakhshi, F., E-mail: farzadkhodabakhshi83@gmail.com [Department of Materials Science and Engineering, School of Engineering, Shiraz University, Zand Boulevard, Shiraz (Iran, Islamic Republic of); Simchi, A., E-mail: simchi@sharif.edu [Department of Materials Science and Engineering, Sharif University of Technology, P.O. Box 11365-9466, Azadi Avenue, 14588 Tehran (Iran, Islamic Republic of); Institute for Nanoscience and Nanotechnology, Sharif University of Technology, P.O. Box 11365-9466, Azadi Avenue, 14588 Tehran (Iran, Islamic Republic of); Kokabi, A.H. [Department of Materials Science and Engineering, Sharif University of Technology, P.O. Box 11365-9466, Azadi Avenue, 14588 Tehran (Iran, Islamic Republic of); Švec, P. [Institute of Physics, Slovak Academy of Sciences, Dúbravská cesta 9, Bratislava (Slovakia); Simančík, F. [Institute of Materials and Machine Mechanics, Slovak Academy of Sciences, Racianska 75, Bratislava (Slovakia); Gerlich, A.P. [Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON (Canada)

    2015-08-26

    An aluminum–magnesium alloy was friction-stir processed in the presence of TiO{sub 2} nanoparticles which were pre-placed in a groove on the surface to produce a composite. Field emission-scanning and transmission electron microscopy studies show that solid state chemical reactions occur between the Al–Mg matrix and the ceramic particles upon the severe plastic deformation process. The microstructure of the aluminum alloy consists of a coarse grain structure, large complex (Fe,Mn,Cr){sub 3}SiAl{sub 12} particles, and small Mg{sub 2}Si precipitates. After friction stir processing, a deformed grain structure containing rod-like Al–Fe–Mn–Si precipitates is attained, along with cuboidal (~100 nm) Cr{sub 2} precipitates and spherical (~100 and 5 nm) Mg{sub 2}Si particles. In the presence of TiO{sub 2} nanoparticles, magnesium oxide (MgO) and titanium aluminide (Al{sub 3}Ti) nanophases are formed. It is shown that these microstructural modifications lead to a significant enhancement in the hardness and tensile strength of the aluminum alloy. The relationship between the microstructural evolution and mechanical properties and the role of hard inclusions are presented and discussed. An analysis based on strengthening models indicates that the yield strength of the nanocomposite is mainly controlled by dislocations and grain boundaries rather than the nano-scale inclusions.

  15. Effect of process parameters on microstructure and mechanical behaviors of friction stir linear welded aluminum to magnesium

    International Nuclear Information System (INIS)

    Rao, H.M.; Ghaffari, B.; Yuan, W.; Jordon, J.B.; Badarinarayan, H.

    2016-01-01

    The microstructure and lap-shear behaviors of friction stir linear welded wrought Al alloy AA6022-T4 to cast Mg alloy AM60B joints were examined. A process window was developed to initially identify the potential process conditions. Multitudes of welds were produced by varying the tool rotation rate and tool traverse speed. Welds produced at 1500 revolutions per minute (rpm) tool rotation rate and either 50 mm/min or 75 mm/min tool traverse speed displayed the highest quasi-static failure load of ~3.3 kN per 30 mm wide lap-shear specimens. Analysis of cross sections of untested coupons indicated that the welds made at these optimum welding parameters had negligible microvoids and displayed a favorable weld geometry for the cold lap and hook features at the faying surface, compared to welds produced using other process parameters. Cross sections of the tested coupons indicated that the dominant crack initiated on the advancing side and progressed through the weld nugget, which consists of intermetallic compounds (IMC). This study demonstrates the feasibility of welding wrought Al and cast Mg alloy via friction stir linear welding with promising lap-shear strength results.

  16. Effect of process parameters on microstructure and mechanical behaviors of friction stir linear welded aluminum to magnesium

    Energy Technology Data Exchange (ETDEWEB)

    Rao, H.M. [Research & Development Division, Hitachi America Ltd., Farmington Hills, MI 48335 (United States); Ghaffari, B. [Research and Advanced Engineering, Ford Motor Company, Dearborn, MI 48121 (United States); Yuan, W., E-mail: wei.yuan@hitachi-automotive.us [Research & Development Division, Hitachi America Ltd., Farmington Hills, MI 48335 (United States); Jordon, J.B. [Department of Mechanical Engineering, The University of Alabama, Tuscaloosa, AL 35487 (United States); Badarinarayan, H. [Research & Development Division, Hitachi America Ltd., Farmington Hills, MI 48335 (United States)

    2016-01-10

    The microstructure and lap-shear behaviors of friction stir linear welded wrought Al alloy AA6022-T4 to cast Mg alloy AM60B joints were examined. A process window was developed to initially identify the potential process conditions. Multitudes of welds were produced by varying the tool rotation rate and tool traverse speed. Welds produced at 1500 revolutions per minute (rpm) tool rotation rate and either 50 mm/min or 75 mm/min tool traverse speed displayed the highest quasi-static failure load of ~3.3 kN per 30 mm wide lap-shear specimens. Analysis of cross sections of untested coupons indicated that the welds made at these optimum welding parameters had negligible microvoids and displayed a favorable weld geometry for the cold lap and hook features at the faying surface, compared to welds produced using other process parameters. Cross sections of the tested coupons indicated that the dominant crack initiated on the advancing side and progressed through the weld nugget, which consists of intermetallic compounds (IMC). This study demonstrates the feasibility of welding wrought Al and cast Mg alloy via friction stir linear welding with promising lap-shear strength results.

  17. Friction stir method for forming structures and materials

    Science.gov (United States)

    Feng, Zhili; David, Stan A.; Frederick, David Alan

    2011-11-22

    Processes for forming an enhanced material or structure are disclosed. The structure typically includes a preform that has a first common surface and a recess below the first common surface. A filler is added to the recess and seams are friction stir welded, and materials may be stir mixed.

  18. Modification of vacuum plasma sprayed tungsten coating on reduced activation ferritic/martensitic steels by friction stir processing

    International Nuclear Information System (INIS)

    Tanigawa, Hiroyasu; Ozawa, Kazumi; Morisada, Yoshiaki; Noh, Sanghoon; Fujii, Hidetoshi

    2015-01-01

    Highlights: • Friction stir processing (FSP) was applied on vacuum plasma spray (VPS) W to improve its low thermal conductivity and weakness due to high porosity. • FSP can achieve significant improvement both in mechanical and thermal properties of VPS-W coating. • It was indicated that the double pass FSP at 600 rpm/50 mm/min/2 ton on VPS-W show the most dense microstructure and hardest mechanical property. • Hardness test over FSPed VPS-W layer revealed that the hardness of W becomes higher than that of bulk W. • The thermal conductivity of double pass FSPed VPS-W was about 80% of bulk W at 200 °C, and it becomes equivalent to that of bulk W over 800 °C. - Abstract: Tungsten (W) is the primary candidate material as a plasma facing material in fusion devices, as for its high melting temperature, good thermal conductivity and low sputtering rate, and vacuum plasma spray (VPS) technique is preferred as it is applicable for large area without brittle interlayer, but the thermal conductivity of W layer is very poor, and easy to detach, mainly caused by its porous structure. W Friction stir processing (FSP) was applied on VPS-W to improve these poor properties, and it was suggested that FSP can contribute to significant improvement in both mechanical and thermal properties of the VPS-W coating.

  19. A bottom-up approach for optimization of friction stir processing parameters; a study on aluminium 2024-T3 alloy

    International Nuclear Information System (INIS)

    Nadammal, Naresh; Kailas, Satish V.; Suwas, Satyam

    2015-01-01

    Highlights: • An experimental bottom-up approach has been developed for optimizing the process parameters for friction stir processing. • Optimum parameter processed samples were tested and characterized in detail. • Ultimate tensile strength of 1.3 times the base metal strength was obtained. • Residual stresses on the processed surface were only 10% of the yield strength of base metal. • Microstructure observations revealed fine equi-axed grains with precipitate particles at the grain boundaries. - Abstract: Friction stir processing (FSP) is emerging as one of the most competent severe plastic deformation (SPD) method for producing bulk ultra-fine grained materials with improved properties. Optimizing the process parameters for a defect free process is one of the challenging aspects of FSP to mark its commercial use. For the commercial aluminium alloy 2024-T3 plate of 6 mm thickness, a bottom-up approach has been attempted to optimize major independent parameters of the process such as plunge depth, tool rotation speed and traverse speed. Tensile properties of the optimum friction stir processed sample were correlated with the microstructural characterization done using Scanning Electron Microscope (SEM) and Electron Back-Scattered Diffraction (EBSD). Optimum parameters from the bottom-up approach have led to a defect free FSP having a maximum strength of 93% the base material strength. Micro tensile testing of the samples taken from the center of processed zone has shown an increased strength of 1.3 times the base material. Measured maximum longitudinal residual stress on the processed surface was only 30 MPa which was attributed to the solid state nature of FSP. Microstructural observation reveals significant grain refinement with less variation in the grain size across the thickness and a large amount of grain boundary precipitation compared to the base metal. The proposed experimental bottom-up approach can be applied as an effective method for

  20. Microstructure and mechanical properties of Cu/SiC metal matrix composite fabricated via friction stir processing

    International Nuclear Information System (INIS)

    Akramifard, H.R.; Shamanian, M.; Sabbaghian, M.; Esmailzadeh, M.

    2014-01-01

    Highlights: • Designing a net hole was effective to achieve uniform distribution SiC particles and prevent agglomeration of them. • SZ has fine and equiaxed grains and distribution of SiC particles in the matrix is almost uniform. • No intermetallic compound was formed after FSP. • In comparison to pure Cu, Cu/SiC composite shows higher hardness and better wear behavior. - Abstract: In the present investigation, pure Cu sheets were reinforced with 25 μm SiC particles to fabricate a composite surface layer by friction stir processing (FSP). In order to improve distribution of reinforcing SiC particles, a net of holes were designed by drill on the surface of pure Cu sheet. For evaluation of microstructure, Optical Microscope (OM) and Scanning Electron Microscope (SEM) were used. Microstructural observation confirmed fine and equiaxed grains in the stir zone (SZ) and showed that SiC particles act as heterogeneous nucleation sites in the dynamic recrystallization of Cu grains. Moreover, agglomeration of particles was not observed and fine particles had a good distribution in SZ. In the SEM micrographs, porosities were detected as microstructure defects. Microhardness measurements showed that surface hardness was two times as high as that of substrate. The rotational wear tests demonstrated that use of SiC particles enhanced wear resistance and increased average friction coefficient of pure Cu. No intermetallic compound was found in Cu/SiC composite as revealed by XRD analysis

  1. Effect of Processing Parameters on Plastic Flow and Defect Formation in Friction-Stir-Welded Aluminum Alloy

    Science.gov (United States)

    Zeng, X. H.; Xue, P.; Wang, D.; Ni, D. R.; Xiao, B. L.; Ma, Z. Y.

    2018-04-01

    The effect of processing parameters on material flow and defect formation during friction stir welding (FSW) was investigated on 6.0-mm-thick 2014Al-T6 rolled plates with an artificially thickened oxide layer on the butt surface as the marker material. It was found that the "S" line in the stir zone (SZ) rotated with the pin and stayed on the retreating side (RS) and advancing side (AS) at low and high heat inputs, respectively. When the tool rotation rate was extremely low, the oxide layer under the pin moved to the RS first and then to the AS perpendicular to the welding direction, rather than rotating with the pin. The material flow was driven by the shear stresses produced by the forces at the pin-workpiece interface. With increases of the rotation rate, the depth of the shoulder-affected zone (SAZ) first decreased and then increased due to the decreasing shoulder friction force and increasing heat input. Insufficient material flow appeared in the whole of the SZ at low rotation rates and in the bottom of the SZ at high rotation rates, resulting in the formation of the "S" line. The extremely inadequate material flow is the reason for the lack of penetration and the kissing bonds in the bottom of the SZ at extremely low and low rotation rates, respectively.

  2. Multi-response optimization of process parameters in friction stir welded AM20 magnesium alloy by Taguchi grey relational analysis

    Directory of Open Access Journals (Sweden)

    Prakash Kumar Sahu

    2015-03-01

    Full Text Available The purpose of this paper is to optimize the process parameter to get the better mechanical properties of friction stir welded AM20 magnesium alloy using Taguchi Grey relational analysis (GRA. The considered process parameters are welding speed, tool rotation speed, shoulder diameter and plunging depth. The experiments were carried out by using Taguchi's L18 factorial design of experiment. The processes parameters were optimized and ranked the parameters based on the GRA. The percentage influence of each process parameter on the weld quality was also quantified. A validation experimental run was conducted using optimal process condition, which was obtained from the analysis, to show the improvement in mechanical properties of the joint. This study also shows the feasibility of the GRA with Taguchi technique for improvement in welding quality of magnesium alloy.

  3. Effect of Tip Shape of Frictional Stir Burnishing Tool on Processed Layer’s Hardness, Residual Stress and Surface Roughness

    Directory of Open Access Journals (Sweden)

    Yoshimasa Takada

    2018-01-01

    Full Text Available Friction stir burnishing (FSB is a surface-enhancement method used after machining, without the need for an additional device. The FSB process is applied on a machine that uses rotation tools (e.g., machining center or multi-tasking machine. Therefore, the FSB process can be applied immediately after the cutting process using the same machine tool. Here, we apply the FSB to the shaft materials of 0.45% C steel using a multi-tasking machine. In the FSB process, the burnishing tool rotates at a high-revolution speed. The thin surface layer is rubbed and stirred as the temperature is increased and decreased. With the FSB process, high hardness or compressive residual stress can be obtained on the surface layer. However, when we applied the FSB process using a 3 mm diameter sphere tip shape tool, the surface roughness increased substantially (Ra = 20 µm. We therefore used four types of tip shape tools to examine the effect of burnishing tool tip radius on surface roughness, hardness, residual stress in the FSB process. Results indicated that the surface roughness was lowest (Ra = 10 µm when the tip radius tool diameter was large (30 mm.

  4. Cladding of Advanced Al Alloys Employing Friction Stir Welding

    NARCIS (Netherlands)

    van der Stelt, A.A.; Bor, Teunis Cornelis; Geijselaers, Hubertus J.M.; Akkerman, Remko; van den Boogaard, Antonius H.

    2013-01-01

    In this paper an advanced solid state cladding process, based on Friction Stir Welding, is presented. The Friction Surface Cladding (FSC) technology enables the deposition of a solid-state coating using filler material on a substrate with good metallurgical bonding. A relatively soft AA1050 filler

  5. Controlling the length scale and distribution of the ductile phase in metallic glass composites through friction stir processing.

    Science.gov (United States)

    Arora, Harpreet Singh; Mridha, Sanghita; Grewal, Harpreet Singh; Singh, Harpreet; Hofmann, Douglas C; Mukherjee, Sundeep

    2014-06-01

    We demonstrate the refinement and uniform distribution of the crystalline dendritic phase by friction stir processing (FSP) of titanium based in situ ductile-phase reinforced metallic glass composite. The average size of the dendrites was reduced by almost a factor of five (from 24 μ m to 5 μ m) for the highest tool rotational speed of 900 rpm. The large inter-connected dendrites become more fragmented with increased circularity after processing. The changes in thermal characteristics were measured by differential scanning calorimetry. The reduction in crystallization enthalpy after processing suggests partial devitrification due to the high strain plastic deformation. FSP resulted in increased hardness and modulus for both the amorphous matrix and the crystalline phase. This is explained by interaction of shear bands in amorphous matrix with the strain-hardened dendritic phase. Our approach offers a new strategy for microstructural design in metallic glass composites.

  6. Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

    Energy Technology Data Exchange (ETDEWEB)

    Gupta, Varun; Upadhyay, Piyush; Fifield, Leonard S.; Roosendaal, Timothy; Sun, Xin; Nelaturu, Phalgun; Carlson, Blair

    2018-04-01

    The friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For the welds in lap configuration, an enhancement to this technology is made by introducing a short hard insert, referred to as cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanically coupled computational model employing coupled Eulerian-Lagrangian approach is developed to quantitatively capture the morphology of these interlocks during the FSW process. The simulations using developed model are validated by the experimental observations.The identified interface morphology coupled with the predicted temperature field from this process-structure model can then be used to estimate the post-weld microstructure and joint strength.

  7. Gimballed Shoulders for Friction Stir Welding

    Science.gov (United States)

    Carter, Robert; Lawless, Kirby

    2008-01-01

    In a proposed improvement of tooling for friction stir welding, gimballed shoulders would supplant shoulders that, heretofore, have been fixedly aligned with pins. The proposal is especially relevant to self-reacting friction stir welding. Some definitions of terms, recapitulated from related prior NASA Tech Briefs articles, are prerequisite to a meaningful description of the proposed improvement. In friction stir welding, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a pin that rotates with the shoulder and protrudes from the shoulder into the depth of the workpiece. In conventional friction stir welding, the main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional friction stir welding is augmented with an auto-adjustable pin-tool (APT) capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or forcecontrol system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding as practiced heretofore, there are two shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. Both shoulders rotate with the pin and remain aligned coaxially with the pin. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft into the friction-stir-welding machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. This concludes the prerequisite definitions of terms.

  8. Electrochemical properties in a seawater environment of 5456-H116 aluminum alloy subjected to optimal friction stir processing

    International Nuclear Information System (INIS)

    Park, Jae-Cheul; Kim, Seong-Jong

    2010-01-01

    The mechanical properties of aluminum alloy may be enhanced by modifying the microstructure of the metal by friction stir processing (FSP). Previous studies have demonstrated that the mechanical characteristics of 5456-H116 Al alloy subjected to FSP, at 250 rpm and 15 mm min -1 using a full screw probe, are similar to those of the original alloy. In the present work, the same alloy was processed under these optimal conditions, and the range of favorable protection potentials with regard to hydrogen embrittlement and stress corrosion cracking was determined to lie between -1.3 and -0.7 V (versus Ag/AgCl). The electrochemical behavior of the specimens subjected to FSP was superior to that of the original 5456-H116 Al alloy.

  9. Electrochemical properties in a seawater environment of 5456-H116 aluminum alloy subjected to optimal friction stir processing

    Science.gov (United States)

    Park, Jae-Cheul; Kim, Seong-Jong

    2010-05-01

    The mechanical properties of aluminum alloy may be enhanced by modifying the microstructure of the metal by friction stir processing (FSP). Previous studies have demonstrated that the mechanical characteristics of 5456-H116 Al alloy subjected to FSP, at 250 rpm and 15 mm min-1 using a full screw probe, are similar to those of the original alloy. In the present work, the same alloy was processed under these optimal conditions, and the range of favorable protection potentials with regard to hydrogen embrittlement and stress corrosion cracking was determined to lie between -1.3 and -0.7 V (versus Ag/AgCl). The electrochemical behavior of the specimens subjected to FSP was superior to that of the original 5456-H116 Al alloy.

  10. Process Parameters Optimization for Friction Stir Welding of Pure Aluminium to Brass (CuZn30 using Taguchi Technique

    Directory of Open Access Journals (Sweden)

    Elfar O. M. R.

    2016-01-01

    Full Text Available In this research, the friction stir welding of dissimilar commercial pure aluminium and brass (CuZn30 plates was investigated and the process parameters were optimized using Taguchi L9 orthogonal array. The considered process parameters were the rotational speed, traverse speed and pin offset. The optimum setting was determined with reference to ultimate tensile strength of the joint. The predicted optimum value of ultimate tensile strength was confirmed by experimental run using optimum parameters. Analysis of variance revealed that traverse speed is the most significant factor in controlling the joint tensile strength and pin offset also plays a significant role. In this investigation, the optimum tensile strength is 50% of aluminium base metal. Metallographic examination revealed that intermetallic compounds were formed in the interface of the optimum joint where the tensile failure was observed to take place.

  11. Microstructure and sliding wear characterization of Cu/TiB2 copper matrix composites fabricated via friction stir processing

    Directory of Open Access Journals (Sweden)

    I. Dinaharan

    2017-09-01

    Full Text Available The poor wear performance of copper is improved by reinforcing hard ceramic particles. The present work reports the fabrication of Cu/TiB2 (0, 6, 12, 18 vol.% copper matrix composites (CMCs using friction stir processing (FSP. TiB2 particles were initially packed together into a machined groove and were subjected to FSP under a constant set of process parameters. The microstructure was observed using optical, scanning and transmission electron microscopy. The wear behavior was examined using a pin-on-disc apparatus. The micrographs showed a homogeneous distribution of TiB2 particles without aggregation and segregation. The distribution of TiB2 particles was closely persistent across the stir zone. TiB2 particles were well bonded with the copper matrix without any interfacial reaction. Many TiB2 particles fractured during FSP. The grains in the composite were extensively refined because of dynamic recrystallization and pinning effect of TiB2 particles. The wear behavior under dry sliding condition was presented in detail.

  12. Influence of ceramic particulate type on microstructure and tensile strength of aluminum matrix composites produced using friction stir processing

    Directory of Open Access Journals (Sweden)

    I. Dinaharan

    2016-06-01

    Full Text Available Friction stir processing (FSP was applied to produce aluminum matrix composites (AMCs. Aluminum alloy AA6082 was used as the matrix material. Various ceramic particles, such as SiC, Al2O3, TiC, B4C and WC, were used as reinforcement particle. AA6082 AMCs were produced using a set of optimized process parameters. The microstructure was studied using optical microscopy, filed emission scanning electron microscopy and electron back scattered diagram. The results indicated that the type of ceramic particle did not considerably vary the microstructure and ultimate tensile strength (UTS. Each type of ceramic particle provided a homogeneous dispersion in the stir zone irrespective of the location and good interfacial bonding. Nevertheless, AA6082/TiC AMC exhibited superior hardness and wear resistance compared to other AMCs produced in this work under the same set of experimental conditions. The strengthening mechanisms and the variation in the properties are correlated to the observed microstructure. The details of fracture mode are further presented.

  13. Effect of tool plunge depth on reinforcement particles distribution in surface composite fabrication via friction stir processing

    Directory of Open Access Journals (Sweden)

    Sandeep Rathee

    2017-04-01

    Full Text Available Aluminium matrix surface composites are gaining alluring role especially in aerospace, defence, and marine industries. Friction stir processing (FSP is a promising novel solid state technique for surface composites fabrication. In this study, AA6061/SiC surface composites were fabricated and the effect of tool plunge depth on pattern of reinforcement particles dispersion in metal matrix was investigated. Six varying tool plunge depths were chosen at constant levels of shoulder diameter and tool tilt angle to observe the exclusive effect of plunge variation. Process parameters chosen for the experimentation are speed of rotation, travel speed and tool tilt angle which were taken as 1400 rpm, 40 mm/min, and 2.5°respectively. Macro and the microstructural study were performed using stereo zoom and optical microscope respectively. Results reflected that lower plunge depth levels lead to insufficient heat generation and cavity formation towards the stir zone center. On the other hand, higher levels of plunge depth result in ejection of reinforcement particles and even sticking of material to tool shoulder. Thus, an optimal plunge depth is needed in developing defect free surface composites.

  14. Thermomechanical Modelling of Friction Stir Welding

    DEFF Research Database (Denmark)

    Hattel, Jesper Henri; Schmidt, Henrik Nikolaj Blicher; Tutum, Cem Celal

    2009-01-01

    Friction Stir Welding (FSW) is a fully coupled thermomechanical process and should in general be modelled as such. Basically, there are two major application areas of thermomechanical models in the investigation of the FSW process: i) Analysis of the thermomechanical conditions such as e.g. heat...... generation and local material deformation (often referred to as flow) during the welding process itself. ii) Prediction of the residual stresses that will be present in the joint structure post to welding. While the former in general will call for a fully-coupled thermomechanical procedure, however...... for the FSW process at hand, the heat generation must either be prescribed analytically or based on a fully coupled analysis of the welding process itself. Along this line, a recently proposed thermal-pseudo-mechanical model is presented in which the temperature dependent yield stress of the weld material...

  15. Fabrication of Al5083 surface composites reinforced by CNTs and cerium oxide nano particles via friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Hosseini, S.A. [Department of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz (Iran, Islamic Republic of); Ranjbar, Khalil, E-mail: k_ranjbar@scu.ac.ir [Department of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz (Iran, Islamic Republic of); Dehmolaei, R. [Department of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz (Iran, Islamic Republic of); Amirani, A.R. [12th Ghaem Street, Bld. Hashemzadeh, Shahrak Golestan, Tehran (Iran, Islamic Republic of)

    2015-02-15

    Highlights: • Using friction stir processing, an effect of CNTs and CeO{sub 2} reinforcements on mechanical and corrosion properties of Al5083 alloy is reported. • The strength of Al5083 was increased by 42%, its matrix grain size reduced five times, and hardness was doubled by the incorporation of CNTs-CeO{sub 2} mixture in the volume ratio of 75-25 respectively. • Unlike the CNTs, incorporation of nanosized CeO{sub 2} particles resulted in remarkable increase in pitting resistance of the alloy. - Abstract: In the present investigation, friction stir processing (FSP) was utilized to incorporate Multi Walled Carbon Nano Tubes (MWCNT) and nanosized cerium oxide particles into the matrix of Al5083 alloy to form surface reinforced composites. The effect of these nanosized reinforcements either separately or in the combined form, on microstructural modification, mechanical properties and corrosion resistance of FSPed Al5083 surface composites was studied. A threaded cylindrical hardened steel tool was used with the rotation speeds of 600 and 800 rpm and travel speeds of 35 and 45 mm/min and a tilt angle of 5°. Mechanical properties and corrosion resistance of FSPed samples were evaluated and compared with the base alloy. The maximum tensile strength and hardness value were achieved for the hybrid composite containing a mixture of CNTs and cerium oxide in the volume ratio of 75-25, respectively, whereas a significant increase in pitting resistance of the base alloy was obtained when cerium oxide alone was incorporated. The corrosion behavior of the samples was investigated by potentiodynamic polarization tests and assessed in term of pitting potential and passivation range. Microstructural analysis carried out by using optical and electron microscopes showed that reinforcements are well dispersed inside the nugget zone (NZ), and remarkable grain refinement is gained. The study was aimed to fabricate surface composites with improved mechanical properties and

  16. Characterization of molybdenum particles reinforced Al6082 aluminum matrix composites with improved ductility produced using friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Selvakumar, S., E-mail: lathaselvam1963@gmail.com [Department of Mechanical Engineering, Nehru Institute of Technology, Coimbatore 641105, Tamil Nadu (India); Department of Mechanical Engineering, Anna University, Chennai 600025, Tamil Nadu (India); Dinaharan, I., E-mail: dinaweld2009@gmail.com [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park Kingsway Campus, Johannesburg 2006 (South Africa); Palanivel, R., E-mail: rpalanivelme@gmail.com [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park Kingsway Campus, Johannesburg 2006 (South Africa); Ganesh Babu, B., E-mail: profbgb@gmail.com [Department of Mechanical Engineering, Roever College of Engineering and Technology, Perambalur 621212, Tamil Nadu (India)

    2017-03-15

    Aluminum matrix composites (AMCs) reinforced with various ceramic particles suffer a loss in ductility. Hard metallic particles can be used as reinforcement to improve ductility. The present investigation focuses on using molybdenum (Mo) as potential reinforcement for Mo(0,6,12 and 18 vol.%)/6082Al AMCs produced using friction stir processing (FSP). Mo particles were successfully retained in the aluminum matrix in its elemental form without any interfacial reaction. A homogenous distribution of Mo particles in the composite was achieved. The distribution was independent upon the region within the stir zone. The grains in the composites were refined considerably due to dynamic recrystallization and pinning effect. The tensile test results showed that Mo particles improved the strength of the composite without compromising on ductility. The fracture surfaces of the composites were characterized with deeply developed dimples confirming appreciable ductility. - Highlights: •Molybdenum particles used as reinforcement for aluminum composites to improve ductility. •Molybdenum particles were retained in elemental form without interfacial reaction. •Homogeneous dispersion of molybdenum particles were observed in the composite. •Molybdenum particles improved tensile strength without major loss in ductility. •Deeply developed dimples on the fracture surfaces confirmed improved ductility.

  17. Effect of Post Heat Treatment on the Microstructure and Microhardness of Friction Stir Processed NiAl Bronze (NAB Alloy

    Directory of Open Access Journals (Sweden)

    Yuting Lv

    2015-09-01

    Full Text Available NiAl bronze (NAB alloy is prepared by using friction stir processing (FSP technique at a tool rotation rate of 1200 rpm and a traverse speed of 150 mm/min. A post heat treatment is performed at the temperature of 675 °C. The effect of heat treatment on the microstructure and microhardness is studied. The results show that the microstructure of the FSP NAB alloy consists of high density dislocations, retained β phase (β′ phase and recrystallized grains. When annealed at 675 °C, discontinuous static recrystallization (DSRX takes place. The content of β′ phase gradually decreases and fine κ phase is precipitated. After annealing for 2 h, both the microhardness of the FSP sample in the stir zone (SZ and the difference in hardness between the SZ and base metal decrease due to the reduction of the dislocation density and β′ phase, accompanying recrystallized grain coarsening. With further increasing of the annealing time to 4 h, the aforementioned difference in hardness nearly disappears.

  18. Characterization of molybdenum particles reinforced Al6082 aluminum matrix composites with improved ductility produced using friction stir processing

    International Nuclear Information System (INIS)

    Selvakumar, S.; Dinaharan, I.; Palanivel, R.; Ganesh Babu, B.

    2017-01-01

    Aluminum matrix composites (AMCs) reinforced with various ceramic particles suffer a loss in ductility. Hard metallic particles can be used as reinforcement to improve ductility. The present investigation focuses on using molybdenum (Mo) as potential reinforcement for Mo(0,6,12 and 18 vol.%)/6082Al AMCs produced using friction stir processing (FSP). Mo particles were successfully retained in the aluminum matrix in its elemental form without any interfacial reaction. A homogenous distribution of Mo particles in the composite was achieved. The distribution was independent upon the region within the stir zone. The grains in the composites were refined considerably due to dynamic recrystallization and pinning effect. The tensile test results showed that Mo particles improved the strength of the composite without compromising on ductility. The fracture surfaces of the composites were characterized with deeply developed dimples confirming appreciable ductility. - Highlights: •Molybdenum particles used as reinforcement for aluminum composites to improve ductility. •Molybdenum particles were retained in elemental form without interfacial reaction. •Homogeneous dispersion of molybdenum particles were observed in the composite. •Molybdenum particles improved tensile strength without major loss in ductility. •Deeply developed dimples on the fracture surfaces confirmed improved ductility.

  19. Power characteristics of the metal compounds formation process during the friction stir welding

    Directory of Open Access Journals (Sweden)

    Rzaev Radmir

    2017-01-01

    Full Text Available An influence of the power characteristics on the formation process of the uniform metals compound during the welding with friction stirringis being examined in this article.A dependency between the machine-tool engine power input and the instrument tilt during the FSW for the aluminum alloy AD31, copper alloy M1, titanium alloy OT4-1 and steel St-3 low-alloyed has been explored. A question of the stabilization of power consumption process while the establishment of superplastic condition of welded metal during the FSW has also been reviewed. A dependency revealed between the power characteristics, the geometry of the formation, the rotation speeds, the longitudinal displacement of the tool and its dimensions for fixed values of the parameters during the FSW.

  20. Friction stir weld tools having fine grain structure

    Science.gov (United States)

    Grant, Glenn J.; Frye, John G.; Kim, Jin Yong; Lavender, Curt A.; Weil, Kenneth Scott

    2016-03-15

    Tools for friction stir welding can be made with fewer process steps, lower cost techniques, and/or lower cost ingredients than other state-of-the-art processes by utilizing improved compositions and processes of fabrication. Furthermore, the tools resulting from the improved compositions and processes of fabrication can exhibit better distribution and homogeneity of chemical constituents, greater strength, and/or increased durability. In one example, a friction stir weld tool includes tungsten and rhenium and is characterized by carbide and oxide dispersoids, by carbide particulates, and by grains that comprise a solid solution of the tungsten and rhenium. The grains do not exceed 10 micrometers in diameter.

  1. Friction stir welding of 6061 aluminium alloy

    International Nuclear Information System (INIS)

    Abdel Rahman, M.A.M.S.

    2009-01-01

    6061 AA (Al-Mg-Si alloy) has gathered wide acceptance in the fabrication of light weight structures requiring a high strength-to-weight ratio and good corrosion resistance such as marine frames, pipelines, storage tanks, and aircraft components [1]. It is also used for the manufacturing of fuel elements in the nuclear research reactors. Compared to many of the fusion welding processes that are routinely used for joining structural alloys, friction stir welding (FSW) is a solid state joining process in which the material that is being welded is not melted and recast [2]. The welding parameters such as tool rotational speed, welding traverse speed, and tool profile play a major role in deciding the weld quality. Several FSW tools (differ from each other in pin angle, shoulder diameter, and shoulder concavity) have been used to fabricate a number of joints in order to obtain a tool with which a sound weld can be produced. It was found that the FSW tool with tapered cone pin, concave shoulder, and shoulder diameter equal to four times the welded plate thickness is suitable to produce a sound weld. The effect of the traverse speed on the global and local tensile properties of friction stir welded joints has been investigated in the 6061-T6 AA. The global tensile properties of the FSW joints were improved with increasing the traverse speed at constant rotation rate. It is found that the global tensile strength of the FSW joint is limited by the local tensile strength of the nearest region to the weld center at which the cross section is composed mainly of the HAZ. The effect of the initial butt surface on the formation of the zigzag line on the tensile properties of the welds was examined by using three types of welding samples differ in the preparation of the initial butt surface. The first type of samples welded without removing the oxide layer from the initial butt surface (uncleaned butt surfaces joint). In the second type of samples the oxide layer was removed from

  2. Numerical optimisation of friction stir welding: review of future challenges

    DEFF Research Database (Denmark)

    Tutum, Cem Celal; Hattel, Jesper Henri

    2011-01-01

    During the last decade, the combination of increasingly more advanced numerical simulation software with high computational power has resulted in models for friction stir welding (FSW), which have improved the understanding of the determining physical phenomena behind the process substantially....... This has made optimisation of certain process parameters possible and has in turn led to better performing friction stir welded products, thus contributing to a general increase in the popularity of the process and its applications. However, most of these optimisation studies do not go well beyond manual...

  3. Effect of heat treatment and number of passes on the microstructure and mechanical properties of friction stir processed AZ91C magnesium alloy

    Energy Technology Data Exchange (ETDEWEB)

    Dadashpour, M.; Yeşildal, R. [University of Ataturk, Erzurum (Turkmenistan); Mostafapour, A.; Rezazade, V. [University of Tabriz, Tabriz (Iran, Islamic Republic of)

    2016-02-15

    In this paper, the effect of heat treatment and number of passes on microstructure and mechanical properties of friction stir processed AZ91C magnesium alloy samples were investigated. From six samples of as-cast AZ91C magnesium alloy, three plates were pre-heated at temperature of 375°C for 3 hours, and then were treated at temperature of 415°C for 18 hours and finally were cooled down in air. Three plates were relinquished without heat treatment. 8 mm thick as-cast AZ91C magnesium alloy plates were friction stir processed at constant traverse speed of 40 mm/min and tool rotation speed of 1250 rpm. After process, microstructural characterization of samples was analyzed using optical microscopy and tensile and Vickers hardness tests were performed. It was found that heat treated samples had finer grains, higher hardness, improved tensile strength and elongation relative to non-heat treated ones. As the number of passes increased, higher UTS and TE were achieved due to finer grains and more dissolution of β phase (Mg17Al12). The micro-hardness characteristics and tensile improvement of the friction stir processed samples depend significantly on grain size, removal of voids and porosities and dissolution of β phase in the stir zone.

  4. Unstable Temperature Distribution in Friction Stir Welding

    Directory of Open Access Journals (Sweden)

    Sadiq Aziz Hussein

    2014-01-01

    Full Text Available In the friction stir welding process, a nonuniform and high generated temperature is undesirable. Unstable temperature and distribution affect thermal and residual stresses along the welding line, thus necessitating mitigation. This paper presents a simple method to prevent significant temperature difference along the welding line and also to help nullifying some defect types associated with this welding, such as end-hole, initial unwelded line, and deformed areas. In the experimental investigation, a heat and force thermocouple and dynamometer were utilized while couple-field thermomechanical models were used to evaluate temperature and its distribution, plastic strain, and material displacement. The suggested method generated uniform temperature distributions. Measurement results are discussed, showing a good correlation with predictions.

  5. Orbital friction stir welding of aluminium pipes

    International Nuclear Information System (INIS)

    Engelhard, G.; Hillers, T.

    2002-01-01

    Friction stir welding (FSW) was originally developed for flat plates. This contribution shows how it can be applied to the welding of aluminium pipes. Pipes made of AlMG 3 (EN5754), AlMg 4.5Mn (EN5083) and AlMgSi 0.5 (EN6106) with dimensions of Da 600 and 520 x 10-8 mm were welded. The FSW orbital system comprises an annular cage with integrated FSW head, a hydraulic system, and a control unit. The welds were tested successfully according to EN 288. The mechanical and technical properties of the welds were somewhat better than with the TIG orbital process, and welding times were about 40 percent shorter [de

  6. Metal Flow in Friction Stir Welding

    Science.gov (United States)

    Nunes, Arthur C., Jr.

    2006-01-01

    The plastic deformation field in Friction Stir Welding (FSW) is compared to that in metal cutting. A shear surface around the FSW tool analogous to the metal cutting shear plane is identified and comprises the basis of the "rotating plug" flow field model and the "wiping" model of tool interaction with weld metal. Within the context of these models: The FSW shear rate is estimated to be comparable to metal cutting shear rates. The effect of tool geometry on the FSW shear surface is discussed and related to published torque measurements. Various FS W structural features are explained, including a difference in structure of bimetallic welds when alloys on the advancing and retreating sides of the weld seam are exchanged. The joining mechanism and critical parameters of the FSW process are made clear.

  7. An analysis to optimize the process parameters of friction stir welded ...

    African Journals Online (AJOL)

    user

    International Journal of Engineering, Science and Technology .... Figure.2 Schematic representation of (a) flat shoulder with cylindrical pin and (b) concave ... gap between the plate surface and tool shoulder which creates some pressure over ..... surface of the stir zone consists of fully ferritic grains, below the layer by which ...

  8. Friction stir welding process and material microstructure evolution modeling in 2000 and 5000 series of aluminum alloy

    Science.gov (United States)

    Yalavarthy, Harshavardhan

    Interactions between the rotating and advancing pin-shaped tool (terminated at one end with a circular-cylindrical shoulder) with the clamped welding-plates and the associated material and heat transport during a Friction Stir Welding (FSW) process are studied computationally using a fully-coupled thermo-mechanical finite-element analysis. To surmount potential numerical problems associated with extensive mesh distortions/entanglement, an Arbitrary Lagrangian Eulerian (ALE) formulation was used which enabled adaptive re-meshing (to ensure the continuing presence of a high-quality mesh) while allowing full tracking of the material free surfaces. To demonstrate the utility of the present computational approach, the analysis is applied to the cases of same-alloy FSW of two Aluminum-alloy grades: (a) AA5083 (a solid-solution strengthened and strain-hardened/stabilized Al-Mg-Mn alloy); and (b) AA2139 (a precipitation hardened quaternary Al-Cu-Mg-Ag alloy). Both of these alloys are currently being used in military-vehicle hull structural and armor systems. In the case of non-age-hardenable AA5083, the dominant microstructure evolution processes taking place during FSW are extensive plastic deformation and dynamic recrystallization of highly-deformed material subjected to elevated temperatures approaching the melting temperature. To account for the competition between plastic-deformation controlled strengthening and dynamic-recrystallization induced softening phenomena during the FSW process, the original Johnson-Cook strain- and strain-rate hardening and temperature-softening material strength model is modified in the present work using the available recrystallization-kinetics experimental data. In the case of AA2139, in addition to plastic deformation and dynamic recrystallization, precipitates coarsening, over-aging, dissolution and re-precipitation had to be also considered. Limited data available in the open literature pertaining to the kinetics of the aforementioned

  9. Performance Improvement of Friction Stir Welds by Better Surface Finish

    Science.gov (United States)

    Russell, Sam; Nettles, Mindy

    2015-01-01

    The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled.

  10. Near Net Manufacturing Using Thin Gage Friction Stir Welding

    Science.gov (United States)

    Takeshita, Jennifer; Potter, David; Holquin, Michael

    2006-01-01

    Friction Stir Welding (FSW) and near net spin forming of FSW aluminumn blanks were investigated for large-scale pressure vessel applications. With a specific focus on very thin gage 2xxx and 7xxx aluminum alloys, the program concentrated on the following: the criteria used for material selection, a potential manufacturing flow, and the effectiveness and associated risks of near net spin forming. Discussion will include the mechanical properties of the friction stir welds and the parent material from before and after the spin forming process. This effort was performed under a NASA Space Exploration initiative focused on increasing the affordability, reliability and performance of pressure vessels larger than 10 ft. diameter.

  11. Heat Control via Torque Control in Friction Stir Welding

    Science.gov (United States)

    Venable, Richard; Colligan, Kevin; Knapp, Alan

    2004-01-01

    In a proposed advance in friction stir welding, the torque exerted on the workpiece by the friction stir pin would be measured and controlled in an effort to measure and control the total heat input to the workpiece. The total heat input to the workpiece is an important parameter of any welding process (fusion or friction stir welding). In fusion welding, measurement and control of heat input is a difficult problem. However, in friction stir welding, the basic principle of operation affords the potential of a straightforward solution: Neglecting thermal losses through the pin and the spindle that supports it, the rate of heat input to the workpiece is the product of the torque and the speed of rotation of the friction stir weld pin and, hence, of the spindle. Therefore, if one acquires and suitably processes data on torque and rotation and controls the torque, the rotation, or both, one should be able to control the heat input into the workpiece. In conventional practice in friction stir welding, one uses feedback control of the spindle motor to maintain a constant speed of rotation. According to the proposal, one would not maintain a constant speed of rotation: Instead, one would use feedback control to maintain a constant torque and would measure the speed of rotation while allowing it to vary. The torque exerted on the workpiece would be estimated as the product of (1) the torque-multiplication ratio of the spindle belt and/or gear drive, (2) the force measured by a load cell mechanically coupled to the spindle motor, and (3) the moment arm of the load cell. Hence, the output of the load cell would be used as a feedback signal for controlling the torque (see figure).

  12. Influence of tool geometry and process parameters on macrostructure and static strength in friction stir spot welded polyethylene sheets

    International Nuclear Information System (INIS)

    Bilici, Mustafa Kemal; Yuekler, Ahmet Irfan

    2012-01-01

    Highlights: → All velding parameters and different tool geometries have demonstrated a different effects on weld strength. → Friction stir spot welding of polyethylene mechanical scission is very important. → Metric screw the tool has a great influence on the weld strength of FSSW. -- Abstract: The effect of important welding parameters and tool properties that are effective on static strength in friction stir spot welds of polyethylene sheets were studied. Six different tool pin profiles (straight cylindrical, tapered cylindrical, threaded cylindrical, triangular, square and hexagonal) with different shoulder geometries, different pin length, pin angle and concavity angle were used to fabricate the joints. The tool rotational speed, tool plunge depth and dwell time were determined welding parameters. All the welding operations were done at the room temperature. Welding force and welding zone material temperature measurements were also done. Lap-shear tests were carried out to find the weld static strength. Weld cross section appearance observations were also done. From the experiments, the effect of pin profile, pin length, pin angle, dwell time and tool rotational speed on friction stir spot welding formation and weld strength was determined.

  13. The microstructure, texture, and room temperature mechanical properties of friction stir processed Mg-Y-Nd alloy

    Energy Technology Data Exchange (ETDEWEB)

    Jamili, A.M. [The Complex Laboratory of Hot Deformation and Thermomechanical Processing of High Performance Engineering Materials, School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Zarei-Hanzaki, A., E-mail: zareih@ut.ac.ir [The Complex Laboratory of Hot Deformation and Thermomechanical Processing of High Performance Engineering Materials, School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Abedi, H.R. [The Complex Laboratory of Hot Deformation and Thermomechanical Processing of High Performance Engineering Materials, School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Minárik, P. [Department of Physics of Materials, Charles University, Prague (Czech Republic); Soltani, R. [School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of)

    2017-04-06

    The effects of severe plastic straining, in the course of single and multi-pass friction stir processing (FSP), on the microstructure, texture and mechanical properties of an as-extruded WE43 Magnesium alloy are addressed in the present study. The latter was explored by applying a set of 1 and 3-passes FSP trials on the experimental material. The evolved microstructures were characterized through electron backscatter diffraction analyses. The results indicated an extraordinary reduction in grain size in addition to remarkable decrease in second phase volume fraction in the light of preferred strain rate and temperature conditions. The micro-textures of processed specimens were evaluated through plotting the Schmid factor maps and its distribution. The corresponding results showed that the basal planes poles intensity was increased after each step of FSP trials. The prismatic texture analyses also indicated the randomized and weakened distributed planes. The room temperature mechanical properties of the processed materials were also measured using tensile testing technique. The optimization of the strength and ductility values was attributed to the grain refinement, dynamic dissolution of the second phase and the texture strengthening at proper thermomechanical conditions.

  14. Analysis and Comparison of Friction Stir Welding and Laser Assisted Friction Stir Welding of Aluminum Alloy.

    Science.gov (United States)

    Campanelli, Sabina Luisa; Casalino, Giuseppe; Casavola, Caterina; Moramarco, Vincenzo

    2013-12-18

    Friction Stir Welding (FSW) is a solid-state joining process; i.e. , no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force.

  15. A Brief Introduction to the Theory of Friction Stir Welding

    Science.gov (United States)

    Nunes, Arthur C., Jr.

    2008-01-01

    Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and is already an important welding process for the aerospace industry, where welds of optimal quality are demanded. The structure of welds determines weld properties. The structure of friction stir welds is determined by the flow field in the weld metal in the vicinity of the weld tool. A simple kinematic model of the FSW flow field developed at Marshall Space Flight Center, which enables the basic features of FSW microstructure to be understood and related to weld process parameters and tool design, is explained.

  16. Lateral position detection and control for friction stir systems

    Science.gov (United States)

    Fleming, Paul; Lammlein, David; Cook, George E.; Wilkes, Don Mitchell; Strauss, Alvin M.; Delapp, David; Hartman, Daniel A.

    2010-12-14

    A friction stir system for processing at least a first workpiece includes a spindle actuator coupled to a rotary tool comprising a rotating member for contacting and processing the first workpiece. A detection system is provided for obtaining information related to a lateral alignment of the rotating member. The detection system comprises at least one sensor for measuring a force experienced by the rotary tool or a parameter related to the force experienced by the rotary tool during processing, wherein the sensor provides sensor signals. A signal processing system is coupled to receive and analyze the sensor signals and determine a lateral alignment of the rotating member relative to a selected lateral position, a selected path, or a direction to decrease a lateral distance relative to the selected lateral position or selected path. In one embodiment, the friction stir system can be embodied as a closed loop tracking system, such as a robot-based tracked friction stir welding (FSW) or friction stir processing (FSP) system.

  17. The Role of Friction Stir Processing (FSP Parameters on TiC Reinforced Surface Al7075-T651 Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    Felipe García-Vázquez

    Full Text Available Abstract: Aluminum alloys are very promising for structural applications in aerospace, military and transportation industries due to their light weight, high strength-to-weight ratio and excellent resistance to corrosion. In comparison to unreinforced aluminum alloys, aluminum/aluminum alloy matrix composites reinforced with ceramic phases exhibit higher strength and hardness, improved tribological characteristics. A novel surface modifying technique, friction stir processing (FSP, has been developed for fabrication of surface composite with an improved performance. The effect of FSP parameters such as number of passes, direction of each pass, sealed or unsealed groove on microstructure was investigated. In this work, nano-particles of TiC (2% in weight were added to aluminum alloy AA7075-T651 to produce a functional surface. Fixed parameters for this AA7075 alloy were used; rotation speed of 1000 rpm, travel speed of 300 mm/min and pin penetration of 2.8 mm. Optical microscopy (OM, scanning electron microscopy (SEM and atomic force microscopy (AFM were employed to study the microstructure of the fabricated surface composites. The results indicated that the selected FSP parameters influenced the area of surface composite, distribution of TiC particles and micro-hardness of the surface composites. Finally, in order to evaluate rate wear the pin on disk test was carried out.

  18. Multi-Objective Optimization of Friction Stir Welding Process Parameters of AA6061-T6 and AA7075-T6 Using a Biogeography Based Optimization Algorithm

    Directory of Open Access Journals (Sweden)

    Mehran Tamjidy

    2017-05-01

    Full Text Available The development of Friction Stir Welding (FSW has provided an alternative approach for producing high-quality welds, in a fast and reliable manner. This study focuses on the mechanical properties of the dissimilar friction stir welding of AA6061-T6 and AA7075-T6 aluminum alloys. The FSW process parameters such as tool rotational speed, tool traverse speed, tilt angle, and tool offset influence the mechanical properties of the friction stir welded joints significantly. A mathematical regression model is developed to determine the empirical relationship between the FSW process parameters and mechanical properties, and the results are validated. In order to obtain the optimal values of process parameters that simultaneously optimize the ultimate tensile strength, elongation, and minimum hardness in the heat affected zone (HAZ, a metaheuristic, multi objective algorithm based on biogeography based optimization is proposed. The Pareto optimal frontiers for triple and dual objective functions are obtained and the best optimal solution is selected through using two different decision making techniques, technique for order of preference by similarity to ideal solution (TOPSIS and Shannon’s entropy.

  19. Multi-Objective Optimization of Friction Stir Welding Process Parameters of AA6061-T6 and AA7075-T6 Using a Biogeography Based Optimization Algorithm.

    Science.gov (United States)

    Tamjidy, Mehran; Baharudin, B T Hang Tuah; Paslar, Shahla; Matori, Khamirul Amin; Sulaiman, Shamsuddin; Fadaeifard, Firouz

    2017-05-15

    The development of Friction Stir Welding (FSW) has provided an alternative approach for producing high-quality welds, in a fast and reliable manner. This study focuses on the mechanical properties of the dissimilar friction stir welding of AA6061-T6 and AA7075-T6 aluminum alloys. The FSW process parameters such as tool rotational speed, tool traverse speed, tilt angle, and tool offset influence the mechanical properties of the friction stir welded joints significantly. A mathematical regression model is developed to determine the empirical relationship between the FSW process parameters and mechanical properties, and the results are validated. In order to obtain the optimal values of process parameters that simultaneously optimize the ultimate tensile strength, elongation, and minimum hardness in the heat affected zone (HAZ), a metaheuristic, multi objective algorithm based on biogeography based optimization is proposed. The Pareto optimal frontiers for triple and dual objective functions are obtained and the best optimal solution is selected through using two different decision making techniques, technique for order of preference by similarity to ideal solution (TOPSIS) and Shannon's entropy.

  20. Fabrication of Al/Graphite/Al2O3 Surface Hybrid Nano Composite by Friction Stir Processing and Investigating The Wear and Microstructural Properties of The Composite

    Directory of Open Access Journals (Sweden)

    A. Mostafapour

    2012-10-01

    Full Text Available Friction stir processing was applied for fabricating an aluminum alloy based hybrid nano composite reinforced with nano sized Al2O3 and micro sized graphite particles. A mixture of Al2O3 and graphite particles was packed into a groove with 1 mm width and 4.5 mm depth, which had been cut in 5083 aluminum plate of 10 mm thick. Packed groove was subjected to friction stir processing in order to implement powder mixture into the aluminum alloy matrix. Microstructural properties were investigated by means of optical microscopy and scanning electron microscopy (SEM. It was found that reinforcement particle mixture was distributed uniformly in nugget zone. Wear resistance of composite was measured by dry sliding wear test. As a result, hybrid composite revealed significant reduction in wear rate in comparison with Al/AL2O3 composite produced by friction stir processing. Worn surface of the wear test samples were examined by SEM in order to determine wear mechanism.

  1. Enhanced mechanical properties of tungsten inert gas welded AZ31 magnesium alloy joint using two-pass friction stir processing with rapid cooling

    Energy Technology Data Exchange (ETDEWEB)

    Xu, Nan, E-mail: xunan@hhu.edu.cn; Bao, Yefeng

    2016-02-08

    In this study, tungsten inert gas (TIG) welded AZ31 magnesium alloy joint was subjected to two-pass rapid cooling friction stir processing (RC-FSP). The main results show that, two-pass RC-FSP causes the significant dissolution of the coarse eutectic β-Mg{sub 17}Al{sub 12} phase into the magnesium matrix and the remarkable grain refinement in the stir zone. The low-hardness region which frequently located at heat-affected zone was eliminated. The stir zone showed ultrafine grains of 3.1 μm, and exhibited a good combination of ultrahigh tensile strength of 284 MPa and large elongation of 7.1%. This work provides an effective strategy to enhance the strength of TIG welded magnesium alloy joint without ductility loss.

  2. Enhanced mechanical properties of tungsten inert gas welded AZ31 magnesium alloy joint using two-pass friction stir processing with rapid cooling

    International Nuclear Information System (INIS)

    Xu, Nan; Bao, Yefeng

    2016-01-01

    In this study, tungsten inert gas (TIG) welded AZ31 magnesium alloy joint was subjected to two-pass rapid cooling friction stir processing (RC-FSP). The main results show that, two-pass RC-FSP causes the significant dissolution of the coarse eutectic β-Mg_1_7Al_1_2 phase into the magnesium matrix and the remarkable grain refinement in the stir zone. The low-hardness region which frequently located at heat-affected zone was eliminated. The stir zone showed ultrafine grains of 3.1 μm, and exhibited a good combination of ultrahigh tensile strength of 284 MPa and large elongation of 7.1%. This work provides an effective strategy to enhance the strength of TIG welded magnesium alloy joint without ductility loss.

  3. Fatigue and Damage Tolerance of Friction Stir Welded Joints for Aerospace Applications

    NARCIS (Netherlands)

    Lemmen, H.J.K.

    2010-01-01

    Friction stir welding is a young welding process with high potential to replace riveted joints in aerospace structures like the fuselage. Friction stir welding is a robust process and capable of welding high strength aluminum alloys. Therefore it can lead to both costs and weight savings. To

  4. Thermal modelling of friction stir welding

    DEFF Research Database (Denmark)

    Schmidt, Henrik Nikolaj Blicher; Hattel, Jesper Henri

    2008-01-01

    The objective of the present work is to present the basic elements of the thermal modelling of friction stir welding as well as to clarify some of the uncertainties in the literature regarding the different contributions to the heat generation. Some results from a new thermal pseudomechanical model...... in which the temperature-dependent yield stress of the weld material controls the heat generation are also presented....

  5. Influence of fibre distribution and grain size on the mechanical behaviour of friction stir processed Mg–C composites

    Energy Technology Data Exchange (ETDEWEB)

    Mertens, A., E-mail: anne.mertens@ulg.ac.be [Université de Liège, Faculty of Applied Science, A& M Department, Metallic Materials Science Unit (Belgium); Simar, A. [Université catholique de Louvain, Institute of Mechanics, Materials and Civil Engineering (Belgium); Adrien, J.; Maire, E. [Institut National des Sciences Appliquées de Lyon (INSA Lyon), MATEIS Laboratory (France); Montrieux, H.-M. [Université de Liège, Faculty of Applied Science, A& M Department, Metallic Materials Science Unit (Belgium); Delannay, F. [Université catholique de Louvain, Institute of Mechanics, Materials and Civil Engineering (Belgium); Lecomte-Beckers, J. [Université de Liège, Faculty of Applied Science, A& M Department, Metallic Materials Science Unit (Belgium)

    2015-09-15

    Short C fibres–Mg matrix composites have been produced by friction stir processing sandwiches made of a layer of C fabric stacked between two sheets of Mg alloy AZ31B or AZ91D. This novel processing technique can allow the easy production of large-scale metal matrix composites. The paper investigates the microstructure of FSPed C fibre–Mg composites in relation with the fragmentation of the C fibres during FSP and their influence on the tensile properties. 3D X-ray tomography reveals that the fibres orient like onion rings and are more or less fragmented depending on the local shear stress during the process. The fibre volume fraction can be increased from 2.3% to 7.1% by reducing the nugget volume, i.e. by using a higher advancing speed in AZ31B alloy or a stronger matrix alloy, like AZ91D alloy. A higher fibre volume fraction leads to a smaller grain size which brings about an increase of the composite yield strength by 15 to 25%. However, a higher fibre volume fraction also leads to a lower fracture strain. Fracture surface observations reveal that damage occurs by fibre/matrix decohesion along fibres oriented perpendicularly to the loading direction. - Graphical abstract: Display Omitted - Highlights: • C–Mg MMCs were produced by FSP sandwiches made of a C fabric between Mg sheets. • Fibre fragmentation and erosion is larger when the temperature reached during FSP is lower. • A lower advancing speed brings a lower fibre volume fraction and a lower grain size. • X-ray tomography reveals that fibres orient along the FSP material flow. • The fibres and grain size reduction increase the yield strength by 15 to 25%.

  6. Microstructural evolution in friction stir welding of nanostructured ODS alloys

    International Nuclear Information System (INIS)

    Chen, C.-L.; Tatlock, G.J.; Jones, A.R.

    2010-01-01

    Nanostructured oxide dispersion strengthened (ODS) Fe-based alloys manufactured by mechanical alloying (MA) are generally considered to be promising candidate materials for high-temperature applications up to at least 1100 o C because of their excellent creep strength and good oxidation resistance. However, a key issue with these alloys is the difficulty in using fusion welding techniques to join components due to oxide particle agglomeration and loss in the weld zone and the disruption and discontinuity in the grain structure introduced at the bond. In this study, the evolution of microstructure has been comprehensively studied in friction stir welds in a ferritic ODS alloy. Initially, electron backscattering diffraction (EBSD) was used to analyze the grain orientation, the grain boundary geometries and recrystallization behaviour. It suggested that deformation heterogeneities were introduced during the friction stirring process which facilitated the onset of recrystallization. Transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM) were used to observe the effects of the friction stir welding (FSW) process on the grain structure and the distribution of Y 2 O 3 and other particles in the metal substrates in the FSW and adjacent regions, after the alloys had been recrystallized at temperatures up to 1380 o C for 1 h in air. The results show that fine-equiaxed grains and a uniform distribution of oxide particles were present in the friction stirred region but that the grain boundaries in the parent metal were pinned by particles. Friction stirring appeared to release these boundaries and allowed secondary recrystallization to occur after further heat treatment. The FSW process appears to be a promising technique for joining ferritic ODS alloys in the form of sheet and tube.

  7. Recent developments in Micro Friction Stir Welding: A review

    International Nuclear Information System (INIS)

    Sithole, Keydon; Rao, Veeredhi Vasudeva

    2016-01-01

    The advent of friction stir welding (FSW) in 1991 has been evolutionary in the joining of metals and related materials. Friction stir welding has enabled the joining of metals that could not be joined by other welding processes. Research has shown that dissimilar materials with very different properties, plastics, composites and even wood can be joined by FSW. Recent activities in the application of FSW has seen the development of micro friction stir welding (μFSW), which is the FSW of very thin sections of thickness 1000 μm (1 mm) or less. Micro friction stir welding further extends the applications of FSW to areas such as copper electrical contacts, tailor-welded blanks, wood. Though μFSW is relatively new development significant work has been done to date with interesting research findings being reported. This paper aims to review developments in μFSW to date. The focus of the paper will be on problems peculiar to μFSW due to downscaling to the micro scale and other practical considerations. (paper)

  8. Hybrid friction stir welding for dissimilar materials through electro-plastic effect

    Science.gov (United States)

    Liu, Xun; Lan, Shuhuai; Ni, Jun

    2018-05-29

    A hybrid Friction Stir Welding approach and device for dissimilar materials joining employing Electro-Plastic Effect. The approach and device include an introduction of high density, short period current pulses into traditional friction stir welding process, which therefore can generate a localized softened zone in the workpiece during plastic stirring without significant additional temperature increase. This material softened zone is created by high density current pulses based on Electro-Plastic Effect and will move along with the friction stir welding tool. Smaller downward force, larger processing window and better joint quality for dissimilar materials are expected to be achieved through this hybrid welding technique.

  9. Fabrication and characterization of functionally graded Al–SiC nanocomposite by using a novel multistep friction stir processing

    International Nuclear Information System (INIS)

    Salehi, Mojtaba; Farnoush, Hamidreza; Mohandesi, Jamshid Aghazadeh

    2014-01-01

    Highlights: • A novel multistep FSP to fabricate functionally-graded bulk nanocomposites. • The composition of FG sample was changed from 18 to 0 wt% SiC along five layers. • The 3.2 times higher hardness than the base metal in FG sample along the thickness. • The 15% enhancement in hardness of FG sample with respect to homogenous sample. • Microhardness and inverse of interparticle spacing was correlated linearly. - Abstract: Functionally graded materials are one of the most promising candidates among advanced materials. However, some challenges still exist in its fabrication methods. The current study aims to produce functionally-graded bulk Al–SiC nanocomposites by a novel multistep friction stir processing (FSP) for the first time. The SiC nanoparticles were packed into a groove on the 6061 aluminum plate and FSP was performed by using a tool with pin length of 6 mm. Subsequently, FSP was reapplied on another groove by using a tool with a shorter pin length of 3.2 mm. The desirable distribution of SiC nanoparticles in the matrix was confirmed by scanning electron and atomic force microscopes. The composition of graded sample was changed continuously from 18 to 0 wt% SiC along the thickness. Accordingly, the microhardness profile showed a maximum of 160 Hv in the enriched zone which is 3.2 times higher than the hardness of the particle-depleted zone. However, a constant hardness value of 135 Hv was obtained along the thickness of homogenous sample which is 15% lower than that of superficial layer in graded sample. Moreover, the hardness values were linearly correlated with the inverse of interparticle spacing

  10. The Plunge Phase of Friction Stir Welding

    Science.gov (United States)

    McClure, John C.

    2005-01-01

    The many advantages of Friction Stir Welding have led to a relatively rapid acceptance in the often conservative welding community. Because the process is so different from traditional fusion welding, with which most investigators are most familiar, there remain many aspects of FSW for which there is no clear consensus. For example, the well known onion rings seen in transverse sections have been variously interpreted as grain size variations, variation in density of second phase particles and parts of the carousel of material rotating with the pin that have been shed from the carousel. Using Orientation Imaging Microscopy, Schneider has recently noted that the onion rings have a different orientation (and hence etch differently) than the surrounding material, and this orientation is consistent with slip plane orientations at the edge of the carousel. Likewise, the forces and torque exerted by the FSW tool on the work piece largely remain unaccounted for. Although these forces are routinely measured by investigators with commercial instrumented welders, they are rarely reported or even qualitatively analyzed. This paper will introduce a model based on a carousel or disk of material that rotates with the tool to estimate the torque and plunge force required to plunge a tool into the work piece. A stationary tool is modeled rather than the moving tool because effects such as thermal transients and metallurgical changes in the sample (primarily aging in aluminum) can be more easily accounted for. It is believed, however, that with some modifications the model should be applicable to a moving tool also.

  11. Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology

    Energy Technology Data Exchange (ETDEWEB)

    Hovanski, Yuri; Upadyay, Piyush; Kleinbaum, Sarah; Carlson, Blair; Boettcher, Eric; Ruokolainen, Robert

    2017-04-05

    One challenge in adapting welding processes to dissimilar material joining is the diversity of melting temperatures of the different materials. Although the use of mechanical fasteners and adhesives have mostly paved the way for near-term implementation of dissimilar material systems, these processes only accentuate the need for low-cost welding processes capable of joining dissimilar material components regardless of alloy, properties, or melting temperature. Friction stir scribe technology was developed to overcome the challenges of joining dissimilar material components where melting temperatures vary greatly, and properties and/or chemistry are not compatible with more traditional welding processes. Although the friction stir scribe process is capable of joining dissimilar metals and metal/polymer systems, a more detailed evaluation of several aluminum/steel joints is presented herein to demonstrate the ability to both chemically and mechanically join dissimilar materials.

  12. Friction stir welding of Aluminium matrix composites – A Review

    Directory of Open Access Journals (Sweden)

    Subramanya Prabhu

    2018-01-01

    Full Text Available Friction stir welding (FSW is established as one of the prominent welding techniques to join aluminium matrix composites (AMCs. It is a solid state welding process, takes place well below the melting temperature of the material, eliminates the detrimental effects of conventional fusion welding process. Although the process is capable to join AMCs, challenges are still open that need to be fulfill to widen its applications. This paper gives the outline of the friction stir welding technique used to join AMCs. Effect of process variables on the microstructure and mechanical properties of the joints, behavior of reinforcing materials during welding, effect of tool profiles on the joint strength are discussed in detail. Few improvements and direction for future research are also proposed.

  13. A sustainable solid state recycling of pure aluminum by means of friction stir extrusion process (FSE)

    Science.gov (United States)

    Mehtedi, Mohamad El; Forcellese, Archimede; Simoncini, Michela; Spigarelli, Stefano

    2018-05-01

    In this research, the feasibility of solid-state recycling of pure aluminum AA1099 machining chips using FSE process is investigated. In the early stage, a FE simulation was conducted in order to optimize the die design and the process parameters in terms of plunge rotational speed and extrusion rate. The AA1099 aluminum chips were produced by turning of an as-received bar without lubrication. The chips were compacted on a MTS machine up to 150KN of load. The extruded samples were analyzed by optical and electron microscope in order to see the material flow and to characterize the microstructure. Finally, micro-hardness Vickers profiles were carried out, in both longitudinal and transversal direction of the obtained profiles, in order to investigate the homogeneity of the mechanical properties of the extrudate.

  14. Versatile Friction Stir Welding/Friction Plug Welding System

    Science.gov (United States)

    Carter, Robert

    2006-01-01

    A proposed system of tooling, machinery, and control equipment would be capable of performing any of several friction stir welding (FSW) and friction plug welding (FPW) operations. These operations would include the following: Basic FSW; FSW with automated manipulation of the length of the pin tool in real time [the so-called auto-adjustable pin-tool (APT) capability]; Self-reacting FSW (SRFSW); SR-FSW with APT capability and/or real-time adjustment of the distance between the front and back shoulders; and Friction plug welding (FPW) [more specifically, friction push plug welding] or friction pull plug welding (FPPW) to close out the keyhole of, or to repair, an FSW or SR-FSW weld. Prior FSW and FPW systems have been capable of performing one or two of these operations, but none has thus far been capable of performing all of them. The proposed system would include a common tool that would have APT capability for both basic FSW and SR-FSW. Such a tool was described in Tool for Two Types of Friction Stir Welding (MFS- 31647-1), NASA Tech Briefs, Vol. 30, No. 10 (October 2006), page 70. Going beyond what was reported in the cited previous article, the common tool could be used in conjunction with a plug welding head to perform FPW or FPPW. Alternatively, the plug welding head could be integrated, along with the common tool, into a FSW head that would be capable of all of the aforementioned FSW and FPW operations. Any FSW or FPW operation could be performed under any combination of position and/or force control.

  15. Development of empirical relationships for prediction of mechanical and wear properties of AA6082 aluminum matrix composites produced using friction stir processing

    Directory of Open Access Journals (Sweden)

    I. Dinaharan

    2016-09-01

    Full Text Available Friction Stir Processing (FSP has been established as a potential solid state production method to prepare aluminum matrix composites (AMCs. FSP was effectively applied to produce AA6082 AMCs reinforced with various ceramic particles such as SiC, Al2O3, TiC, B4C and WC in this work. Empirical relationships were estimated to predict the influence of FSP process parameters on the properties such as area of stir zone, microhardness and wear rate of AMCs. FSP experiments were executed using a central composite rotatable design consisting of four factors and five levels. The FSP parameters analyzed were tool rotational speed, traverse speed, groove width and type of ceramic particle. The effect of those parameters on the properties of AMCs was deduced using the developed empirical relationships. The predicted trends were explained with the aid of observed macro and microstructures.

  16. Friction stir welding of single crystal aluminium

    DEFF Research Database (Denmark)

    Fonda, Richard Warren; Wert, John A.; Reynolds, A.P.

    2007-01-01

    Friction stir welds were prepared in different orientations in an aluminium single crystal. The welds were quenched to preserve the microstructure surrounding the tool and then electron backscattered diffraction was used to reveal the generation of grain boundaries and the evolution...... of crystallographic texture around the tool in each weld. The extent of both dynamic recrystallisation and conventional recrystallisation varied considerably as a function of weld orientation. As the base plate begins to interact with the deformation field surrounding the tool, regions of the single crystal rotate...

  17. Effects of processing parameters on the friction stir spot joining of Al5083-O aluminum alloy to DP590 steel

    Science.gov (United States)

    Sung, Back-Sub; Bang, Hee-Seon; Jeong, Su-Ok; Choi, Woo-Seong; Kwon, Yong-Hyuk; Bang, Han-Sur

    2017-05-01

    Two dissimilar materials, aluminum alloy Al5083-O and advanced high strength steel DP590, were successfully joined by using friction stir spot joining (FSSJ). Satisfactory joint strengths were obtained at a rotational speed of 300 rpm and a plunge depth of 0.7 mm. Resulting joints were welded without a non-welded zone. This may be attributed to the enhanced smooth material flow owing to sufficient stirring effect and tool down force between the upper Al5083-O side and the lower DP590 side. The maximum tensile shear strength was 6.5 kN, which was higher than the joint strength required by the conventional method of resistance spot welding. The main fracture mode was plug fracture in the tensile shear test of joints. An intermetallic compound (IMC) layer with material Al-Fe joints. Thus, the use of FSSJ to weld the dissimilar materials Al5083-O and DP590 resulted in mechanically and metallurgically sound joints.

  18. Modelling of the temperature field that accompanies friction stir welding

    Directory of Open Access Journals (Sweden)

    Nosal Przemysław

    2017-01-01

    Full Text Available The thermal modelling of the Friction Stir Welding process allows for better recognition and understanding of phenomena occurring during the joining process of different materials. It is of particular importance considering the possibilities of process technology parameters, optimization and the mechanical properties of the joint. This work demonstrates the numerical modelling of temperature distribution accompanying the process of friction stir welding. The axisymmetric problem described by Fourier’s type equation with internal heat source is considered. In order to solve the diffusive initial value problem a fully implicit scheme of the finite difference method is applied. The example under consideration deals with the friction stir welding of a plate (0.7 cm thick made of Al 6082-T6 by use of a tool made of tungsten alloy, whereas the material subjected to welding was TiC powder. Obtained results confirm both quantitatively and qualitatively experimental observations that the superior temperature corresponds to the zone where the pin joints the shoulder.

  19. Certification of a weld produced by friction stir welding

    Science.gov (United States)

    Obaditch, Chris; Grant, Glenn J

    2013-10-01

    Methods, devices, and systems for providing certification of friction stir welds are disclosed. A sensor is used to collect information related to a friction stir weld. Data from the sensor is compared to threshold values provided by an extrinsic standard setting organizations using a certification engine. The certification engine subsequently produces a report on the certification status of the weld.

  20. α″ Martensite and Amorphous Phase Transformation Mechanism in TiNbTaZr Alloy Incorporated with TiO2 Particles During Friction Stir Processing

    Science.gov (United States)

    Ran, Ruoshi; Liu, Yiwei; Wang, Liqiang; Lu, Eryi; Xie, Lechun; Lu, Weijie; Wang, Kuaishe; Zhang, Lai-Chang

    2018-06-01

    This work studied the formation of the α″ martensite and amorphous phases of TiNbTaZr alloy incorporated with TiO2 particles during friction stir processing. Formation of the amorphous phase in the top surface mainly results from the dissolution of oxygen, rearrangement of the lattice structure, and dislocations. High-stress stemming caused by dislocations and high-stress concentrations at crystal-amorphous interfaces promote the formation of α″ martensite. Meanwhile, an α″ martensitic transformation is hindered by oxygen diffusion from TiO2 to the matrix, thereby increasing resistance to shear.

  1. The effect of texture and grain size on improving the mechanical properties of Mg-Al-Zn alloys by friction stir processing.

    Science.gov (United States)

    Peng, Jinhua; Zhang, Zhen; Liu, Zhao; Li, Yaozu; Guo, Peng; Zhou, Wei; Wu, Yucheng

    2018-03-08

    Friction stir processing (FSP) was used to achieve grain refinement on Mg-Al-Zn alloys, which also brought in significant texture modification. The different micro-texture characteristics were found to cause irregular micro-hardness distribution in FSPed region. The effects of texture and grain size were investigated by comparative analyses with strongly textured rolling sheet. Grain refinement improved both strength and elongation in condition of a basal texture while such led to an increment in yield stress and a drop in elongation and ultimate stress when the basal texture was modified by FSP.

  2. A model to describe the surface gradient-nanograin formation and property of friction stir processed laser Co-Cr-Ni-Mo alloy

    Science.gov (United States)

    Li, Ruidi; Yuan, Tiechui; Qiu, Zili

    2014-07-01

    A gradient-nanograin surface layer of Co-base alloy was prepared by friction stir processing (FSP) of laser-clad coating in this work. However, it is lack of a quantitatively function relationship between grain refinement and FSP conditions. Based on this, an analytic model is derived for the correlations between carbide size, hardness and rotary speed, layer depth during in-situ FSP of laser-clad Co-Cr-Ni-Mo alloy. The model is based on the principle of typical plastic flow in friction welding and dynamic recrystallization. The FSP experiment for modification of laser-clad Co-based alloy was conducted and its gradient nanograin and hardness were characterized. It shows that the model is consistent with experimental results.

  3. Enhancing Corrosion and Wear Resistance of AA6061 by Friction Stir Processing with Fe78Si₉B13 Glass Particles.

    Science.gov (United States)

    Guo, Lingyu; Liu, Yan; Shen, Kechang; Song, Chaoqun; Yang, Min; Kim, Kibuem; Wang, Weimin

    2015-08-07

    The AA6061-T6 aluminum alloy samples including annealed Fe 78 Si₉B 13 particles were prepared by friction stir processing (FSP) and investigated by various techniques. The Fe 78 Si₉B 13 -reinforced particles are uniformly dispersed in the aluminum alloy matrix. The XRD results indicated that the lattice parameter of α-Al increases and the preferred orientation factors F of (200) plane of α-Al reduces after friction stir processing. The coefficient of thermal expansion (CTE) for FSP samples increases at first with the temperature but then decreases as the temperature further increased, which can be explained by the dissolving of Mg and Si from β phase and Fe 78 Si₉B 13 particles. The corrosion and wear resistance of FSP samples have been improved compared with that of base metal, which can be attributed to the reduction of grain size and the CTE mismatch between the base metal and reinforced particles by FSP, and the lubrication effect of Fe 78 Si₉B 13 particles also plays a role in improving wear resistance. In particular, the FSP sample with reinforced particles in amorphous state exhibited superior corrosion and wear resistance due to the unique metastable structure.

  4. Enhancing Corrosion and Wear Resistance of AA6061 by Friction Stir Processing with Fe78Si9B13 Glass Particles

    Directory of Open Access Journals (Sweden)

    Lingyu Guo

    2015-08-01

    Full Text Available The AA6061-T6 aluminum alloy samples including annealed Fe78Si9B13 particles were prepared by friction stir processing (FSP and investigated by various techniques. The Fe78Si9B13-reinforced particles are uniformly dispersed in the aluminum alloy matrix. The XRD results indicated that the lattice parameter of α-Al increases and the preferred orientation factors F of (200 plane of α-Al reduces after friction stir processing. The coefficient of thermal expansion (CTE for FSP samples increases at first with the temperature but then decreases as the temperature further increased, which can be explained by the dissolving of Mg and Si from β phase and Fe78Si9B13 particles. The corrosion and wear resistance of FSP samples have been improved compared with that of base metal, which can be attributed to the reduction of grain size and the CTE mismatch between the base metal and reinforced particles by FSP, and the lubrication effect of Fe78Si9B13 particles also plays a role in improving wear resistance. In particular, the FSP sample with reinforced particles in amorphous state exhibited superior corrosion and wear resistance due to the unique metastable structure.

  5. Friction stir welding sets sail in China

    International Nuclear Information System (INIS)

    Luan, Guohong

    2007-01-01

    Today, Friction Stir Welding has set sail in China. As the pioneer of FSW development in the China territory, China FSW Centre hes made outstanding achievements in FSW technique development, FSW engineering, FSW equipment and FSW product. But the real industrial applications of FSW in China are just begining. With the planned national long-term development programmes and huge market requirement in aerospace, aviation, shipbuilding, railway, power and energy industries, FSW will continue to develop rapidly in the next 10 years. FSW will continue to develop rapidly in the next 10 years. FSW not only raises the level of joining techniques in Chinese industrial companies, but also increase the competitive ability of the industrial products made in china

  6. Effects of Fusion Tack Welds on Self-Reacting Friction Stir Welds

    Science.gov (United States)

    Nunes, A. C., Jr.; Pendleton, M. L.; Brooke, S. A.; Russell, C. K.

    2012-01-01

    In order to know whether fusion tack welds would affect the strength of self-reacting friction stir seam welds in 2195-T87 aluminum alloy, the fracture stresses of 144 tensile test coupons cut from 24 welded panels containing segments of friction stir welds were measured. Each of the panels was welded under unique processing conditions. A measure of the effect of the tack welds for each panel was devised. An analysis of the measures of the tack weld effect supported the hypothesis that fusion tack welds do not affect the strength of self-reacting friction stir welds to a 5% level of confidence.

  7. Some microstructural characterisations in a friction stir welded oxide dispersion strengthened ferritic steel alloy

    International Nuclear Information System (INIS)

    Legendre, F.; Poissonnet, S.; Bonnaillie, P.; Boulanger, L.; Forest, L.

    2009-01-01

    The goal of this study is to characterize microstructure of a friction stir welded oxide dispersion strengthened alloy. The welded material is constituted by two sheets of an yttria-dispersion-strengthened PM 2000 ferritic steel. Different areas of the friction stir welded product were analyzed using field emission gun secondary electron microscopy (FEG-SEM) and electron microprobe whereas nanoindentation was used to evaluate mechanical properties. The observed microstructural evolution, including distribution of the yttria dispersoids, after friction stir welding process is discussed and a correlation between the microstructure and the results of nanoindentation tests is established.

  8. Hybrid multi-response optimization of friction stir spot welds: failure ...

    Indian Academy of Sciences (India)

    O O OJO

    2018-06-08

    Jun 8, 2018 ... Friction stir spot welding; effective bonded size; failure load; expelled flash volume; hybrid multi- response ... eliminated with the application of FSSW process. Conse- ... design of experiment is generally applied in either single.

  9. Effect of process parameters on tensile strength of friction stir welding A356/C355 aluminium alloys joint

    Energy Technology Data Exchange (ETDEWEB)

    Dwivedi, Shashi Prakash [Noida Institute of Engineering and Technology, Greater Noida (Korea, Republic of)

    2014-01-15

    In the present investigation, A356/C355 aluminium alloys are welded by friction stir welding by controlling various welding parameters. A356 and C355 aluminium alloys materials have a set of mechanical and physical properties that are ideally suited for application in aerospace and automobile industries and not widely used because of its poor weldebility. To overcome this barrier, weldebility analysis of A356 and C355 aluminium alloys with high speed steel (Wc-Co) tool has been investigated. An attempt has been made to investigate the influence of the rotational speed of the tools, the axial force and welding speed on tensile strength of A356/C355 aluminium alloys joint. The experiments were conducted on a milling machine. The main focus of investigation is to determine good tensile strength. Response surface methodology (box Behnken design) is chosen to design the optimum welding parameters leading to maximum tensile strength. The result shows that axial force increases, tensile strength decreases. Whereas tool rotational speed and welding speed increase, tensile strength increases. Optimum values of axial force (3 /KN), tool rotational speed (900 RPM) and welding speed (75 mm/min.) during welding of A356/C355 aluminium alloys joint to maximize the tensile strength (Predicted 223.2 MPa) have been find out.

  10. Effect of process parameters on tensile strength of friction stir welding A356/C355 aluminium alloys joint

    International Nuclear Information System (INIS)

    Dwivedi, Shashi Prakash

    2014-01-01

    In the present investigation, A356/C355 aluminium alloys are welded by friction stir welding by controlling various welding parameters. A356 and C355 aluminium alloys materials have a set of mechanical and physical properties that are ideally suited for application in aerospace and automobile industries and not widely used because of its poor weldebility. To overcome this barrier, weldebility analysis of A356 and C355 aluminium alloys with high speed steel (Wc-Co) tool has been investigated. An attempt has been made to investigate the influence of the rotational speed of the tools, the axial force and welding speed on tensile strength of A356/C355 aluminium alloys joint. The experiments were conducted on a milling machine. The main focus of investigation is to determine good tensile strength. Response surface methodology (box Behnken design) is chosen to design the optimum welding parameters leading to maximum tensile strength. The result shows that axial force increases, tensile strength decreases. Whereas tool rotational speed and welding speed increase, tensile strength increases. Optimum values of axial force (3 /KN), tool rotational speed (900 RPM) and welding speed (75 mm/min.) during welding of A356/C355 aluminium alloys joint to maximize the tensile strength (Predicted 223.2 MPa) have been find out.

  11. Probing weld quality monitoring in friction stir welding through characterization of signals by fractal theory

    Energy Technology Data Exchange (ETDEWEB)

    Das, Bipul; Bag, Swarup; Pal, Sukhomay [Indian Institute of Technology Guwahati, Assam (India)

    2017-05-15

    Providing solutions towards the improvisation of welding technologies is the recent trend in the Friction stir welding (FSW) process. We present a monitoring approach for ultimate tensile strength of the friction stir welded joints based on information extracted from process signals through implementing fractal theory. Higuchi and Katz algorithms were executed on current and tool rotational speed signals acquired during friction stir welding to estimate fractal dimensions. Estimated fractal dimensions when correlated with the ultimate tensile strength of the joints deliver an increasing trend with the increase in joint strength. It is observed that dynamicity of the system strengthens the weld joint, i.e., the greater the fractal dimension, the better will be the quality of the weld. Characterization of signals by fractal theory indicates that the single-valued indicator can be an alternative for effective monitoring of the friction stir welding process.

  12. Probing weld quality monitoring in friction stir welding through characterization of signals by fractal theory

    International Nuclear Information System (INIS)

    Das, Bipul; Bag, Swarup; Pal, Sukhomay

    2017-01-01

    Providing solutions towards the improvisation of welding technologies is the recent trend in the Friction stir welding (FSW) process. We present a monitoring approach for ultimate tensile strength of the friction stir welded joints based on information extracted from process signals through implementing fractal theory. Higuchi and Katz algorithms were executed on current and tool rotational speed signals acquired during friction stir welding to estimate fractal dimensions. Estimated fractal dimensions when correlated with the ultimate tensile strength of the joints deliver an increasing trend with the increase in joint strength. It is observed that dynamicity of the system strengthens the weld joint, i.e., the greater the fractal dimension, the better will be the quality of the weld. Characterization of signals by fractal theory indicates that the single-valued indicator can be an alternative for effective monitoring of the friction stir welding process.

  13. Weld defect identification in friction stir welding using power spectral density

    Science.gov (United States)

    Das, Bipul; Pal, Sukhomay; Bag, Swarup

    2018-04-01

    Power spectral density estimates are powerful in extraction of useful information retained in signal. In the current research work classical periodogram and Welch periodogram algorithms are used for the estimation of power spectral density for vertical force signal and transverse force signal acquired during friction stir welding process. The estimated spectral densities reveal notable insight in identification of defects in friction stir welded samples. It was observed that higher spectral density against each process signals is a key indication in identifying the presence of possible internal defects in the welded samples. The developed methodology can offer preliminary information regarding presence of internal defects in friction stir welded samples can be best accepted as first level of safeguard in monitoring the friction stir welding process.

  14. Recent Developments and Research Progress on Friction Stir Welding of Titanium Alloys: An Overview

    Science.gov (United States)

    Karna, Sivaji; Cheepu, Muralimohan; Venkateswarulu, D.; Srikanth, V.

    2018-03-01

    Titanium and its alloys are joined by various welding processes. However, Fusion welding of titanium alloys resulted solidification problems like porosity, segregation and columnar grains. The problems occurred in conventional welding processes can be resolved using a solid state welding i.e. friction stir welding. Aluminium and Magnesium alloys were welded by friction stir welding. However alloys used for high temperature applications such as titanium alloys and steels are arduous to weld using friction stir welding process because of tool limitations. Present paper summarises the studies on joining of Titanium alloys using friction stir welding with different tool materials. Selection of tool material and effect of welding conditions on mechanical and microstructure properties of weldments were also reported. Major advantage with friction stir welding is, we can control the welding temperature above or below β-transus temperature by optimizing the process parameters. Stir zone in below beta transus condition consists of bi-modal microstructure and microstructure in above β-transus condition has large prior β- grains and α/β laths present in the grain. Welding experiments conducted below β- transus condition has better mechanical properties than welding at above β-transus condition. Hardness and tensile properties of weldments are correlated with the stir zone microstructure.

  15. Thermal Stir Welding: A New Solid State Welding Process

    Science.gov (United States)

    Ding, R. Jeffrey

    2003-01-01

    Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.

  16. Torque Control of Friction Stir Welding, Phase I

    Data.gov (United States)

    National Aeronautics and Space Administration — Longhurst Engineering, PLC and Vanderbilt University propose the innovation of torque control of friction stir welding (FSW) as a replacement to force control of...

  17. In-Space Friction Stir Welding Machine, Phase I

    Data.gov (United States)

    National Aeronautics and Space Administration — Longhurst Engineering, PLC, and Vanderbilt University propose an in-space friction stir welding (FSW) machine for joining complex structural aluminum components. The...

  18. Controlling Force and Depth in Friction Stir Welding

    Science.gov (United States)

    Adams, Glynn; Loftus, Zachary; McCormac, Nathan; Venable, Richard

    2005-01-01

    Feedback control of the penetration force applied to a pin tool in friction stir welding has been found to be a robust and reliable means for controlling the depth of penetration of the tool. This discovery has made it possible to simplify depth control and to weld with greater repeatability, even on workpieces with long weld joints. Prior to this discovery, depths of penetration in friction stir welding were controlled by hard-tooled roller assemblies or by depth actuators controlled by feedback from such external sensors as linear variable-differential transformers or laser-based devices. These means of control are limited: A hard-tooled roller assembly confines a pin tool to a preset depth that cannot be changed easily during the welding process. A measurement by an external sensor is only an indirect indicative of the depth of penetration, and computations to correlate such a measurement with a depth of penetration are vulnerable to error. The present force-feedback approach exploits the proportionality between the depth and the force of penetration Unlike a depth measurement taken by an external sensor, a force measurement can be direct because it can be taken by a sensor coupled directly to the pin tool. The reading can be processed through a modern electronic servo control system to control an actuator to keep the applied penetration force at the desired level. In comparison with the older depth-control methods described above, this method offers greater sensitivity to plasticizing of the workpiece metal and is less sensitive to process noise, resulting in a more consistent process. In an experiment, a tapered panel was friction stir welded while controlling the force of penetration according to this method. The figure is a plot of measurements taken during the experiment, showing that force was controlled with a variation of 200 lb (890 N), resulting in control of the depth of penetration with a variation of 0.004 in. (0.1 mm).

  19. Microstructures and mechanical properties of Al/Al2O3 surface nano-composite layer produced by friction stir processing

    International Nuclear Information System (INIS)

    Shafiei-Zarghani, A.; Kashani-Bozorg, S.F.; Zarei-Hanzaki, A.

    2009-01-01

    In this study, a new processing technique, friction stir processing (FSP) was attempted to incorporate nano-sized Al 2 O 3 into 6082 aluminum alloy to form particulate composite surface layer. Samples were subjected to various numbers of FSP passes from one to four, with and without Al 2 O 3 powder. Microstructural observations were carried out by employing optical and scanning electron microscopy (SEM) of the cross sections both parallel and perpendicular to the tool traverse direction. Mechanical properties include microhardness and wear resistance, were evaluated in detail. The results show that the increasing in number of FSP passes causes a more uniform in distribution of nano-sized alumina particles. The microhardness of the surface improves by three times as compared to that of the as-received Al alloy. A significant improvement in wear resistance in the nano-composite surfaced Al is observed as compared to the as-received Al

  20. Microstructural Characterization of Friction Stir Welded Aluminum-Steel Joints

    Science.gov (United States)

    2013-08-01

    Sterling, R.J. Steel, C.-O. Pettersson. “Microstructure and mechanical properties of friction stir welded SAF 2507 super duplex stainless steel.” Mater...MICROSTRUCTURAL CHARACTERIZATION OF FRICTION STIR WELDED ALUMINUM-STEEL JOINTS By ERIN ELIZABETH PATTERSON A thesis submitted in...for his work producing the dissimilar weld samples used in this study. Without his work, this project would not have been possible. I would also

  1. Multiaxial fatigue of aluminium friction stir welded joints: preliminary results

    Directory of Open Access Journals (Sweden)

    D. G. Hattingh

    2015-07-01

    Full Text Available The aim of the present research is to check the accuracy of the Modified Wöhler Curve Method (MWCM in estimating the fatigue strength of friction stir (FS welded tubular joints of Al 6082-T6 subjected to in-phase and out-of-phase multiaxial fatigue loading. The welded samples being investigated were manufactured by equipping an MTS I-STIR process development system with a retracting tool that was specifically designed and optimised for this purpose. These specimens were tested under proportional and non-proportional tension and torsion, the effect of non-zero mean stresses being also investigated. The validation exercise carried out by using the generated experimental results allowed us to prove that the MWCM (applied in terms of nominal stresses is highly accurate in predicting the fatigue strength of the tested FS welded joints, its usage resulting in estimates falling with the uniaxial and torsional calibration scatter bands.

  2. Influence of CNTs decomposition during reactive friction-stir processing of an Al-Mg alloy on the correlation between microstructural characteristics and microtextural components.

    Science.gov (United States)

    Khodabakhshi, F; Nosko, M; Gerlich, A P

    2018-05-03

    Multipass friction-stir processing was employed to uniformly disperse multiwalled carbon nanotubes (MW-CNTs) within an Al-Mg alloy metal matrix. Decomposition of MW-CNTs occurs in situ as a result of solid-state chemical reactions, forming fullerene (C60) and aluminium carbide (Al 4 C 3 ) phases during reactive high temperature severe plastic processing. The effects of this decomposition on the microstructural features, dynamic restoration mechanisms and crystallographic microtextural developments are studied for the first time by using electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) analysis. The formation of an equiaxed grain structure with an average size of ∼1.5 μm occurs within the stirred zone (SZ) under the influence of inclusions which hinder grain boundary migration via Zener-Smith pinning mechanisms during the discontinuous dynamic recrystallisation (DDRX). Formation of two strong Cubic and Brass microtextural components in the heat affected zone (HAZ) and thermomechanical affected zone (TMAZ) was noted as compared to the completely random and Cube components found in the base and SZ regions, respectively. The microstructural modification led to hardening and tensile strength improvement for the processed nanocomposite by ∼55% and 110%, respectively with respect to the annealed Al-Mg base alloy. © 2018 The Authors Journal of Microscopy © 2018 Royal Microscopical Society.

  3. The Role of Friction Stir Welding in Nuclear Fuel Plate Fabrication

    International Nuclear Information System (INIS)

    Burkes, D.; Medvedev, P.; Chapple, M.; Amritkar, A.; Wells, P.; Charit, I

    2009-01-01

    The friction bonding process combines desirable attributes of both friction stir welding and friction stir processing. The development of the process is spurred on by the need to fabricate thin, high density, reduced enrichment fuel plates for nuclear research reactors. The work seeks to convert research and test reactors currently operating on highly enriched uranium fuel to operate on low enriched uranium fuel without significant loss in reactor performance, safety characteristics, or significant increase in cost. In doing so, the threat of global nuclear material proliferation will be reduced. Feasibility studies performed on the process show that this is a viable option for mass production of plate-type nuclear fuel. Adapting the friction stir weld process for nuclear fuel fabrication has resulted in the development of several unique ideas and observations. Preliminary results of this adaptation and process model development are discussed

  4. Inspecting Friction Stir Welding using Electromagnetic Probes

    Science.gov (United States)

    Kinchen, David G.

    2004-01-01

    A report describes the use of advanced electromagnetic probes to measure the dimensions, the spatial distribution of electrical conductivity, and related other properties of friction stir welds (FSWs) between parts made of the same or different aluminum alloy(s). The probes are of the type described in in another Tech Brief. To recapitulate: A probe of this type is essentially an eddy-current probe that includes a primary (driver) winding that meanders and multiple secondary (sensing) windings that meander along the primary winding. Electrical conductivity is commonly used as a measure of heat treatment and tempering of aluminum alloys, but prior to the development of these probes, the inadequate sensitivity and limited accuracy of electrical-conductivity probes precluded such use on FSWs between different aluminum alloys, and the resolution of those probes was inadequate for measurement of FSW dimensions with positions and metallurgical properties. In contrast, the present probes afford adequate accuracy and spatial resolution for the purposes of measuring the dimensions of FSW welds and correlating spatially varying electrical conductivities with metallurgical properties, including surface defects.

  5. Achieving excellent thermal stability and very high activation energy in an ultrafine-grained magnesium silver rare earth alloy prepared by friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Khan MD, F. [Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai 600036 (India); Panigrahi, S.K., E-mail: skpanigrahi@iitm.ac.in [Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai 600036 (India)

    2016-10-15

    Ultrafine-grained microstructure of a QE22 alloy prepared by Friction Stir processing (FSP) is isochronally annealed to study the thermal stability and grain growth kinetics. The FSPed microstructure of QE22 alloy is thermally stable under ultrafine-grained regime up to 300 °C and the activation energy required for grain growth is found to be exceptionally high as compared to conventional ultrafine-grained magnesium alloys. The high thermal stability and activation energy of the FSPed QE22 alloy is due to Zener pinning effect from thermally stable eutectic Mg{sub 12}Nd and fine precipitates Mg{sub 12}Nd{sub 2}Ag and solute drag effect from segregation of Neodymium (Nd) solute atoms at grain boundaries.

  6. Stir zone microstructure of commercial purity titanium friction stir welded using pcBN tool

    International Nuclear Information System (INIS)

    Zhang Yu; Sato, Yutaka S.; Kokawa, Hiroyuki; Park, Seung Hwan C.; Hirano, Satoshi

    2008-01-01

    In the present study, friction stir welding was applied to commercial purity titanium using a polycrystalline cubic boron nitride tool, and microstructure and hardness in the weld were examined. Additionally, the microstructural evolution during friction stir welding was also discussed. The stir zone consisted of fine equiaxed α grains surrounded by serrate grain boundaries, which were produced through the β → α allotropic transformation during the cooling cycle of friction stir welding. The fine α grains caused higher hardness than that in the base material. A lath-shaped α grain structure containing Ti borides and tool debris was observed in the surface region of the stir zone, whose hardness was the highest in the weld

  7. Improving friction stir welding of blanks of different thicknesses

    Energy Technology Data Exchange (ETDEWEB)

    Fratini, L. [Dipartimento di Tecnologia Meccanica, Produzione e Ingegneria Gestionale, Universita di Palermo, Viale delle Scienze, 90128 Palermo (Italy)], E-mail: abaqus@dtpm.unipa.it; Buffa, G. [Dipartimento di Tecnologia Meccanica, Produzione e Ingegneria Gestionale, Universita di Palermo, Viale delle Scienze, 90128 Palermo (Italy); Shivpuri, R. [Ohio State University, Department of Industrial, Welding and Systems Engineering, 1971 Neil Avenue, 210 Baker Systems, Columbus, Ohio 43210 (United States)

    2007-06-25

    Friction stir welding (FSW) appears to be a promising process even in the welding of blanks of different thicknesses. Actually, such particular tailor welded blanks (TWBs) are usually characterized by a reduction in ductility due to the utilized fusion welding process. In this paper the authors, starting from a preliminary feasibility study, investigate the possibility to improve the mechanical performances of friction stir welded blanks of aluminum alloy with different thicknesses. Both experiments and a FE analyses are developed for a few case studies with different thickness ratios between the blanks. The numerical investigations are performed with the aim to highlight the material temperature distribution during the process in order to determine process conditions for which an almost symmetric thermal flow is obtained in the two blanks of the joint. In this way, a few simple process design rules are derived and verified through experiments. In particular a thickness ratio up to 2 was considered and a joint resistance of about the 80% of the parent material ultimate tensile strength was observed.

  8. Improving friction stir welding of blanks of different thicknesses

    International Nuclear Information System (INIS)

    Fratini, L.; Buffa, G.; Shivpuri, R.

    2007-01-01

    Friction stir welding (FSW) appears to be a promising process even in the welding of blanks of different thicknesses. Actually, such particular tailor welded blanks (TWBs) are usually characterized by a reduction in ductility due to the utilized fusion welding process. In this paper the authors, starting from a preliminary feasibility study, investigate the possibility to improve the mechanical performances of friction stir welded blanks of aluminum alloy with different thicknesses. Both experiments and a FE analyses are developed for a few case studies with different thickness ratios between the blanks. The numerical investigations are performed with the aim to highlight the material temperature distribution during the process in order to determine process conditions for which an almost symmetric thermal flow is obtained in the two blanks of the joint. In this way, a few simple process design rules are derived and verified through experiments. In particular a thickness ratio up to 2 was considered and a joint resistance of about the 80% of the parent material ultimate tensile strength was observed

  9. Metal Cutting Theory and Friction Stir Welding Tool Design

    Science.gov (United States)

    Payton, Lewis N.

    2003-01-01

    Friction Stir Welding (FSW) is a relatively new industrial process that was invented at The Weld Institute (TWI, United Kingdom) and patented in 1992 under research funded by in part by the National Aeronautics and Space Administration (NASA). Often quoted advantages of the process include good strength and ductility along with minimization of residual stress and distortion. Less well advertised are the beneficial effects of this solid state welding process in the field of occupational and environmental safety. It produces superior weld products in difficult to weld materials without producing any toxic fumes or solid waste that must be controlled as hazardous waste. In fact, it reduces noise pollution in the workspace as well. In the early days of FSW, most welding was performed on modified machine tools, in particular on milling machines with modified milling cutters. In spite of the obvious milling heritage of the process, the techniques and lessons learned from almost 250 years of successful metalworking with milling machines have not been applied in the field of modern Friction Stir Welding. The goal of the current research was to study currently successful FSW tools and parameterize the process in such a way that the design of new tools for new materials could be accelerated. Along the way, several successful new tooling designs were developed for current issues at the Marshall Space Flight Center with accompanying patent disclosures

  10. Investigation on the effect of Friction Stir Processing Parameters on Micro-structure and Micro-hardness of Rice Husk Ash reinforced Al6061 Metal Matrix Composites

    Science.gov (United States)

    Fatchurrohman, N.; Farhana, N.; Marini, C. D.

    2018-03-01

    Friction stir processing (FSP) is an alternative way to produce the surface composites of aluminium alloy in order to modify the microstructure and improve the mechanical properties. In this experiment, Al6061 aluminium alloy has been chosen to be used as the matrix base plate for the FSP. Al606 has potential for the use in advanced application but it has low wear resistance. While, the reinforced used was rice husk ash (RHA) in order to produce surface composites which increased the micro hardness of the plate composites. The Al6061 was stirred individually and with 5 weight % of RHA at three different tool rotational speeds of 800 rpm, 1000 rpm and 1200 rpm. After running the FSP, the result in the distribution of particles and the micro hardness of the specimens were identified. The result showed that Al6061 plate with the existing 5 weight % of RHA reinforced at the highest of tool rotational speeds of 1200rpm has the best distribution of particles and the highest result in average of micro hardness with 80Hv.

  11. Mechanism for Self-Reacted Friction Stir Welding

    Science.gov (United States)

    Venable, Richard; Bucher, Joseph

    2004-01-01

    A mechanism has been designed to apply the loads (the stirring and the resection forces and torques) in self-reacted friction stir welding. This mechanism differs somewhat from mechanisms used in conventional friction stir welding, as described below. The tooling needed to apply the large reaction loads in conventional friction stir welding can be complex. Self-reacted friction stir welding has become popular in the solid-state welding community as a means of reducing the complexity of tooling and to reduce costs. The main problems inherent in self-reacted friction stir welding originate in the high stresses encountered by the pin-and-shoulder assembly that produces the weld. The design of the present mechanism solves the problems. The mechanism includes a redesigned pin-and-shoulder assembly. The welding torque is transmitted into the welding pin by a square pin that fits into a square bushing with set-screws. The opposite or back shoulder is held in place by a Woodruff key and high-strength nut on a threaded shaft. The Woodruff key reacts the torque, while the nut reacts the tensile load on the shaft.

  12. Effects of alumina nanoparticles on the microstructure, strength and wear resistance of poly(methyl methacrylate)-based nanocomposites prepared by friction stir processing.

    Science.gov (United States)

    Aghajani Derazkola, Hamed; Simchi, Abdolreza

    2018-03-01

    In this study, alumina-reinforced poly(methyl methacrylate) nanocomposites (PMMA/Al 2 O 3 ) containing up to 20vol% nanoparticles with an average diameter of 50nm were prepared by friction stir processing. The effects of nanoparticle volume fraction on the microstructural features and mechanical properties of PMMA were studied. It is shown that by using a frustum pin tool and employing an appropriate processing condition, i.e. a rotational speed of 1600rpm/min and transverse velocity of 120mm/min, defect free nanocomposites at microscale with fine distribution of the nanoparticles can successfully been prepared. Mechanical evaluations including tensile, flexural, hardness and impact tests indicate that the strength and toughness of the material gradually increases with the nanoparticle concentration and reach to a flexural strength of 129MPa, hardness of 101 Shore D, and impact energy 2kJ/m 2 for the nanocomposite containing 20vol% alumina. These values are about 10% and 20% better than untreated and FSP-treated PMMA (without alumina addition). Fractographic studies indicate typical brittle features with crack deflection around the nanoparticles. More interestingly, the sliding wear rate in a pin-on-disk configuration and the friction coefficient are reduced up to 50% by addition of alumina nanoparticles. The worn surfaces exhibit typical sliding and ploughing features. Copyright © 2018 Elsevier Ltd. All rights reserved.

  13. Laser cladding assisted by friction stir processing for preparation of deformed crack-free Ni-Cr-Fe coating with nanostructure

    Science.gov (United States)

    Xie, Siyao; Li, Ruidi; Yuan, Tiechui; Chen, Chao; Zhou, Kechao; Song, Bo; Shi, Yusheng

    2018-02-01

    Although laser cladding has find its widespread application in surface hardening, this technology has been significantly limited by the solidification crack, which usually initiates along grain boundary due to the brittle precipitation in grain boundary and networks formation during the laser rapid melting/solidification process. This paper proposed a novel laser cladding technology assisted by friction stir processing (FSP) to eliminate the usual metallurgical defects by the thermomechanical coupling effect of FSP with the Ni-Cr-Fe as representative coating material. By the FSP assisted laser cladding, the crack in laser cladding Ni-Cr-Fe coating was eliminated and the coarse networks of laser cladding coating was transformed into dispersed nanoparticles. Moreover, the plastic layers with thicknesses 47-140 μm can be observed, with gradient grain refinement from substrate to the top surface in which grain size reached 300 nm and laser photocoagulation net second phase crushed in the layer. In addition, cracks closed in the plastic zone. The refinement of grain resulted the hardness increased to over 400 HV, much higher than the 300 HV of the laser cladding structure. After FSP, the friction coefficient decreased from 0.6167 to 0.5645 which promoted the wear resistance.

  14. Structure formation of 5083 alloy during friction stir welding

    Science.gov (United States)

    Zaikina, A. A.; Kolubaev, A. V.; Sizova, O. V.; Ivanov, K. V.; Filippov, A. V.; Kolubaev, E. A.

    2017-12-01

    This paper provides a comparative study of structures obtained by friction stir welding and sliding friction of 5083 Al alloy. Optical and electron microscopy reveals identical fine-grained structures with a grain size of ˜5 µm both in the weld nugget zone and subsurface layer in friction independently of the initial grain size of the alloy. It has been suggested that the grain boundary sliding is responsible for the specific material flow pattern in both techniques considered.

  15. JOINING DISSIMILAR MATERIALS USING FRICTION STIR SCRIBE TECHNIQUE

    Energy Technology Data Exchange (ETDEWEB)

    Upadhyay, Piyush; Hovanski, Yuri; Jana, Saumyadeep; Fifield, Leonard S.

    2016-09-01

    Development of robust and cost effective method of joining dissimilar materials can provide a critical pathway to enable widespread use of multi-material design and components in mainstream industrial applications. The use of multi-material components such as Steel-Aluminum, Aluminum-Polymer allows design engineers to optimize material utilization based on service requirements and often lead weight and cost reductions. However producing an effective joint between materials with vastly different thermal, microstructural and deformation response is highly problematic using conventional joining and /or fastening methods. This is especially challenging in cost sensitive high volume markets that largely rely on low–cost joining solutions. Friction Stir Scribe technology was developed to meet the demands of joining materials with drastically different properties and melting regimes. The process enables joining of light metals like Magnesium and Aluminum to high temperature materials like Steels and Titanium. Additionally viable joints between polymer composites and metal can also be made using this method. This paper will present state of the art, progress made and challenges associated with this innovative derivative of Friction Stir welding in reference to joining dissimilar metals and polymer/metal combinations.

  16. Joining Dissimilar Materials Using Friction Stir Scribe Technique

    Energy Technology Data Exchange (ETDEWEB)

    Upadhyay, Piyush [Pacific Northwest National Laboratory, Richland 99352, WA e-mail: piyush.upadhyay@pnnl.gov; Hovanski, Yuri [Pacific Northwest National Laboratory, Richland 99352, WA; Jana, Saumyadeep [Pacific Northwest National Laboratory, Richland 99352, WA; Fifield, Leonard S. [Pacific Northwest National Laboratory, Richland 99352, WA

    2016-10-03

    Development of a robust and cost-effective method of joining dissimilar materials could provide a critical pathway to enable widespread use of multi-material designs and components in mainstream industrial applications. The use of multi-material components such as steel-aluminum and aluminum-polymer would allow design engineers to optimize material utilization based on service requirements and could often lead to weight and cost reductions. However, producing an effective joint between materials with vastly different thermal, microstructural, and deformation responses is highly problematic using conventional joining and/or fastening methods. This is especially challenging in cost sensitive, high volume markets that largely rely on low cost joining solutions. Friction stir scribe technology was developed to meet the demands of joining materials with drastically different properties and melting regimes. The process enables joining of light metals like magnesium and aluminum to high temperature materials like steel and titanium. Viable joints between polymer composites and metal can also be made using this method. This paper will present the state of the art, progress made, and challenges associated with this innovative derivative of friction stir welding in reference to joining dissimilar metals and polymer/metal combinations.

  17. Microstructure Evolution during Friction Stir Spot Welding of TRIP Steel

    DEFF Research Database (Denmark)

    Lomholt, Trine Colding; Pantleon, Karen; Somers, Marcel A. J.

    2010-01-01

    In this study, the feasibility of friction stir spot welding of TRIP steel is investigated. In addition to manufacturing successful welds, the present study aims at a fundamental understanding of the mechanisms occurring at the (sub)micron scale during friction stir spot welding. As one of the ma...... electron microscopy, and electron backscatter diffraction. Microhardness measurements and lap-shear tensile tests completed the investigations of the welded samples and allow evaluation of the quality of the welds.......In this study, the feasibility of friction stir spot welding of TRIP steel is investigated. In addition to manufacturing successful welds, the present study aims at a fundamental understanding of the mechanisms occurring at the (sub)micron scale during friction stir spot welding. As one of the main...... parameters to control friction stir welding, the influence of the rotational speed of the tool was investigated. Three different rotational speeds (500 rpm, 1000 rpm and 1500 rpm, respectively) were applied. The microstructure of the welded samples was investigated with reflected light microscopy, scanning...

  18. Prolegomena to the Study of Friction Stir Welding

    Science.gov (United States)

    Nunes, Arthur C., Jr.

    2010-01-01

    The literature contains many approaches toward modeling of the friction stir welding (FSW) process with varying treatments of the weld metal properties. It is worthwhile to consider certain fundamental features of the process before attempting to interpret FSW phenomena: Because of the unique character of metal deformation (as opposed to, say, viscous deformation) a velocity "discontinuity" or shear surface occurs in FSW and determines much of the character of the welding mechanism. A shear surface may not always produce a sound bond. Balancing mechanical power input against conduction and convection heat losses yields a relation, a "temperature index", between spindle speed and travel speed to maintain constant weld temperature. But many process features are only weakly dependent upon temperature. Thus, unlike modeling of metal forming processes, it may be that modeling the FSW process independently of the material conditions has some merit.

  19. Friction stir welding (FSW) of AA 6061 T6

    International Nuclear Information System (INIS)

    Cabot, Pedro; Monglioni, Alberto; Carella, Eduardo

    2002-01-01

    The friction-stir process (FSW) developed by England's TWI in the last decade is a new concept in solid phase friction welding that is particularly appropriate for soldering aluminum and its alloys. It offers interesting aspects and can advantageously replace the usual arch processes. It is an automatic process that solders together long pieces by butt or lap welding and, therefore, overcomes the greater limitation of the conventional friction process that can be applied only to pieces with revolution symmetry. FSW is based essentially on the use of a cylindrical tool with a special profile, which is inserted between the surfaces where the materials meet to join them together at a certain rotation speed and under a specific force. The pieces must be rigidly butt bonded or overlapped to prevent movement when the tool moves forward along the joint producing the dispersion of oxides, local plastisizing of the material and the weld. Since its creation FSW has been the subject of many international publications, but until the present work there was no technologically relevant data about tools and procedures. For this reason, when its promising and novel nature was noticed, the CNEA began its own development project in 1997. The main characteristics of the tool are reviewed here and the results of tests carried out to evaluate the influence of the feed velocity on the mechanical properties of the butt joining of a 6.25 mm thick AA6061 T6 plate. Different accumulated aspects of the experience are discussed as well (cw)

  20. Low temperature friction stir welding of P91 steel

    Directory of Open Access Journals (Sweden)

    Prasad Rao Kalvala

    2016-08-01

    Full Text Available Bead-on-plate friction stir welds were made on P91 alloy with low and high rotational speeds (100 and 1000 RPM to study their effects on weld microstructural changes and impression creep behavior. Temperatures experienced by the stir zone were recorded at the weld tool tip. Different zones of welds were characterized for their microstructural changes, hardness and creep behavior (by impression creep tests. The results were compared with submerged arc fusion weld. Studies revealed that the stir zone temperature with 100 RPM was well below Ac1 temperature of P91 steel while it was above Ac3 with 1000 RPM. The results suggest that the microstructural degradation in P91 welds can be controlled by low temperature friction stir welding technique.

  1. Influence of tool geometry and processing parameters on welding defects and mechanical properties for friction stir welding of 6061 Aluminium alloy

    Science.gov (United States)

    Daneji, A.; Ali, M.; Pervaiz, S.

    2018-04-01

    Friction stir welding (FSW) is a form of solid state welding process for joining metals, alloys, and selective composites. Over the years, FSW development has provided an improved way of producing welding joints, and consequently got accepted in numerous industries such as aerospace, automotive, rail and marine etc. In FSW, the base metal properties control the material’s plastic flow under the influence of a rotating tool whereas, the process and tool parameters play a vital role in the quality of weld. In the current investigation, an array of square butt joints of 6061 Aluminum alloy was to be welded under varying FSW process and tool geometry related parameters, after which the resulting weld was evaluated for the corresponding mechanical properties and welding defects. The study incorporates FSW process and tool parameters such as welding speed, pin height and pin thread pitch as input parameters. However, the weld quality related defects and mechanical properties were treated as output parameters. The experimentation paves way to investigate the correlation between the inputs and the outputs. The correlation between inputs and outputs were used as tool to predict the optimized FSW process and tool parameters for a desired weld output of the base metals under investigation. The study also provides reflection on the effect of said parameters on a welding defect such as wormhole.

  2. Modelling the Thermomechanical Conditions in Friction Stir Welding

    DEFF Research Database (Denmark)

    Schmidt, Henrik Nikolaj Blich

    Friction Stir Welding is a solid-state welding process invented by TWI in 1991. The FSW process is unique in the sense that joining of un-weldable alloys readily can be made. The thermomechanical conditions present in the workpiece during the welding process are of great interest since...... these control the properties of the weld. In the present work, a set of experimental, analytical and numerical analyses are carried out in order to evaluate the thermomechanical conditions descriptive for welding of aluminium, in this case AA2024-T3, under a specific set of welding parameters. Despite...... these specific data, the developed models can be applied for other alloys and welding parameters as well. A detailed experiment is carried out which constitutes the basis for the development and validation of the numerical and analytical models presented in this work. The contact condition at the tool...

  3. Microstructures, mechanical, and biological properties of a novel Ti-6V-4V/zinc surface nanocomposite prepared by friction stir processing

    Directory of Open Access Journals (Sweden)

    Zhu C

    2018-03-01

    Full Text Available Chenyuan Zhu,1,2,* Yuting Lv,3,4,* Chao Qian,1,2,* Zihao Ding,3,5 Ting Jiao,1,2 Xiaoyu Gu,1,2 Eryi Lu,6 Liqiang Wang,3 Fuqiang Zhang1,2 1Department of Prosthodontics, Ninth People’s Hospital, Shanghai Jiao Tong University School of Medicine, 2Shanghai Key Laboratory of Stomatology, Shanghai Research Institute of Stomatology, National Clinical Research Center of Stomatology, 3State Key Laboratory of Metal Matrix Composites, Shanghai Jiao Tong University, Shanghai, 4College of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao, People’s Republic of China; 5Department of Materials Science and Engineering, Carnegie Mellon University, Pittsburgh, PA, USA; 6Department of Stomatology, Ren Ji Hospital, Shanghai Jiao Tong University School of Medicine, Shanghai, People’s Republic of China *These authors contributed equally to this work Background: The interaction between the material and the organism affects the survival rate of the orthopedic or dental implant in vivo. Friction stir processing (FSP is considered a new solid-state processing technology for surface modification. Purpose: This study aims to strengthen the surface mechanical properties and promote the osteogenic capacity of the biomaterial by constructing a Ti-6Al-4V (TC4/zinc (Zn surface nanocomposites through FSP. Methods: FSP was used to modify the surface of TC4. The microstructures and mechanical properties were analyzed by scanning electron microscopy, transmission electron microscopy, nanoindentation and Vickers hardness. The biological properties of the modified surface were evaluated by the in vitro and in vivo study. Results: The results showed that nanocrystalline and numerous β regions, grain boundary a phase, coarser acicular α phase and finer acicular martensite α' appeared because of the severe plastic deformation caused by FSP, resulting in a decreased elastic modulus and an increased surface hardness. With the addition of

  4. Development of a Robust and Cost-Effective Friction Stir Welding Process for Use in Advanced Military Vehicles

    Science.gov (United States)

    2011-01-01

    aluminum alloys, as well 81 as aluminum matrix composites can be readily FSWed; 82 (j) due to lower attendant temperatures, the residual stres - 83 ses... role of the precipitation hardening mechanism in heat- 372treatable alloys is concerned, the following main observations 373can be made. Typically in...stirring/mixing 470(which plays a critical role in weld quality/joint-strength) is 471increased. 472Nodal Velocity Field. The distribution of nodal

  5. A Survey on Friction Stir Welding Of Dissimilar Magnesium Alloys

    Science.gov (United States)

    Unnikrishnan, M. A.; Raja, Dhas. J. Edwin

    2017-10-01

    There is a consistent demand for superior materials in every industry. The areas on demand are automobile and aerospace sectors in major.. The most commonly used material in these fields is Aluminium.Though it possess all the properties up to some extent constant demand is pushing for alternate materials. Dissimilar alloys have been a relatively new approach towards these fields.. Friction stir welding dissimilar alloys is a big leap in Automobile sector. In this paper a detailed review of Friction stir welding of Dissimilar Magnesium alloys has been done. This work will serve as a reference to subsequent researchers.

  6. In-process tool rotational speed variation with constant heat input in friction stir welding of AZ31 sheets with variable thickness

    Science.gov (United States)

    Buffa, Gianluca; Campanella, Davide; Forcellese, Archimede; Fratini, Livan; Simoncini, Michela

    2017-10-01

    In the present work, friction stir welding experiments on AZ31 magnesium alloy sheets, characterized by a variable thickness along the welding line, were carried out. The approach adapted during welding consisted in maintaining constant the heat input to the joint. To this purpose, the rotational speed of the pin tool was increased with decreasing thickness and decreased with increasing thickness in order to obtain the same temperatures during welding. The amount by which the rotational speed was changed as a function of the sheet thickness was defined on the basis of the results given by FEM simulations of the FSW process. Finally, the effect of the in-process variation of the tool rotational speed on the mechanical and microstructural properties of FSWed joints was analysed by comparing both the nominal stress vs. nominal strain curves and microstructure of FSWed joints obtained in different process conditions. It was observed that FSW performed by keeping constant the heat input to the joint leads to almost coincident results both in terms of the curve shape, ultimate tensile strength and ultimate elongation values, and microstructure.

  7. Mathematical Modelling of a Friction Stir Welding Process to Predict the Joint Strength of Two Dissimilar Aluminium Alloys Using Experimental Data and Genetic Programming

    Directory of Open Access Journals (Sweden)

    Mohammed Yunus

    2018-01-01

    Full Text Available Friction stir welding (FSW is the most popular and efficient method of solid-state joining for similar as well as dissimilar metals and alloys. It is mostly used in applications for aerospace, rail, automotive, and marine industries. Many researchers are currently working with different perspectives on this FSW process for various combinations of materials. The general input process parameters are the thickness of the plate, axial load, rotational speed, welding speed, and tilt angle. The output parameters are joint hardness, % of elongation, and impact and yield strengths. Genetic programming (GP is a relatively new method of evolutionary computing with the principal advantage of this approach being to evaluate efficacious predictive mathematical models or equations without any prior assumption regarding the possible form of the functional relationship. This paper both defines and illustrates how GP can be applied to the FSW process to derive precise relationships between the output and input parameters in order to obtain a generalized prediction model. A GP model will assist engineers in quantifying the performance of FSW, and the results from this study can then be utilized to estimate future requirements based on the historical data to provide a robust solution. The obtained results from the GP models showed good agreement with experimental and target data at an average prediction error of 0.72%.

  8. Tool for Two Types of Friction Stir Welding

    Science.gov (United States)

    Carter, Robert

    2006-01-01

    A tool that would be useable in both conventional and self-reacting friction stir welding (FSW) has been proposed. The tool would embody both a prior tooling concept for self-reacting FSW and an auto-adjustable pin-tool (APT) capability developed previously as an augmentation for conventional FSW. Some definitions of terms are prerequisite to a meaningful description of the proposed tool. In conventional FSW, depicted in Figure 1, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a rotating pin that protrudes from the shoulder into the depth of the workpiece. The main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional FSW is augmented with an APT capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or force-control system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding (SR-FSW), there are two rotating shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft, back into the FSW machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. A tool for SRFSW embodying this concept was reported in "Mechanism for Self-Reacted Friction Stir Welding" (MFS-31914), NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 53. In its outward appearance, the proposed tool (see Figure 2) would fit the above description of an SR

  9. Non-dimensional characterization of the friction stir/spot welding process using a simple Couette flow model part I: Constant property Bingham plastic solution

    International Nuclear Information System (INIS)

    Buck, Gregory A.; Langerman, Michael

    2004-01-01

    A simplified model for the material flow created during a friction stir/spot welding process has been developed using a boundary driven cylindrical Couette flow model with a specified heat flux at the inner cylinder for a Bingham plastic material. Non-dimensionalization of the constant property governing equations identified three parameters that influence the velocity and temperature fields. Analytic solutions to these equations are presented and some representative results from a parametric study (parameters chosen and varied over ranges expected for the welding of a wide variety of metals) are discussed. The results also provide an expression for the critical radius (location of vanishing material velocity) as functions of the relevant non-dimensional parameters. A final study was conducted in which values for the non-dimensional heat flux parameter were chosen to produce peak dimensional temperatures on the order of 80% of the melting temperature for a typical 2000 series aluminum. Under these conditions it was discovered that the ratio of the maximum rate of shear work within the material (viscous dissipation) to the rate of energy input at the boundary due to frictional heating, ranged from about 0.0005% for the lowest pin tool rotation rate, to about 1.3% for the highest tool rotation rate studied. Curve fits to previous Gleeble data taken for a number of aluminum alloys provide reasonable justification for the Bingham plastic constitutive model, and although these fits indicate a strong temperature dependence for critical flow stress and viscosity, this work provides a simple tool for more sophisticated model validation. Part II of this study will present numerical solutions for velocity and temperature fields resulting from the non-linear coupling of the momentum and energy equations created by temperature dependent transport properties

  10. Pin Tool Geometry Effects in Friction Stir Welding

    Science.gov (United States)

    Querin, J. A.; Rubisoff, H. A.; Schneider, J. A.

    2009-01-01

    In friction stir welding (FSW) there is significant evidence that material can take one of two different flow paths when being displaced from its original position in front of the pin tool to its final position in the wake of the weld. The geometry of the pin tool, along with the process parameters, plays an important role in dictating the path that the material takes. Each flow path will impart a different thermomechanical history on the material, consequently altering the material microstructure and subsequent weld properties. The intention of this research is to isolate the effect that different pin tool attributes have on the flow paths imparted on the FSWed material. Based on published weld tool geometries, a variety of weld tools were fabricated and used to join AA2219. Results from the tensile properties and microstructural characterization will be presented.

  11. Joining dissimilar materials using Friction Stir scribe technique

    Energy Technology Data Exchange (ETDEWEB)

    Upadhyay, Piyush; Hovanski, Yuri; Jana, Saumyadeep; Fifield, Leonard S.

    2016-10-03

    The ability to effectively join materials with vastly different melting points like Aluminum-Steel, Polymer composites - metals has been one of the road blocks in realizing multi-material components for light weighting efforts. Friction stir scribe (FSS) technique is a promising method that produces continuous overlap joint between materials with vastly different melting regimes and high temperature flow characteristics. FSS uses an offset cutting tool at the tip of the FSW pin to create an insitu mechanical interlock between material interfaces. With investments from Vehicle Technology office, US DOE and several automotive manufacturers and suppliers PNNL is developing the FSS process and has demonstrated viability of joining several material combinations. Details of welding trails, unique challenges and mitigation strategies in different material combinations will be discussed. Joint characterization including mechanical tests and joint performances will also be presented.

  12. Microstructure characterization of Friction Stir Spot Welded TRIP steel

    DEFF Research Database (Denmark)

    Lomholt, Trine Colding; Adachi, Yoshitaka; Peterson, Jeremy

    2012-01-01

    Transformation Induced Plasticity (TRIP) steels have not yet been successfully joined by any welding technique. It is desirable to search for a suitable welding technique that opens up for full usability of TRIP steels. In this study, the potential of joining TRIP steel with Friction Stir Spot...

  13. Defect Detectability Improvement for Conventional Friction Stir Welds

    Science.gov (United States)

    Hill, Chris

    2013-01-01

    This research was conducted to evaluate the effects of defect detectability via phased array ultrasound technology in conventional friction stir welds by comparing conventionally prepped post weld surfaces to a machined surface finish. A machined surface is hypothesized to improve defect detectability and increase material strength.

  14. Friction Stir Welding of Dissimilar Al/Al and Al/Non-Al Alloys: A Review

    Science.gov (United States)

    Wang, Xiangbin; Pan, Yi; Lados, Diana A.

    2018-05-01

    Friction stir welding is a solid-state welding technique that has many advantages over traditional fusion welding, and has been widely adopted in the aerospace and automotive industries. This article reviews research developments in friction stir welding of dissimilar alloys systems, including combinations of aluminum alloys with Mg alloys, Cu, and steel. Microstructural evolution, hardness, tensile and fatigue properties, residual stresses, and corrosion behavior of dissimilar welds will be reported. The effects of processing parameters such as tool rotation and traverse speeds, tool position, material position, and tool geometry on the weld quality are also presented. Discussions on future research directions in friction stir welding will also be provided in the context of existing literature and future high-integrity applications.

  15. Friction stir scribe welding technique for dissimilar joining of aluminium and galvanised steel

    Energy Technology Data Exchange (ETDEWEB)

    Wang, Tianhao [Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX, USA; Sidhar, Harpreet [Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX, USA; Mishra, Rajiv S. [Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX, USA; Hovanski, Yuri [Pacific Northwest National Laboratory, Energy Materials and Manufacturing, Richland, WA, USA; Upadhyay, Piyush [Pacific Northwest National Laboratory, Energy Materials and Manufacturing, Richland, WA, USA; Carlson, Blair [General Motors Technical Center, Warren, MI, USA

    2017-10-04

    Friction stir scribe technology, a derivative of friction stir welding, was applied for the dissimilar lap welding of an aluminum alloy and galvanized mild steel sheets. During the process, the rotating tool with a cobalt steel scribe first penetrated the top material — aluminum — and then the scribe cut the bottom material — steel. The steel was displaced into the upper material to produce a characteristic hook feature. Lap welds were shear tested, and their fracture paths were studied. Welding parameters affected the welding features including hook height, which turned out to be highly related to fracture position. Therefore, in this paper, the relationships among welding parameters, hook height, joint strength and fracture position are presented. In addition, influence of zinc coating on joint strength was also studied. Keywords: friction stir scribe technology; dissimilar material welding; zinc coating; hook height; joint strength; fracture position

  16. The effect of postprocessing on tensile property and microstructure evolution of friction stir welding aluminum alloy joint

    International Nuclear Information System (INIS)

    Hu, Z.L.; Wang, X.S.; Pang, Q.; Huang, F.; Qin, X.P.; Hua, L.

    2015-01-01

    Friction stir welding is an efficient manufacturing method for joining aluminum alloy and can dramatically reduce grain size conferring excellent plastic deformation properties. Consequently, friction stir welding is used to manufacture tailor welded blanks to optimize weight or performance in the final component. In the study, the microstructural evolution and mechanical properties of friction stir welding joint during plastic forming and subsequent heat treatment were investigated. The microstructural characteristics of the friction stir welding joints were studied by Electron Backscattered Diffraction and Transmission Electron Microscopy. The mechanical properties were evaluated by tensile and microhardness tests. It is found that the tensile and yield strengths of friction stir welding joints are significantly improved after severe plastic deformation due to the grain refinement. Following heat treatment, the strength of the friction stir welding joints significantly decrease due to the obvious abnormal grain growth. Careful attention must be given to the processing route of any friction stir welding joint intended for plastic forming, especially the annealing between forming passes. Severe plastic deforming of the friction stir welding joint leads to a high level of stored energy/dislocation density, which causes the abnormal grain growth during subsequent heat treatment, and consequently reduce the mechanical properties of the friction stir welding joint. - Highlights: • Great changes are observed in the microstructure of FSW joint after postprocessing. • Postprocessing shows great effect on the microstructure stability of FSW joint. • The weld shows more significant decrease in strength than the BM due to the AGG. • Attention must be given to the processing route of FSW joint for plastic forming

  17. Colosed-Loop Control of the Thermal Stir Welding Process to Enable Rapid Process/Ppart Qualification, Phase I

    Data.gov (United States)

    National Aeronautics and Space Administration — Thermal Stir Welding (TSW) provides advancement over the more conventional Friction Stir Welding (C-FSW) process because it separates the primary processes variables...

  18. Closed-Loop Control of the Thermal Stir Welding Process to Enable Rapid Process/Part Qualification, Phase II

    Data.gov (United States)

    National Aeronautics and Space Administration — Thermal Stir Welding (TSW) provides advancement over the more conventional Friction Stir Welding (C-FSW) process because it separates the primary processes variables...

  19. Microstructure evolution in dissimilar AA6060/copper friction stir welded joints

    Science.gov (United States)

    Kalashnikova, T. A.; Shvedov, M. A.; Vasilyev, P. A.

    2017-12-01

    Friction stir welding process has been applied for making a dissimilar copper/aluminum alloy joint. The grain microstructure and mechanical properties of the obtained joint were studied. The structure of the cross-section of the FSW compound was analyzed. The microstructural evolution of the joint was examined using optical microscopy. The mechanical properties of the intermetallic particles were evaluated by measuring the microhardness according to the Vickers method. The microhardness of the intermetallic particles was by a factor of 4 lower than that of the particles obtained by fusion welding. The results of the investigations enable using friction stir welding for making dissimilar joints.

  20. Friction stir welding of AA6082-T6 sheets: Numerical analysis and experimental tests

    International Nuclear Information System (INIS)

    Buffa, G.; Fratini, L.

    2004-01-01

    3D numerical simulation of the Friction Stir Welding process is developed with the aim to highlight the process mechanics in terms of metal flux and temperature, strain and strain rate distributions. The numerical results have been validated though a set of experimental tests

  1. Robust Optimization of Thermal Aspects of Friction Stir Welding Using Manifold Mapping Techniques

    DEFF Research Database (Denmark)

    Larsen, Anders Astrup; Lahaye, Domenico; Schmidt, Henrik Nikolaj Blicher

    2008-01-01

    The aim of this paper is to optimize a friction stir welding process taking robustness into account. The optimization problems are formulated with the goal of obtaining desired mean responses while reducing the variance of the response. We restrict ourselves to a thermal model of the process...

  2. On the Similarity of Deformation Mechanisms During Friction Stir Welding and Sliding Friction of the AA5056 Alloy

    Science.gov (United States)

    Kolubaev, A. V.; Zaikina, A. A.; Sizova, O. V.; Ivanov, K. V.; Filippov, A. V.; Kolubaev, E. A.

    2018-04-01

    A comparative investigation of the structure of an aluminum-manganese alloy is performed after its friction stir welding and sliding friction. Using the methods of optical and electron microscopy, it is shown that during friction identical ultrafine-grained structures are formed in the weld nugget and in the surface layer, in which the grains measure 5 μm irrespective of the initial grain size of the alloy. An assumption is made that the microstructure during both processes under study is formed by the mechanism of rotational plasticity.

  3. A Preliminary Report on the Strength and Metallography of a Bimetallic Friction Stir Weld Joint Between AA6061 and MIL-DTL-46100E High Hardness Steel Armor

    Science.gov (United States)

    2012-11-26

    bimetallic friction stir weld joint between AA6061 and MIL-DTL-46100E High Hardness steel armor. ABSTRACT One half inch thick plates of 6061-T6 aluminum...alloy and High Hardness steel armor (MIL- STD-46100) were successfully joined by the friction stir welding (FSW) process using a tungsten-rhenium...4. TITLE AND SUBTITLE A preliminary report on the strength and metallography of a bimetallic friction stir weld joint between AA6061 and MIL-DTL

  4. Microstructural characterizations and mechanical properties in underwater friction stir welding of aluminum and magnesium dissimilar alloys

    International Nuclear Information System (INIS)

    Zhao, Yong; Lu, Zhengping; Yan, Keng; Huang, Linzhao

    2015-01-01

    Highlights: • Aluminum and magnesium alloys were joined by underwater friction stir welding. • Underwater FSW was conducted to improve properties of joint with lower heat input. • Microstructures and mechanical properties of dissimilar joint were investigated. • Intermetallic compounds developed in the fracture interface were analyzed. • Fracture features of the tensile samples were analyzed. - Abstract: Formation of intermetallic compounds in the stir zone of dissimilar welds affects the mechanical properties of the joints significantly. In order to reduce heat input and control the amount and morphological characteristics of brittle intermetallic compounds underwater friction stir welding of 6013 Al alloy and AZ31 Mg alloy was carried out. Microstructures, mechanical properties, elements distribution, and the fracture surface of the joints were analyzed by optical microscopy, scanning electron microscopy and energy dispersive X-ray spectroscopy, etc. The result shows that sound dissimilar joint with good mechanical properties can be obtained by underwater friction stir welding. Al and Mg alloys were stirred together and undergone the process of recrystallization, forming complex intercalated flow patterns in the stir zone. Tensile strength of the dissimilar joint was up to 152.3 MPa. Maximum hardness (142HV) appeared in the middle of the centerline of the specimen. Intermetallic compounds layer consisting of Al 3 Mg 2 and Mg 17 Al 12 formed in the Al/Mg interface and resulted in the fracture of the joint

  5. Dissimilar friction stir welds in AA5083-AA6082: The effect of process parameters on residual stress

    International Nuclear Information System (INIS)

    Steuwer, A.; Peel, M.J.; Withers, P.J.

    2006-01-01

    The effect of tool traverse and rotation speeds on the residual stresses are quantified for welds between non-age-hardening AA5083 and age-hardening AA6082 and compared to single alloy joints made from each of the two constituents. The residual stresses have been characterised non-destructively by neutron diffraction and synchrotron X-ray diffraction. The region around the weld line was characterised by significant tensile residual stress fields which are balanced by compressive stresses in the parent material. The rotation speed of the tool has been found to have a substantially greater influence than the transverse speed on the properties and residual stresses in the welds, particularly on the AA5083 side where the location of the peak stress moves from the stir zone to beyond the edge of the tool shoulder. The changes in residual stress are related to microstructural and hardness changes as determined in a previous study . In particular the larger stresses under the weld tool on the AA5083 side compared to the AA6082 side are related to a transient reduction in yield stress due to dissolution of the hardening precipitates during welding prior to natural aging after welding

  6. Experimental and numerical investigation on under-water friction stir welding of armour grade AA2519-T87 aluminium alloy

    OpenAIRE

    Sree Sabari, S.; Malarvizhi, S.; Balasubramanian, V.; Madusudhan Reddy, G.

    2016-01-01

    Friction stir welding (FSW) is a promising welding process that can join age hardenable aluminium alloys with high joint efficiency. However, the thermal cycles experienced by the material to be joined during FSW resulted in the deterioration of mechanical properties due to the coarsening and dissolution of strengthening precipitates in the thermo-mechanical affected zone (TMAZ) and heat affected zone (HAZ). Under water friction stir welding (UWFSW) is a variant of FSW process which can maint...

  7. Tensile Properties and Fracture Behavior of Aluminum Alloy Foam Fabricated from Die Castings without Using Blowing Agent by Friction Stir Processing Route.

    Science.gov (United States)

    Hangai, Yoshihiko; Kamada, Hiroto; Utsunomiya, Takao; Kitahara, Soichiro; Kuwazuru, Osamu; Yoshikawa, Nobuhiro

    2014-03-21

    Al foam has been used in a wide range of applications owing to its light weight, high energy absorption and high sound insulation. One of the promising processes for fabricating Al foam involves the use of a foamable precursor. In this study, ADC12 Al foams with porosities of 67%-78% were fabricated from Al alloy die castings without using a blowing agent by the friction stir processing route. The pore structure and tensile properties of the ADC12 foams were investigated and compared with those of commercially available ALPORAS. From X-ray computed tomography (X-ray CT) observations of the pore structure of ADC12 foams, it was found that they have smaller pores with a narrower distribution than those in ALPORAS. Tensile tests on the ADC12 foams indicated that as their porosity increased, the tensile strength and tensile strain decreased, with strong relation between the porosity, tensile strength, and tensile strain. ADC12 foams exhibited brittle fracture, whereas ALPORAS exhibited ductile fracture, which is due to the nature of the Al alloy used as the base material of the foams. By image-based finite element (FE) analysis using X-ray CT images corresponding to the tensile tests on ADC12 foams, it was shown that the fracture path of ADC12 foams observed in tensile tests and the regions of high stress obtained from FE analysis correspond to each other. Therefore, it is considered that the fracture behavior of ADC12 foams in relation to their pore structure distribution can be investigated by image-based FE analysis.

  8. Tensile Properties and Fracture Behavior of Aluminum Alloy Foam Fabricated from Die Castings without Using Blowing Agent by Friction Stir Processing Route

    Directory of Open Access Journals (Sweden)

    Yoshihiko Hangai

    2014-03-01

    Full Text Available Al foam has been used in a wide range of applications owing to its light weight, high energy absorption and high sound insulation. One of the promising processes for fabricating Al foam involves the use of a foamable precursor. In this study, ADC12 Al foams with porosities of 67%–78% were fabricated from Al alloy die castings without using a blowing agent by the friction stir processing route. The pore structure and tensile properties of the ADC12 foams were investigated and compared with those of commercially available ALPORAS. From X-ray computed tomography (X-ray CT observations of the pore structure of ADC12 foams, it was found that they have smaller pores with a narrower distribution than those in ALPORAS. Tensile tests on the ADC12 foams indicated that as their porosity increased, the tensile strength and tensile strain decreased, with strong relation between the porosity, tensile strength, and tensile strain. ADC12 foams exhibited brittle fracture, whereas ALPORAS exhibited ductile fracture, which is due to the nature of the Al alloy used as the base material of the foams. By image-based finite element (FE analysis using X-ray CT images corresponding to the tensile tests on ADC12 foams, it was shown that the fracture path of ADC12 foams observed in tensile tests and the regions of high stress obtained from FE analysis correspond to each other. Therefore, it is considered that the fracture behavior of ADC12 foams in relation to their pore structure distribution can be investigated by image-based FE analysis.

  9. A Rotating Plug Model of Friction Stir Welding Heat Transfer

    Science.gov (United States)

    Raghulapadu J. K.; Peddieson, J.; Buchanan, G. R.; Nunes, A. C.

    2006-01-01

    A simplified rotating plug model is employed to study the heat transfer phenomena associated with the fiction stir welding process. An approximate analytical solution is obtained based on this idealized model and used both to demonstrate the qualitative influence of process parameters on predictions and to estimate temperatures produced in typical fiction stir welding situations.

  10. Friction stir weld-bonding defect inspection using phased array ultrasonic testing

    NARCIS (Netherlands)

    Fortunato, J.; Anand, C.; Braga, Daniel F.O.; Groves, R.M.; Moreira, P. M.G.P.; Infante, V

    2017-01-01

    Weight reduction is an important driver of the aerospace industry, which encourages the development of lightweight joining techniques to substitute rivet joints. Friction stir welding (FSW) is a solid-state process that enables the production of lighter joints with a small performance reduction

  11. Optimization of Thermal Aspects of Friction Stir Welding – Initial Studies Using a Space Mapping Technique

    DEFF Research Database (Denmark)

    Larsen, Anders Astrup; Bendsøe, Martin P.; Schmidt, Henrik Nikolaj Blicher

    2007-01-01

    The aim of this paper is to optimize a thermal model of a friction stir welding process. The optimization is performed using a space mapping technique in which an analytical model is used along with the FEM model to be optimized. The results are compared to traditional gradient based optimization...

  12. A fundamental study on the structural integrity of magnesium alloys joined by friction stir welding

    Science.gov (United States)

    Rao, Harish Mangebettu

    The goal of this research is to study the factors that influence the physical and mechanical properties of lap-shear joints produced using friction stir welding. This study focuses on understanding the effect of tool geometry and weld process parameters including the tool rotation rate, tool plunge depth and dwell time on the mechanical performance of similar magnesium alloy and dissimilar magnesium to aluminum alloy weld joints. A variety of experimental activities were conducted including tensile and fatigue testing, fracture surface and failure analysis, microstructure characterization, hardness measurements and chemical composition analysis. An investigation on the effect of weld process conditions in friction stir spot welding of magnesium to magnesium produced in a manner that had a large effective sheet thickness and smaller interfacial hook height exhibited superior weld strength. Furthermore, in fatigue testing of friction stir spot welded of magnesium to magnesium alloy, lap-shear welds produced using a triangular tool pin profile exhibited better fatigue life properties compared to lap-shear welds produced using a cylindrical tool pin profile. In friction stir spot welding of dissimilar magnesium to aluminum, formation of intermetallic compounds in the stir zone of the weld had a dominant effect on the weld strength. Lap-shear dissimilar welds with good material mixture and discontinues intermetallic compounds in the stir zone exhibited superior weld strength compared to lap-shear dissimilar welds with continuous formation of intermetallic compounds in the stir zone. The weld structural geometry like the interfacial hook, hook orientation and bond width also played a major role in influencing the weld strength of the dissimilar lap-shear friction stir spot welds. A wide scatter in fatigue test results was observed in friction stir linear welds of aluminum to magnesium alloys. Different modes of failure were observed under fatigue loading including crack

  13. Strengthening analyses and mechanical assessment of Ti/Al{sub 2}O{sub 3} nano-composites produced by friction stir processing

    Energy Technology Data Exchange (ETDEWEB)

    Shafiei-Zarghani, Aziz, E-mail: ashafiei@ut.ac.ir [Center of Excellence for Surface Engineering and Corrosion Protection of Industries, School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Kashani-Bozorg, Seyed Farshid, E-mail: fkashani@ut.ac.ir [Center of Excellence for Surface Engineering and Corrosion Protection of Industries, School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, Tehran (Iran, Islamic Republic of); Gerlich, Adrian P., E-mail: adrian.gerlich@uwaterloo.ca [Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo (Canada)

    2015-04-17

    The present work investigates strengthening mechanisms and mechanical assessment of Ti/Al{sub 2}O{sub 3} nano-composites produced by friction stir processing of commercially pure titanium using nano-sized Al{sub 2}O{sub 3} with different volume fractions and particle sizes. Microstructural analyses were conducted to characterize the grain size of matrix, size and dispersion of reinforcing particles. The mean grain size of the composites ranged from ~0.7 to 1.1 μm that is much lower than 28 μm of the as-received material. Reduction of grain size was found to be in agreement with Rios approach (based on energy dissipated during the motion of an interface through particle dispersion), and showed deviation from Zener pinning model. Scanning and transmission electron microscopies revealed a near uniform dispersion of Al{sub 2}O{sub 3} nano-particles, with only a small fraction of widely spaced clusters. The maximum compression yield strength of the fabricated nano-composite (Ti/3.9%vol of 20 nm-Al{sub 2}O{sub 3}) was found to be ~494 MPa that is ~1.5 times higher than that of the as-received material. Strengthening analyses based on grain refining (Hall–Petch approach), load transfer from matrix to reinforcements, Orowan looping, and enhanced dislocation density due to thermal mismatch effects were carried out considering Al{sub 2}O{sub 3} reinforcement with different volume fractions and sizes. However, Hall–Petch approach was found to be the dominant mechanism for the enhancement of yield strength.

  14. Effect of tool shape and welding parameters on mechanical properties and microstructure of dissimilar friction stir welded aluminium alloys

    OpenAIRE

    Chetan Aneja; Amit Handa

    2016-01-01

    In the present experimental study, dissimilar aluminum alloy AA5083 and AA6082 were friction stir welded by varying tool shape, welding speed and rotary speed of the tool in order to investigate the effect of varying tool shape and welding parameters on the mechanical properties as well as microstructure. The friction stir welding (FSW) process parameters have great influence on heat input per unit length of weld. The outcomes of experimental study prove that mechanical properties increases w...

  15. Friction-stir processing of an AA8026-TiB{sub 2}-Al{sub 2}O{sub 3} hybrid nanocomposite: Microstructural developments and mechanical properties

    Energy Technology Data Exchange (ETDEWEB)

    Eskandari, H.; Taheri, R. [Department of Mechanical Engineering, Persian Gulf University, Bushehr 75168 (Iran, Islamic Republic of); Khodabakhshi, F., E-mail: farzadkhodabakhshi83@gmail.com [Department of Materials Science and Engineering, School of Engineering, Shiraz University, Zand Boulevard, Shiraz (Iran, Islamic Republic of)

    2016-04-13

    In this study, micro- and nano-sized TiB{sub 2} and Al{sub 2}O{sub 3} particles were incorporated separately and simultaneously through the AA8026 aluminum base alloy during multi-pass friction stir processing (FSP) with 100% overlapping to fabricate metal matrix mono and hybrid nanocomposites. Various FSP conditions including different rotational speeds (w), traverse velocities (v), and processing pass numbers were assessed to attain a homogenous distribution of reinforcing particles through the Al-metal matrix. Moreover, the impacts of size (micro or nano) and type of reinforcement particles (TiB{sub 2} and Al{sub 2}O{sub 3}) on the process-ability of single and hybrid nanocomposite systems were examined. Microstructures of different zones and distributions of reinforcing ceramic particles through the Al-matrix under various processing conditions were studied and characterized by using optical (OM), scanning (SEM), and transmission electron microscopy (TEM) techniques, respectively. The main mechanical characteristics of the prepared nanocomposites, such as, indentation Vickers hardness, tensile properties, and wear resistance were measured and compared for all of the various processing conditions. By optimization of the FSP parameters, as a rotational speed of 1600 rpm and a traverse velocity of 40 mm/min after 4 passes, a uniform AA8026-TiB{sub 2}-Al{sub 2}O{sub 3} hybrid nanocomposite was attained with significant improvements (~70–100%) in the different mechanical properties. As a result, the tensile yield strength of ~270 MPa, elongation of ~4.5%, and indentation Vickers hardness of ~141 HV were obtained. Also, the average wear rate was reduced from the 21×10{sup −3} mg/m value for the AA8026 base alloy down to 2.6×10{sup −3} mg/m for the best processed nanocomposite. A direct relationship between the wear rate and the indentation hardness resistance was demonstrated. Finally, effects of FSP processing conditions and reinforcement particles (type and

  16. Systematic investigation of the fatigue performance of a friction stir welded low alloy steel

    International Nuclear Information System (INIS)

    Toumpis, Athanasios; Galloway, Alexander; Molter, Lars; Polezhayeva, Helena

    2015-01-01

    Highlights: • The fatigue behaviour of a friction stir welded low alloy steel has been assessed. • The welds’ fatigue lives outperform the International Institute of Welding’s recommendations for fusion welds. • The slow weld exhibits the best fatigue performance of the investigated welds. • Fracture surface analysis shows that minor embedded flaws do not offer crack initiation sites. • Process-related surface breaking flaws have a significant effect on the fatigue life. - Abstract: A comprehensive fatigue performance assessment of friction stir welded DH36 steel has been undertaken to address the relevant knowledge gap for this process on low alloy steel. A detailed set of experimental procedures specific to friction stir welding has been put forward, and the consequent study extensively examined the weld microstructure and hardness in support of the tensile and fatigue testing. The effect of varying welding parameters was also investigated. Microstructural observations have been correlated to the weldments’ fatigue behaviour. The typical fatigue performance of friction stir welded steel plates has been established, exhibiting fatigue lives well above the weld detail class of the International Institute of Welding even for tests at 90% of yield strength, irrespective of minor instances of surface breaking flaws which have been identified. An understanding of the manner in which these flaws impact on the fatigue performance has been established, concluding that surface breaking irregularities such as these produced by the tool shoulder’s features on the weld top surface can be the dominant factor for crack initiation under fatigue loading

  17. Friction stir spot welding of dissimilar aluminium alloys

    International Nuclear Information System (INIS)

    Bozkurt, Yahya

    2016-01-01

    Friction stir spot welding (FSSW) has been proposed as an effective technology to spot weld the so-called “difficult to be welded” metal alloys such as thin sheets aluminum alloys and dissimilar materials. FSSW is derived from friction stir welding technology, its principle benefit being low cost joining, lower welding temperature and shorter welding time than conventional welding methods. In this study, dissimilar AlMg 3 and AlCu 4 Mg 1 aluminium alloy plates were FSSWed by offsetting the low strength sheet on upper side of the weld. The effects of tool rotation speed on the microstructure, lap shear fracture load (LSFL), microhardness and fracture features of the weld are investigated by constant welding parameters. The maximum LSFL was obtained by increasing the tool rotational speed. However, the joints exhibited pull-out nugget fracture mode under lap shear tensile testing conditions. The largest completely bonded zone was observed as 5.86 mm which was narrower at the opposite position of the joint. Key words: friction stir spot welding, aluminium alloys, mechanical properties, dissimilar joint, welding parameters

  18. Mechanical properties of friction stir welded aluminum alloys 5083 and 5383

    Directory of Open Access Journals (Sweden)

    Jeom Kee Paik

    2009-09-01

    Full Text Available The use of high-strength aluminum alloys is increasing in shipbuilding industry, particularly for the design and construction of war ships, littoral surface craft and combat ships, and fast passenger ships. While various welding methods are used today to fabricate aluminum ship structures, namely gas metallic arc welding (GMAW, laser welding and friction stir welding (FSW, FSW technology has been recognized to have many advantages for the construction of aluminum structures, as it is a low-cost welding process. In the present study, mechanical properties of friction stir welded aluminum alloys are examined experimentally. Tensile testing is undertaken on dog-bone type test specimen for aluminum alloys 5083 and 5383. The test specimen includes friction stir welded material between identical alloys and also dissimilar alloys, as well as unwelded (base alloys. Mechanical properties of fusion welded aluminum alloys are also tested and compared with those of friction stir welded alloys. The insights developed from the present study are documented together with details of the test database. Part of the present study was obtained from the Ship Structure Committee project SR-1454 (Paik, 2009, jointly funded by its member agencies.

  19. Tensile behavior of friction stir welded AA 6061-T4 aluminum alloy joints

    International Nuclear Information System (INIS)

    Heidarzadeh, A.; Khodaverdizadeh, H.; Mahmoudi, A.; Nazari, E.

    2012-01-01

    Highlights: ► Range of parameters for defect-free friction stir welded AA 6061-T4 was reached. ► A model was developed for predicting UTS and EL of friction stir welded AA 6061-T4. ► The maximum values of UTS and EL of joints were estimated by developed model. ► The optimum values of FSW process parameters were determined. -- Abstract: In this investigation response surface methodology based on a central composite rotatable design with three parameters, five levels and 20 runs, was used to develop a mathematical model predicting the tensile properties of friction stir welded AA 6061-T4 aluminum alloy joints at 95% confidence level. The three welding parameters considered were tool rotational speed, welding speed and axial force. Analysis of variance was applied to validate the predicted model. Microstructural characterization and fractography of joints were examined using optical and scanning electron microscopes. Also, the effects of the welding parameters on tensile properties of friction stir welded joints were analyzed in detail. The results showed that the optimum parameters to get a maximum of tensile strength were 920 rev/min, 78 mm/min and 7.2 kN, where the maximum of tensile elongation was obtained at 1300 rev/min, 60 mm/min and 8 kN.

  20. Analysis of Microstructure Refinement During Single-Pass and Multi-Pass Friction Stir Processing of Nial Propeller Bronze

    Science.gov (United States)

    2010-09-01

    material. For example, tool steel can be used in aluminum, but tungsten-based alloys should be used in copper and titanium based alloys. The material...many other alloys such as copper, nickel, titanium, magnesium, and steels . In addition, each processed alloy had other material characteristics that... bainitic transformation is also possible. The martencite is a B2 structure with a lattice parameter of 2.85±0.03Å [8]. The B2 structure is a BCC structure

  1. Friction Stir Additive Manufacturing: Route to High Structural Performance

    Science.gov (United States)

    Palanivel, S.; Sidhar, H.; Mishra, R. S.

    2015-03-01

    Aerospace and automotive industries provide the next big opportunities for additive manufacturing. Currently, the additive industry is confronted with four major challenges that have been identified in this article. These challenges need to be addressed for the additive technologies to march into new frontiers and create additional markets. Specific potential success in the transportation sectors is dependent on the ability to manufacture complicated structures with high performance. Most of the techniques used for metal-based additive manufacturing are fusion based because of their ability to fulfill the computer-aided design to component vision. Although these techniques aid in fabrication of complex shapes, achieving high structural performance is a key problem due to the liquid-solid phase transformation. In this article, friction stir additive manufacturing (FSAM) is shown as a potential solid-state process for attaining high-performance lightweight alloys for simpler geometrical applications. To illustrate FSAM as a high-performance route, manufactured builds of Mg-4Y-3Nd and AA5083 are shown as examples. In the Mg-based alloy, an average hardness of 120 HV was achieved in the built structure and was significantly higher than that of the base material (97 HV). Similarly for the Al-based alloy, compared with the base hardness of 88 HV, the average built hardness was 104 HV. A potential application of FSAM is illustrated by taking an example of a simple stiffener assembly.

  2. Thermal Management in Friction-Stir Welding of Precipitation-Hardening Aluminum Alloys

    Energy Technology Data Exchange (ETDEWEB)

    Upadhyay, Piyush; Reynolds, Anthony

    2015-05-25

    Process design and implementation in FSW is mostly dependent on empirical information gathered through experience. Basic science of friction stir welding and processing can only be complete when fundamental interrelationships between process control parameters and response variables and resulting weld microstructure and properties are established to a reasonable extent. It is known that primary process control parameters like tool rotation and translation rate and forge axis force have complicated and interactive relationships to the process response variables such as peak temperature, time at temperature etc. Of primary influence to the other process response parameters are temperature and its gradient at the deformation and heat affected zones. Through review of pertinent works in the literature and some experimental results from boundary condition work performed in precipitation hardening aluminum alloys this paper will partially elucidate the nature and effects of temperature transients caused by variation of thermal boundaries in Friction Stir Welding.

  3. Friction Stir Weld Failure Mechanisms in Aluminum-Armor Structures Under Ballistic Impact Loading Conditions

    Science.gov (United States)

    2013-01-01

    REPORT Friction Stir Weld Failure Mechanisms in Aluminum-Armor Structures Under Ballistic Impact Loading Conditions 14. ABSTRACT 16. SECURITY...properties and of the attendant ballistic-impact failure mechanisms in prototypical friction stir welding (FSW) joints found in armor structures made of high...mechanisms, friction stir welding M. Grujicic, B. Pandurangan, A. Arakere, C-F. Yen, B. A. Cheeseman Clemson University Office of Sponsored Programs 300

  4. Mechanical properties of friction stir welded 11Cr-ferritic/martensitic steel

    International Nuclear Information System (INIS)

    Yano, Y.; Sato, Y.S.; Sekio, Y.; Ohtsuka, S.; Kaito, T.; Ogawa, R.; Kokawa, H.

    2013-01-01

    Friction stir welding was applied to the wrapper tube materials, 11Cr-ferritic/martensitic steel, designed for fast reactors and defect-free welds were successfully produced. The mechanical and microstructural properties of the friction stir welded steel were subsequently investigated. The hardness values of the stir zone were approximately 550 Hv (5.4 GPa) with minimal dependence on the rotational speed, even though they were much higher than those of the base material. However, tensile strengths and elongations of the stir zones were high at 298 K, compared to those of the base material. The excellent tensile properties are attributable to the fine grain formation during friction stir welding

  5. Anodising and corrosion resistance of AA 7050 friction stir welds

    International Nuclear Information System (INIS)

    Atz Dick, Pedro; Knörnschild, Gerhard H.; Dick, Luís F.P.

    2017-01-01

    Highlights: • Sulphuric Anodizing films of AA7050 friction stir welds are 25% thinner on the nugget zone. • Semicoherent MgZn_2 precipitates locally pin the formation of anodic oxide film. • Coarse Al_7Cu_2Fe precipitates anodize irregularly and produces locally thicker films. • Localized corrosion occurs preferentially on the nugget zone and is related to the thinner oxide film and irregular anodizing on stirring voids. - Abstract: The influence of friction stir welding on the sulphuric anodising and corrosion of AA7050 was studied in 0.1 M NaCl by the scanning vibrating electrode technique under simultaneous polarization. The oxide films obtained were characterized by scanning electron microscopy. The porous oxide films are up to 25% thicker on the thermomechanically and heat affected zones and 25% thinner on the nugget. This thinner defective oxide film explains the lower pitting resistance of the nugget zone. Individual pit current transients were indirectly determined from current maps. However, the calculated values are lower than expected, due to underestimation of electrolyte conductivity near pits.

  6. Microstructure and properties of friction stir butt-welded AZ31 magnesium alloy

    International Nuclear Information System (INIS)

    Wang Xunhong; Wang Kuaishe

    2006-01-01

    Friction stir welding (FSW) is a relatively new joining technique particularly for magnesium and aluminum alloys that are difficult to fusion weld. In this paper, an excellent friction stir weld of AZ31 magnesium alloy was obtained at proper parameter. In the friction stir zone (FSZ), the microstructure of the base material (BM) is replaced by fine grains and small particles of intermetallic compounds. The average microhardness of the friction stir zone is higher than that of the base material. The maximum tensile strength of joint can reach 93% that of the base material. And the failure locations are almost at the heating affected zone

  7. Mechanical properties and microstructural evaluation of AA1100 to AZ31 dissimilar friction stir welds

    Energy Technology Data Exchange (ETDEWEB)

    Azizieh, M., E-mail: azizieh@gmail.com [Department of Materials Science and Engineering, Ahvaz Branch, Islamic Azad University, Ahvaz (Iran, Islamic Republic of); Sadeghi Alavijeh, A. [School of Mechatronic Systems Engineering, Simon Fraser University, 250-13450 102 Avenue, Surrey, BC V3T 0A3 (Canada); Abbasi, M. [High Temperature Energy Materials, Korea Institute of Science and Technology, Seoul, 136-791 (Korea, Republic of); Balak, Z. [Department of Materials Science and Engineering, Ahvaz Branch, Islamic Azad University, Ahvaz (Iran, Islamic Republic of); Kim, H.S. [Department of Materials Science and Engineering, Pohang University of Science and Technology, Pohang, 790-784 (Korea, Republic of)

    2016-02-15

    In this paper, microstructure and mechanical properties of dissimilar friction stir welds of AA1100 and AZ31 were investigated to understand the effects of rotational and travel speed as well as pin position. The tensile results of welded samples revealed that the sound welds were formed when the stirring pin deviated from the centreline to the AZ31 side. The X-ray diffraction shows that Al{sub 3}Mg{sub 2} and Al{sub 12}Mg{sub 17} intermetallics formation occurs in the stir zone during the welding process. High hardness of these intermetallic phases increased the hardness of the stir zone to 110 Hv. The best tensile results were obtained in the sample processed in the range of 28–32 (rev/mm) rotational to travel speed ratio. - Highlights: • For Al to Mg friction stir welding, tool offset must be to Mg side. • There is an optimum rotational speed for obtain the highest strength. • Intermetallics form in any welding condition. • The volume fraction of intermetallic is directly related to FSW peak temperature.

  8. Counterrotating-Shoulder Mechanism for Friction Stir Welding

    Science.gov (United States)

    Nunes, Arthur C., Jr.

    2007-01-01

    A counterrotating-shoulder mechanism has been proposed as an alternative to the mechanism and fixtures used in conventional friction stir welding. The mechanism would internally react most or all of the forces and torques exerted on the workpiece, making it unnecessary to react the forces and torques through massive external fixtures. In conventional friction stir welding, a rotating pin tool is inserted into, and moved along, a weld seam. As the pin tool moves, it stirs together material from the opposite sides of the seam to form the weld. A large axial plunge force must be exerted upon the workpiece through and by the pin tool and a shoulder attached above the pin tool in order to maintain the pressure necessary for the process. The workpiece is secured on top of an anvil, which supports the workpiece against the axial plunge force and against the torque exerted by the pin tool and shoulder. The anvil and associated fixtures must be made heavy (and, therefore, are expensive) to keep the workpiece stationary. In addition, workpiece geometries must be limited to those that can be accommodated by the fixtures. The predecessor of the proposed counterrotating-shoulder mechanism is a second-generation, self-reacting tool, resembling a bobbin, that makes it possible to dispense with the heavy anvil. This tool consists essentially of a rotating pin tool with opposing shoulders. Although the opposing shoulders maintain the necessary pressure without need to externally apply or react a large plunge force, the torque exerted on the workpiece remains unreacted in the absence of a substantial external fixture. Depending on the RPM and the thickness of the workpiece, the torque can be large. The proposed mechanism (see figure) would include a spindle attached to a pin tool with a lower shoulder. The spindle would be coupled via splines to the upper one of three bevel gears in a differential drive. The middle bevel gear would be the power-input gear and would be coupled to the

  9. A continuum based fem model for friction stir welding-model development

    Energy Technology Data Exchange (ETDEWEB)

    Buffa, G. [Ohio State University, Department of Industrial, Welding and Systems Engineering, 1971 Neil Avenue, 210 Baker Systems, Columbus, OH 43210 (United States) and Dipartimento di Tecnologia Meccanica, Produzione e Ingegneria Gestionale, Universita di Palermo, Viale delle Scienze, 90128 Palermo (Italy)]. E-mail: g.buffa@dtpm.unipa.it; Hua, J. [Ohio State University, Department of Industrial, Welding and Systems Engineering, 1971 Neil Avenue, 210 Baker Systems, Columbus, OH 43210 (United States)]. E-mail: hua.14@osu.edu; Shivpuri, R. [Ohio State University, Department of Industrial, Welding and Systems Engineering, 1971 Neil Avenue, 210 Baker Systems, Columbus, OH 43210 (United States)]. E-mail: shivpuri.1@osu.edu; Fratini, L. [Dipartimento di Tecnologia Meccanica, Produzione e Ingegneria Gestionale, Universita di Palermo, Viale delle Scienze, 90128 Palermo (Italy)]. E-mail: abaqus@dtpm.unipa.it

    2006-03-15

    Although friction stir welding (FSW) has been successfully used to join materials that are difficult-to-weld or unweldeable by fusion welding methods, it is still in its early development stage and, therefore, a scientific knowledge based predictive model is of significant help for thorough understanding of FSW process. In this paper, a continuum based FEM model for friction stir welding process is proposed, that is 3D Lagrangian implicit, coupled, rigid-viscoplastic. This model is calibrated by comparing with experimental results of force and temperature distribution, then is used to investigate the distribution of temperature and strain in heat affect zone and the weld nugget. The model correctly predicts the non-symmetric nature of FSW process, and the relationships between the tool forces and the variation in the process parameters. It is found that the effective strain distribution is non-symmetric about the weld line while the temperature profile is almost symmetric in the weld zone.

  10. A continuum based fem model for friction stir welding-model development

    International Nuclear Information System (INIS)

    Buffa, G.; Hua, J.; Shivpuri, R.; Fratini, L.

    2006-01-01

    Although friction stir welding (FSW) has been successfully used to join materials that are difficult-to-weld or unweldeable by fusion welding methods, it is still in its early development stage and, therefore, a scientific knowledge based predictive model is of significant help for thorough understanding of FSW process. In this paper, a continuum based FEM model for friction stir welding process is proposed, that is 3D Lagrangian implicit, coupled, rigid-viscoplastic. This model is calibrated by comparing with experimental results of force and temperature distribution, then is used to investigate the distribution of temperature and strain in heat affect zone and the weld nugget. The model correctly predicts the non-symmetric nature of FSW process, and the relationships between the tool forces and the variation in the process parameters. It is found that the effective strain distribution is non-symmetric about the weld line while the temperature profile is almost symmetric in the weld zone

  11. Heat generation during plunge stage in friction stir welding

    Directory of Open Access Journals (Sweden)

    Veljić Darko M.

    2013-01-01

    Full Text Available This paper deals with the heat generation in the Al alloy Al2024-T3 plate under different rotating speeds and plunge speeds during the plunge stage of friction stir welding (FSW. A three-dimensional finite element model (FEM is developed in the commercial code ABAQUS/Explicit using the arbitrary Lagrangian-Eulerian formulation, the Johnson-Cook material law and Coulomb’s Law of friction. The heat generation in FSW can be divided into two parts: frictional heat generated by the tool and heat generated by material deformation near the pin and the tool shoulder region. Numerical results obtained in this work indicate a more prominent influence from the friction-generated heat. The slip rate of the tool relative to the workpiece material is related to this portion of heat. The material velocity, on the other hand, is related to the heat generated by plastic deformation. Increasing the plunging speed of the tool decreases the friction-generated heat and increases the amount of deformation-generated heat, while increasing the tool rotating speed has the opposite influence on both heat portions. Numerical results are compared with the experimental ones, in order to validate the numerical model, and a good agreement is obtained.

  12. Multiple Crack Growth Prediction in AA2024-T3 Friction Stir Welded Joints, Including Manufacturing Effects

    DEFF Research Database (Denmark)

    Carlone, Pierpaolo; Citarella, Roberto; Sonne, Mads Rostgaard

    2016-01-01

    A great deal of attention is currently paid by several industries toward the friction stir welding process to realize lightweight structures. Within this aim, the realistic prediction of fatigue behavior of welded assemblies is a key factor. In this work an integrated finite element method - dual...... boundary element method (FEM-DBEM) procedure, coupling the welding process simulation to the subsequent crack growth assessment, is proposed and applied to simulate multiple crack propagation, with allowance for manufacturing effects. The friction stir butt welding process of the precipitation hardened AA...... on a notched specimen. The whole procedure was finally tested comparing simulation outcomes with experimental data. The good agreement obtained highlights the predictive capability of the method. The influence of the residual stress distribution on crack growth and the mutual interaction between propagating...

  13. Friction stir welding (FSW of aluminium foam sandwich panels

    Directory of Open Access Journals (Sweden)

    M. Bušić

    2016-07-01

    Full Text Available The article focuses on the influence of welding speed and tool tilt angle upon the mechanical properties at the friction stir welding of aluminium foam sandwich panels. Double side welding was used for producing butt welds of aluminium sandwich panels applying insertion of extruded aluminium profile. Such insertion provided lower pressure of the tool upon the aluminium panels, providing also sufficient volume of the material required for the weldment formation. Ultimate tensile strength and flexural strength for three-point bending test have been determined for samples taken from the welded joints. Results have confirmed anticipated effects of independent variables.

  14. Tensile behavior of dissimilar friction stir welded joints of aluminium alloys

    International Nuclear Information System (INIS)

    Shanmuga Sundaram, N.; Murugan, N.

    2010-01-01

    The heat treatable aluminium alloy AA2024 is used extensively in the aircraft industry because of its high strength to weight ratio and good ductility. The non-heat treatable aluminium alloy AA5083 possesses medium strength and high ductility and used typically in structural applications, marine, and automotive industries. When compared to fusion welding processes, friction stir welding (FSW) process is an emerging solid state joining process which is best suitable for joining these alloys. The friction stir welding parameters such as tool pin profile, tool rotational speed, welding speed, and tool axial force influence the mechanical properties of the FS welded joints significantly. Dissimilar FS welded joints are fabricated using five different tool pin profiles. Central composite design with four parameters, five levels, and 31 runs is used to conduct the experiments and response surface method (RSM) is employed to develop the model. Mathematical regression models are developed to predict the ultimate tensile strength (UTS) and tensile elongation (TE) of the dissimilar friction stir welded joints of aluminium alloys 2024-T6 and 5083-H321, and they are validated. The effects of the above process parameters and tool pin profile on tensile strength and tensile elongation of dissimilar friction stir welded joints are analysed in detail. Joints fabricated using Tapered Hexagon tool pin profile have the highest tensile strength and tensile elongation, whereas the Straight Cylinder tool pin profile have the lowest tensile strength and tensile elongation. The results are useful to have a better understanding of the effects of process parameters, to fabricate the joints with desired tensile properties, and to automate the FS welding process.

  15. Friction stir welding: multi-response optimisation using Taguchi-based GRA

    Directory of Open Access Journals (Sweden)

    Jitender Kundu

    2016-01-01

    Full Text Available In present experimental work, friction stir welding of aluminium alloy 5083- H321 is performed for optimisation of process parameters for maximum tensile strength. Taguchi’s L9 orthogonal array has been used for three parameters – tool rotational speed (TRS, traverse speed (TS, and tool tilt angle (TTA with three levels. Multi-response optimisation has been carried out through Taguchi-based grey relational analysis. The grey relational grade has been calculated for all three responses – ultimate tensile strength, percentage elongation, and micro-hardness. Analysis of variance is the tool used for obtaining grey relational grade to find out the significant process parameters. TRS and TS are the two most significant parameters which influence most of the quality characteristics of friction stir welded joint. Validation of predicted values done through confirmation experiments at optimum setting shows a good agreement with experimental values.

  16. A review of literature from the First International Conference on Friction Stir Welding

    International Nuclear Information System (INIS)

    Bowyer, W.H.

    2000-06-01

    The papers from the first international conference on Friction Stir Welding (FSW) have been reviewed. Taken together the papers provide a very optimistic picture for the development and application of friction stir welding in general and to the case of the copper canister in particular. Whilst a considerable development effort is in progress the process has been industrialised for joining of aluminium sheet and it is accepted by Lloyds register for this purpose. Development of procedures and equipment to weld thicker materials and a wider range of materials is progressing ahead of the research activity to aid the understanding of the process at this stage. Nevertheless, well-established weld assessment procedures are being applied to experimental welds with very encouraging results. Summaries of the key papers are presented in an appendix

  17. Microstructure of friction stir welded joints of 2017A aluminium alloy sheets.

    Science.gov (United States)

    Mroczka, K; Dutkiewicz, J; Pietras, A

    2010-03-01

    The present study examines a friction stir welded 2017A aluminium alloy. Transmission electron microscope investigations of the weld nugget revealed the average grain size of 5 microm, moderate density of dislocations as well as the presence of nanometric precipitates located mostly in grains interiors. Scanning electron microscope observations of fractures showed the presence of ductile fracture in the region of the weld nugget with brittle precipitates in the lower part. The microhardness analysis performed on the cross-section of the joints showed fairly small changes; however, after the artificial ageing process an increase in hardness was observed. The change of the joint hardness subject to the ageing process indicates partial supersaturation in the material during friction stir welding and higher precipitation hardening of the joint.

  18. Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

    Science.gov (United States)

    Alcorn, John

    2013-01-01

    The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication

  19. Investigation and modelling of friction stir welded copper canisters

    Energy Technology Data Exchange (ETDEWEB)

    Kaellgren, Therese

    2010-02-15

    This work has been focused on characterisation of FSW joints, and modelling of the process, both analytically and numerically. The Swedish model for final deposit of nuclear fuel waste is based on copper canisters as a corrosion barrier with an inner pressure holding insert of cast iron. Friction Stir Welding (FSW) is the method to seal the copper canister, a technique invented by The Welding Institute (TWI). The first simulations were based on Rosenthal's analytical medium plate model. The model is simple to use, but has limitations. Finite element models (FEM) were developed, initially with a two-dimensional geometry. Due to the requirements of describing both the heat flow and the tool movement, three-dimensional models were developed. These models take into account heat transfer, material flow, and continuum mechanics. The geometries of the models are based on the simulation experiments carried out at TWI and at Swedish Nuclear Fuel Waste and Management Co (SKB). Temperature distribution, material flow and their effects on the thermal expansion were predicted for a full-scale canister and lid. The steady state solutions have been compared with temperature measurements, showing good agreement. In order to understand the material flow during welding a marker technique is used, which involves inserting dissimilar material into the weld zone before joining. Different materials are tested showing that brass rods are the most suitable material in these welds. After welding, the weld line is sliced, etched and examined by optical microscope. To understand the material flow further, and in the future predict the flow, a FEM is developed. This model and the etched samples are compared showing similar features. Furthermore, by using this model the area that is recrystallised can be predicted. The predicted area and the grain size and hardness profile agree well

  20. Friction Stir Welding of Copper Canisters for Nuclear Waste

    Energy Technology Data Exchange (ETDEWEB)

    Kaellgren, Therese

    2005-07-01

    The Swedish model for final disposal of nuclear fuel waste is based on copper canisters as a corrosion barrier with an inner pressure holding insert of cast iron. One of the methods to seal the copper canister is to use the Friction Stir Welding (FSW), a method invented by The Welding Institute (TWI). This work has been focused on characterisation of the FSW joints, and modelling of the process, both analytically and numerically. The first simulations were based on Rosenthal's analytical medium plate model. The model is simple to use, but has limitations. Finite element models were developed, initially with a two-dimensional geometry. Due to the requirements of describing both the heat flow and the tool movement, three-dimensional models were developed. These models take into account heat transfer, material flow, and continuum mechanics. The geometries of the models are based on the simulation experiments carried out at TWI and at Swedish Nuclear Fuel Waste and Management Co (SKB). Temperature distribution, material flow and their effects on the thermal expansion were predicted for a full-scale canister and lid. The steady state solutions have been compared with temperature measurements, showing good agreement. Microstructure and hardness profiles have been investigated by optical microscope, Scanning Electron Microscope (SEM), Electron Back Scatter Diffraction (EBSD) and Rockwell hardness measurements. EBSD visualisation has been used to determine the grain size distribution and the appearance of twins and misorientation within grains. The orientation maps show a fine uniform equiaxed grain structure. The root of the weld exhibits the smallest grains and many annealing twins. This may be due to deformation after recrystallisation. The appearance of the nugget and the grain size depends on the position of the weld. A large difference can be seen both in hardness and grain size between the start of the weld and when the steady state is reached.

  1. Friction Stir Weld Restart+Reweld Repair Allowables

    Science.gov (United States)

    Clifton, Andrew

    2008-01-01

    A friction stir weld (FSW) repair method has been developed and successfully implemented on Al 2195 plate material for the Space Shuttle External Fuel Tank (ET). The method includes restarting the friction stir weld in the termination hole of the original weld followed by two reweld passes. Room temperature and cryogenic temperature mechanical properties exceeded minimum FSW design strength and compared well with the development data. Simulated service test results also compared closely to historical data for initial FSW, confirming no change to the critical flaw size or inspection requirements for the repaired weld. Testing of VPPA fusion/FSW intersection weld specimens exhibited acceptable strength and exceeded the minimum design value. Porosity, when present at the intersection was on the root side toe of the fusion weld, the "worst case" being 0.7 inch long. While such porosity may be removed by sanding, this "worst case" porosity condition was tested "as is" and demonstrated that porosity did not negatively affect the strength of the intersection weld. Large, 15-inch "wide panels" FSW repair welds were tested to demonstrate strength and evaluate residual stresses using photo stress analysis. All results exceeded design minimums, and photo stress analysis showed no significant stress gradients due to the presence of the restart and multi-pass FSW repair weld.

  2. Effects of Laser Peening, and Shot Peening, on Friction Stir Welding

    Science.gov (United States)

    Hatamleh, Omar; Hackel, Lloyd; Rankin, Jon; Truong, Chanh; Walter, Matt

    2006-01-01

    A viewgraph presentation describing the effects of laser peening and shot peening on friction stir welding is shown. The topics include: 1) Background; 2) Friction Stir Welding (FSW); 3) Microstructure; 4) Laser & Shot Peening; 5) Residual Stresses; 6) Tensile Behavior; 7) Fatigue Life & Surface Roughness; 8) Crack Growth; and 9) Benefits.

  3. Numerical Simulation of Mechanical Property of Post Friction Stir Weld Artificial Ageing of Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    WAN Zhenyu

    2017-08-01

    Full Text Available KWN model was used to establish the precipitation evolution model of friction stir welding of Al-Mg-Si alloy. The yield strength was divided into three parts:the contribution from grain size, the contribution from solid solution and the contribution from the precipitations. Based on this model, the yield strength and hardness of friction stir weld was predicted. The effect of post weld artificial ageing on mechanical properties of friction stir weld was further investigated. The results indicate that longer holding time can be beneficial to the recovery of mechanical properties in the stirring zone. Higher temperature can lead to quick recovery of mechanical properties in the stirring zone, but when the holding temperature is higher than 200℃, longer holding time can lead the base metal softened, which is harmful to the service of friction stir welds. The mechanical property in the heat affected zone cannot be improved by post weld artificial ageing.

  4. Friction-Stir-Welded and Spin-Formed End Domes for Cryogenic Tanks

    Science.gov (United States)

    Hales, S. J.; Tayon, W. A.; Domack, M. S.

    2012-01-01

    Manufacturing of single-piece end domes for cryogenic tanks employing spin forming of tailored, friction-stir-welded blanks of Al-Li alloy 2195 plate offers cost and reliability benefits. The introduction of plastic deformation into a friction stir weld is a unique feature of the proposed manufacturing route. This investigation addressed abnormal grain growth [AGG] within the friction stir weldments during postfabrication processing of a prototype dome. The phenomenon of AGG was observed during the solution heat treatment [SHT] phase of T8 tempering and is a major concern for meeting specifications. Such abrupt microstructural transitions can be detrimental to notch-sensitive mechanical properties, such as ductility and/or fracture toughness. If the issue of AGG cannot be resolved, then the acceptance of this approach as a viable manufacturing route may be in jeopardy. The innovative approach adopted in this investigation was the insertion of a stand-alone, Intermediate Annealing Treatment [IAT] between the spin forming and T8 processing operations. A simple, recovery annealing step was deemed to be the most readily-scalable solution when fabricating thin-walled, ellipsoidal domes. The research effort culminated in the development of an effective IAT, which resulted in a significant decrease in AGG following SHT. The processing philosophy adopted in designing the IAT is outlined and the microstructural reasons for success are discussed. The analytical results presented are consistent with promoting continuous grain growth during the IAT, thereby suppressing AGG during the SHT.

  5. Residual stresses analysis of friction stir welding using one-way FSI simulation

    International Nuclear Information System (INIS)

    Kang, Sung Wook; Jang, Beom Seon; Song, Ha Cheol

    2015-01-01

    When certain mechanisms, such as plastic deformations and temperature gradients, occur and are released in a structure, stresses remain because of the shape of the structure and external constraints. These stresses are referred to as residual stresses. The base material locally expands during heating in the welding process. When the welding is completed and cooled to room temperature, the residual stresses are left at nearly the yield strength level. In the case of friction stir welding, the maximum temperature is 80% to 90% of the melting point of the materials. Thus, the residual stresses in the welding process are smaller than those in other fusion welding processes; these stresses have not been considered previously. However, friction stir welding residual stresses are sometimes measured at approximately 70% or above. These residual stresses significantly affect fatigue behavior and lifetime. The present study investigates the residual stress distributions in various welding conditions and shapes of friction stir welding. In addition, the asymmetric feature is considered in temperature and residual stress distribution. Heat transfer analysis is conducted using the commercial computational fluid dynamics program Fluent, and results are used in the finite element structural analysis with the ANSYS Multiphysics software. The calculated residual stresses are compared with experimental values using the X-ray diffraction method.

  6. Effect of cryogenic cooling on corrosion of friction stir welded AA7010-T7651

    DEFF Research Database (Denmark)

    Jariyaboon, Manthana; Davenport, A. J.; Ambat, Rajan

    2010-01-01

    Purpose - The purpose of this paper is to study how cryogenic CO2 cooling during the welding process affects corrosion behaviour of friction stir welding (FSW) AA7010-T7651. Design/methodology/approach - Friction stir welded AA7010-17651 was produced with a rotation speed of 288 rpm and a travel...... speed of 58 mm/min. The liquid CO2 was sprayed onto the weld centre line immediately after the toolpiece. The microstructures of welds in different regions were observed using Field Emission Gun Scanning Electron Microscope (FEG-SEM). The effect on the corrosion susceptibility was investigated using...... a gel visualisation test and potentiodynamic polarisation measurements using a micro-electrochemical technique. Findings - The main corrosion region for both FSWs AA7010-T7651 produced with and without cryogenic CO2 cooling is in the HAZ region, which exhibited intergranular attack. Cryogenic cooling...

  7. Microstructure and anisotropic mechanical behavior of friction stir welded AA2024 alloy sheets

    Energy Technology Data Exchange (ETDEWEB)

    Zhang, Zhihan [State Key Laboratory of Solidification Processing, Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi' an 710072, Shaanxi (China); Li, Wenya, E-mail: liwy@nwpu.edu.cn [State Key Laboratory of Solidification Processing, Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi' an 710072, Shaanxi (China); Li, Jinglong [State Key Laboratory of Solidification Processing, Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi' an 710072, Shaanxi (China); Chao, Y.J. [Department of Mechanical Engineering, University of South Carolina, Columbia, SC 29208 (United States); Vairis, A. [Mechanical Engineering Department, TEI of Crete, Heraklion, Crete 71004 (Greece)

    2015-09-15

    The anisotropic mechanical properties of friction stir welded (FSW) AA2024-T3 alloy joints were investigated based on the uniaxial tensile tests. The joint microstructure was examined by using electron back-scattered diffraction and transmission electron microscope. Results show that the evident anisotropic failure and yielding are present in the FSW joints. With the increase of loading angle from 0° to 90° the ultimate tensile strength and elongation of the specimens consistently decrease, or at first decrease and then increase, depending on the FSW process parameters. The specimen cut from the weld direction, i.e. a loading angle of 0°, exhibits the highest strength and elongation. - Highlights: • Microstructure and anisotropy of friction stir welded joints were studied. • The evident anisotropic failure and yielding are present in joints. • The lowest yield stress and UTS are at 45° and 60° loadings, respectively. • Rotation speed heavily impact on the anisotropy of joints.

  8. Microstructure and anisotropic mechanical behavior of friction stir welded AA2024 alloy sheets

    International Nuclear Information System (INIS)

    Zhang, Zhihan; Li, Wenya; Li, Jinglong; Chao, Y.J.; Vairis, A.

    2015-01-01

    The anisotropic mechanical properties of friction stir welded (FSW) AA2024-T3 alloy joints were investigated based on the uniaxial tensile tests. The joint microstructure was examined by using electron back-scattered diffraction and transmission electron microscope. Results show that the evident anisotropic failure and yielding are present in the FSW joints. With the increase of loading angle from 0° to 90° the ultimate tensile strength and elongation of the specimens consistently decrease, or at first decrease and then increase, depending on the FSW process parameters. The specimen cut from the weld direction, i.e. a loading angle of 0°, exhibits the highest strength and elongation. - Highlights: • Microstructure and anisotropy of friction stir welded joints were studied. • The evident anisotropic failure and yielding are present in joints. • The lowest yield stress and UTS are at 45° and 60° loadings, respectively. • Rotation speed heavily impact on the anisotropy of joints

  9. Characteristics of Laser Beam and Friction Stir Welded AISI 409M Ferritic Stainless Steel Joints

    Science.gov (United States)

    Lakshminarayanan, A. K.; Balasubramanian, V.

    2012-04-01

    This article presents the comparative evaluation of microstructural features and mechanical properties of friction stir welded (solid-state) and laser beam welded (high energy density fusion welding) AISI 409M grade ferritic stainless steel joints. Optical microscopy, microhardness testing, transverse tensile, and impact tests were performed. The coarse ferrite grains in the base material were changed to fine grains consisting duplex structure of ferrite and martensite due to the rapid cooling rate and high strain induced by severe plastic deformation caused by frictional stirring. On the other hand, columnar dendritic grain structure was observed in fusion zone of laser beam welded joints. Tensile testing indicates overmatching of the weld metal relative to the base metal irrespective of the welding processes used. The LBW joint exhibited superior impact toughness compared to the FSW joint.

  10. Spatially resolved positron annihilation spectroscopy on friction stir weld induced defects.

    Science.gov (United States)

    Hain, Karin; Hugenschmidt, Christoph; Pikart, Philip; Böni, Peter

    2010-04-01

    A friction stir welded (FSW) Al alloy sample was investigated by Doppler broadening spectroscopy (DBS) of the positron annihilation line. The spatially resolved defect distribution showed that the material in the joint zone becomes completely annealed during the welding process at the shoulder of the FSW tool, whereas at the tip, annealing is prevailed by the deterioration of the material due to the tool movement. This might be responsible for the increased probability of cracking in the heat affected zone of friction stir welds. Examination of a material pairing of steel S235 and the Al alloy Silafont36 by coincident Doppler broadening spectroscopy (CDBS) indicates the formation of annealed steel clusters in the Al alloy component of the sample. The clear visibility of Fe in the CDB spectra is explained by the very efficient trapping at the interface between steel cluster and bulk.

  11. Microstructures and electrochemical behaviors of the friction stir welding dissimilar weld.

    Science.gov (United States)

    Shen, Changbin; Zhang, Jiayan; Ge, Jiping

    2011-06-01

    By using optical microscope, the microstructures of 5083/6082 friction stir welding (FSW) weld and parent materials were analyzed. Meanwhile, at ambient temperature and in 0.2 mol/L NaHS03 and 0.6 mol/L NaCl solutionby gravimetric test, potentiodynamic polarization curve test, electrochemical impedance spectra (EIS) and scanning electron microscope (SEM) observation, the electrochemical behavior of 5083/6082 friction stir welding weld and parent materials were comparatively investigated by gravimetric test, potentiodynamic polarization curve test, electrochemical impedance spectra (EIS) and scanning electron microscope (SEM) observation. The results indicated that at given processing parameters, the anti-corrosion property of the dissimilar weld was superior to those of the 5083 and 6082 parent materials. Copyright © 2011 The Research Centre for Eco-Environmental Sciences, Chinese Academy of Sciences. Published by Elsevier B.V. All rights reserved.

  12. The investigation of abnormal particle-coarsening phenomena in friction stir repair weld of 2219-T6 aluminum alloy

    International Nuclear Information System (INIS)

    Li, Bo; Shen, Yifu

    2011-01-01

    Highlights: → Defective friction stir welds were repaired by overlapping FSW technique. → Abnormal Al 2 Cu-coarsening phenomena were found in 2219-T6 friction stir repair weld. → Three formation mechanisms were proposed for reasonable explanations. -- Abstract: The single-pass friction stir weld of aluminum 2219-T6 with weld-defects was repaired by overlapping friction stir welding technique. However, without any post weld heat treatment process, it was found that the phenomena of abnormal particle-coarsening of Al 2 Cu had occurred in the overlapping friction stir repair welds. The detecting results of non-destructive X-ray inspection proved that not only one group of repair FSW process parameters could lead to occurrence of the abnormal phenomena. And the abnormally coarsened particles always appeared on the advancing side of repair welds rather than the retreating side where the fracture behaviors occurred after mechanical tensile testing. The size of the biggest particle lying in the dark bands of 'Onion-rings' was more than 150 μm. After the related investigation by scanning electron microscope and X-ray energy spectrometer, three types of formation mechanisms were proposed for reasonably explaining the abnormal phenomenon: Aggregation Mechanism, Diffusion Mechanisms I and II. Aggregation Mechanism was according to the motion-laws of stir-pin. Diffusion Mechanisms were based on the classical theories of precipitate growth in metallic systems. The combined action of the three detailed mechanisms contributed to the abnormal coarsening behavior of Al 2 Cu particles in the friction stir repair weld.

  13. Effects of process parameters on microstructure and mechanical properties of friction stir lap linear welded 6061 aluminum alloy to NZ30K magnesium alloy

    Directory of Open Access Journals (Sweden)

    Shuai Tan

    2017-03-01

    Full Text Available The microstructures and lap-shear behaviors of friction stir lap linear welded as-extruded 6061 Al alloy to as-cast Mg–3.0Nd–0.2Zn–0.7Zr (wt.% (NZ30K alloy joints were examined. Various tool rotation and travel speeds were adopted to prepare the joints. The analysis of temperature field indicates that the peak temperature for each sample can reach 450 °C, which exceeds the eutectic reaction temperatures of 437 °C and 450 °C according to the binary phase diagram of Al–Mg system. The fierce intermixing can be found at the interface between Al and Mg alloys, forming the intermetallic of Al3Mg2. Welds with the rotation speed of 900 rpm and travel speed of 120 mm/min display the highest tensile shear failure load of about 2.24 kN. The value was increased by 13% after the sample was heat treated at 400 °C for 0.5 h.

  14. The inhomogeneous microstructure and deformation of similar and dissimilar Al-Zn containing Mg friction stir welds

    Science.gov (United States)

    Hiscocks, Jessica

    The magnesium-based aluminum-zinc alloys have excellent stiffness to weight ratios, and may be combined by friction stir welding to expand the possible applications. The high aluminum alloy AZ80 in particular has the advantage of being relatively stiff but still extrudable. However limited friction stir welding research is available for this alloy and extrapolation from the extensive work in aluminum alloys is impractical due differences in precipitation behaviour, and magnesium's high plastic anisotropy and tendency to form strong textures during friction stir welding. This work investigates the correlations between local friction stir welded microstructures, textures, residual strains, and the local deformation behaviour based on strain mapping during tensile tests. Covering bead-on-plate and butt configurations, joining of similar and dissimilar materials, and a range of processing conditions, many findings of interest for deformation modelling and industrial applications are presented. Synchrotron x-ray diffraction study of an entire friction stir weld was used to determine texture, residual strain and dislocation density data from a single experiment. A number of unique findings were made, mainly related to the asymmetric distribution of properties both between sides of the weld and through the depth. Particularly in the case of strain measurements, features not detectable at coarser measurement spacing or by line scan are presented and compared for multiple processing conditions. Investigation of the longitudinal material flow during welding showed that even when periodicity in grain size, precipitate distribution, or texture was not observed, periodic changes in texture intensity resulting from compaction of material behind the tool were present, providing evidence that movement of nugget material remained periodic. Strain localisation and fracture behaviour were found to be completely different between good quality similar and dissimilar friction stir welds

  15. Inverse Thermal Analysis of Ti-6Al-4V Friction Stir Welds Using Numerical-Analytical Basis Functions with Pseudo-Advection

    Science.gov (United States)

    Lambrakos, S. G.

    2018-04-01

    Inverse thermal analysis of Ti-6Al-4V friction stir welds is presented that demonstrates application of a methodology using numerical-analytical basis functions and temperature-field constraint conditions. This analysis provides parametric representation of friction-stir-weld temperature histories that can be adopted as input data to computational procedures for prediction of solid-state phase transformations and mechanical response. These parameterized temperature histories can be used for inverse thermal analysis of friction stir welds having process conditions similar those considered here. Case studies are presented for inverse thermal analysis of friction stir welds that use three-dimensional constraint conditions on calculated temperature fields, which are associated with experimentally measured transformation boundaries and weld-stir-zone cross sections.

  16. The Effect of Vibration during Friction Stir Welding on Corrosion Behavior, Mechanical Properties, and Machining Characteristics of Stir Zone

    Directory of Open Access Journals (Sweden)

    Sajad Fouladi

    2017-10-01

    Full Text Available Different methods have been applied to refine various characteristics of the zone (or nugget obtained by friction stir welding (FSW. In the current research, joining components are vibrated normal to the weld line during FSW to refine the zone microstructure. This process is described as friction stir vibration welding (FSVW. The effect of FSVW on mechanical properties, corrosion behavior, and machining characteristics of the zone are investigated. Al5052 alloy specimens are welded using FSW and FSVW processes and their different characteristics are compared and discussed. The results show that the strength and ductility of the welded parts increase when the vibration is applied. The outcomes also show that corrosion resistance of the nugget for FSV-welded specimens is lower than FS welded samples, and machining force of the former specimens is higher than the latter ones. These are related to smaller grain size in the zone of FSV-welded specimens compared to FS welded parts. Smaller grain size leads to a greater volume fraction of grain boundaries and, correspondingly, higher strength and hardness, as well as lower corrosion resistance.

  17. Microstructure and mechanical properties of hard zone in friction stir welded X80 pipeline steel relative to different heat input

    Energy Technology Data Exchange (ETDEWEB)

    Aydin, Hakan, E-mail: hakanay@uludag.edu.tr [Engineering and Architecture Faculty, Mechanical Engineering Department, Uludag University, 16059 Gorukle-Bursa (Turkey); Nelson, Tracy W. [Mechanical Engineering Department, Brigham Young University, 435 CTB, Provo, UT 84602 (United States)

    2013-12-01

    The study was conducted to investigate the microstructure and mechanical properties of the hard zone in friction stir welded X80 pipeline steel at different heat inputs. Microstructural analysis of the welds was carried out using optical microscopy, transmission electron microscopy, and microhardness. Heat input during friction stir welding process had a significant influence on the microstructure and mechanical properties in the hard zone along the advancing side of the weld nugget. Based on the results, the linear relationships between heat input and post-weld microstructures and mechanical properties in the hard zone of friction stir welded X80 steels were established. It can be concluded that with decrease in heat input the bainitic structure in the hard zone becomes finer and so hard zone strength increases.

  18. Microstructure and mechanical properties of hard zone in friction stir welded X80 pipeline steel relative to different heat input

    International Nuclear Information System (INIS)

    Aydin, Hakan; Nelson, Tracy W.

    2013-01-01

    The study was conducted to investigate the microstructure and mechanical properties of the hard zone in friction stir welded X80 pipeline steel at different heat inputs. Microstructural analysis of the welds was carried out using optical microscopy, transmission electron microscopy, and microhardness. Heat input during friction stir welding process had a significant influence on the microstructure and mechanical properties in the hard zone along the advancing side of the weld nugget. Based on the results, the linear relationships between heat input and post-weld microstructures and mechanical properties in the hard zone of friction stir welded X80 steels were established. It can be concluded that with decrease in heat input the bainitic structure in the hard zone becomes finer and so hard zone strength increases

  19. Thermal stir welding process

    Science.gov (United States)

    Ding, R. Jeffrey (Inventor)

    2012-01-01

    A welding method is provided for forming a weld joint between first and second elements of a workpiece. The method includes heating the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.

  20. Bonding prediction in friction stir consolidation of aluminum alloys: A preliminary study

    Science.gov (United States)

    Baffari, Dario; Reynolds, Anthony P.; Li, Xiao; Fratini, Livan

    2018-05-01

    Friction Stir Consolidation (FSC) is a solid-state process that results in consolidation of metal powders or chips producing solid billet through severe plastic deformation and the solid-state bonding phenomena. This process can be used both for primary production and for metal scrap recycling. During the FSC process, a rotating die is plunged into a hollow chamber containing the finely divided, unconsolidated material to be processed. In this paper, a FEM numerical model for the prediction of the quality of the consolidated billet is presented. In particular, a dedicated bonding criterion that takes into account the peculiar process mechanics of this innovative technology is proposed.

  1. Designing aluminium friction stir welded joints against multiaxial fatigue

    Directory of Open Access Journals (Sweden)

    L. Susmel

    2016-07-01

    Full Text Available The present paper investigates the accuracy of the Modified Wöhler Curve Method (MWCM in estimating multiaxial fatigue strength of aluminium friction stir (FS welded joints. Having developed a bespoke joining technology, circumferentially FS welded tubular specimens of Al 6082-T6 were tested under proportional and non-proportional tension and torsion, the effect of non-zero mean stresses being also investigated. The validation exercise carried out using the experimental results have demonstrated that the MWCM applied in terms of nominal stresses, notch stresses, and also the Point Method is accurate in predicting the fatigue lifetime of the tested FS welded joints, with its use resulting in life estimates that fall within the uniaxial and torsional calibration scatter bands.

  2. Micro friction stir welding of copper electrical contacts

    Directory of Open Access Journals (Sweden)

    D. Klobčar

    2014-10-01

    Full Text Available The paper presents an analysis of micro friction stir welding (μFSW of electrolytic tough pitch copper (CuETP in a lap and butt joint. Experimental plan was done in order to investigate the influence of tool design and welding parameters on the formation of defect free joints. The experiments were done using universal milling machine where the tool rotation speed varied between 600 and 1 900 rpm, welding speed between 14 and 93 mm/min and tilt angle between 3° and 5°. From the welds samples for analysis of microstructure and samples for tensile tests were prepared. The grain size in the nugget zone was greatly reduced compared to the base metal and the joint tensile strength exceeded the strength of the base metal.

  3. The study on defects in aluminum 2219-T6 thick butt friction stir welds with the application of multiple non-destructive testing methods

    International Nuclear Information System (INIS)

    Li, Bo; Shen, Yifu; Hu, Weiye

    2011-01-01

    Research highlights: → Friction stir weld-defect forming mechanisms of thick butt-joints. → Relationship between weld-defects and friction stir welding process parameters. → Multiple non-destructive testing methods applied to friction stir welds. → Empirical criterion basing on mass-conservation for inner material-loss defects. → Nonlinear correlation between weld strengths and root-flaw lengths. -- Abstract: The present study focused on the relationship between primary friction stir welding process parameters and varied types of weld-defect discovered in aluminum 2219-T6 friction stir butt-welds of thick plates, meanwhile, the weld-defect forming mechanisms were investigated. Besides a series of optical metallographic examinations for friction stir butt welds, multiple non-destructive testing methods including X-ray detection, ultrasonic C-scan testing, ultrasonic phased array inspection and fluorescent penetrating fluid inspection were successfully used aiming to examine the shapes and existence locations of different weld-defects. In addition, precipitated Al 2 Cu phase coarsening particles were found around a 'kissing-bond' defect within the weld stirred nugget zone by means of scanning electron microscope and energy dispersive X-ray analysis. On the basis of volume conservation law in material plastic deformation, a simple empirical criterion for estimating the existence of inner material-loss defects was proposed. Defect-free butt joints were obtained after process optimization of friction stir welding for aluminum 2219-T6 plates in 17-20 mm thickness. Process experiments proved that besides of tool rotation speed and travel speed, more other appropriate process parameter variables played important roles at the formation of high-quality friction stir welds, such as tool-shoulder target depth, spindle tilt angle, and fixture clamping conditions on the work-pieces. Furthermore, the nonlinear correlation between weld tensile strengths and weld crack

  4. Bobbin-Tool Friction-Stir Welding of Thick-Walled Aluminum Alloy Pressure Vessels

    Energy Technology Data Exchange (ETDEWEB)

    Dalder, E C; Pastrnak, J W; Engel, J; Forrest, R S; Kokko, E; Ternan, K M; Waldron, D

    2007-06-06

    It was desired to assemble thick-walled Al alloy 2219 pressure vessels by bobbin-tool friction-stir welding. To develop the welding-process, mechanical-property, and fitness-for-service information to support this effort, extensive friction-stir welding-parameter studies were conducted on 2.5 cm. and 3.8 cm. thick 2219 Al alloy plate. Starting conditions of the plate were the fully-heat-treated (-T62) and in the annealed (-O) conditions. The former condition was chosen with the intent of using the welds in either the 'as welded' condition or after a simple low-temperature aging treatment. Since preliminary stress-analyses showed that stresses in and near the welds would probably exceed the yield-strength of both 'as welded' and welded and aged weld-joints, a post-weld solution-treatment, quenching, and aging treatment was also examined. Once a suitable set of welding and post-weld heat-treatment parameters was established, the project divided into two parts. The first part concentrated on developing the necessary process information to be able to make defect-free friction-stir welds in 3.8 cm. thick Al alloy 2219 in the form of circumferential welds that would join two hemispherical forgings with a 102 cm. inside diameter. This necessitated going to a bobbin-tool welding-technique to simplify the tooling needed to react the large forces generated in friction-stir welding. The bobbin-tool technique was demonstrated on both flat-plates and plates that were bent to the curvature of the actual vessel. An additional issue was termination of the weld, i.e. closing out the hole left at the end of the weld by withdrawal of the friction-stir welding tool. This was accomplished by friction-plug welding a slightly-oversized Al alloy 2219 plug into the termination-hole, followed by machining the plug flush with both the inside and outside surfaces of the vessel. The second part of the project involved demonstrating that the welds were fit for the intended

  5. Aluminum 6060-T6 friction stir welded butt joints: fatigue resistance with different tools and feed rates

    International Nuclear Information System (INIS)

    Baragetti, S.; D'Urso, G.

    2014-01-01

    The fatigue behavior of AA6060-T6 friction stir welded butt joints was investigated. The joints were produced by using both a standard and a threaded tri-flute cylindrical-tool with flat shoulder. The friction stir welding process was carried out using different feed rates. Preliminary tensile tests, micrograph analyses and hardness profile measurements across the welds were carried out. Welded and unwelded fatigue samples were tested under axial loading (R = 0.1) with upper limits of 10 4 and 10 5 cycles, using threaded and unthreaded (standard) tools at different feed rates. The best tensile and fatigue performance was obtained using the standard tool at low feed rate.

  6. 3D modeling of material flow and temperature in Friction Stir Welding Modelagem 3D do fluxo de material e da temperatura na soldagem "Friction Stir"

    Directory of Open Access Journals (Sweden)

    Diego Santiago

    2009-09-01

    Full Text Available The process of Friction Stir Welding (FSW is a welding method developed by the "The Welding Institute" (TWI of England in 1991. The welding equipment consists of a tool that rotates and progresses along the joint of two restrained sheets. The joint is produced by frictional heating which causes the softening of both components into a viscous-plastic condition and also by the resultant flow between the sheets to be joined. Numerical Modeling of the process can provide realistic prediction of the main variables of the process, reducing the number of experimental tests, thus accelerating the design processes while reducing costs and optimizing the involved technological variables. In this study the friction stir welding process is modeled using a general purpose finite element based program, reproducing the material thermal map and the corresponding mass flow. Numerical thermal results are compared against experimental thermographic maps and numerical material flow results are compared with material flow visualization techniques, with acceptable concordance.O processo denominado "Friction Stir Welding" (FSW é um método de soldagem desenvolvido pelo "The Welding Institute" (TWI na Inglaterra em 1991. O equipamento de soldagem consiste de uma ferramenta que gira e avança ao longo da interface entre duas chapas fixas. A junção é produzida pelo calor gerado por fricção o qual causa o amolecimento de ambos os componentes atingindo uma condição visco-plástica e também pelo escoamento resultante entre as laminas a ser unidas. A modelagem numérica do processo pode fornecer uma predição real das principais variáveis do processo, reduzindo o número de testes experimentais, acelerando, portanto os processos de projeto ao mesmo tempo em que reduz custos e permite a otimização das variáveis tecnológicas envolvidas. Neste trabalho, o processo de soldagem por fricção é modelado empregando um programa de propósito geral baseado no m

  7. Friction Stir Welding (FSW) of Aged CuCrZr Alloy Plates

    Science.gov (United States)

    Jha, Kaushal; Kumar, Santosh; Nachiket, K.; Bhanumurthy, K.; Dey, G. K.

    2018-01-01

    Friction Stir Welding (FSW) of Cu-0.80Cr-0.10Zr (in wt pct) alloy under aged condition was performed to study the effects of process parameters on microstructure and properties of the joint. FSW was performed over a wide range of process parameters, like tool-rotation speed (from 800 to 1200 rpm) and tool-travel speed (from 40 to 100 mm/min), and the resulting thermal cycles were recorded on both sides (advancing and retreating) of the joint. The joints were characterized for their microstructure and tensile properties. The welding process resulted in a sound and defect-free weld joint, over the entire range of the process parameters used in this study. Microstructure of the stir zone showed fine and equiaxed grains, the scale of which varied with FSW process parameters. Grain size in the stir zone showed direct correlation with tool rotation and inverse correlation with tool-travel speed. Tensile strength of the weld joints was ranging from 225 to 260 MPa, which is substantially lower than that of the parent metal under aged condition ( 400 MPa), but superior to that of the parent material under annealed condition ( 220 MPa). Lower strength of the FSW joint than that of the parent material under aged condition can be attributed to dissolution of the precipitates in the stir zone and TMAZ. These results are presented and discussed in this paper.

  8. Predicting tensile strength of friction stir welded AA6061 aluminium alloy joints by a mathematical model

    International Nuclear Information System (INIS)

    Elangovan, K.; Balasubramanian, V.; Babu, S.

    2009-01-01

    AA6061 aluminium alloy (Al-Mg-Si alloy) has gathered wide acceptance in the fabrication of light weight structures requiring a high strength-to weight ratio and good corrosion resistance. Compared to the fusion welding processes that are routinely used for joining structural aluminium alloys, friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force etc., and tool pin profile play a major role in deciding the joint strength. An attempt has been made to develop a mathematical model to predict tensile strength of the friction stir welded AA6061 aluminium alloy by incorporating FSW process parameters. Four factors, five levels central composite design has been used to minimize number of experimental conditions. Response surface method (RSM) has been used to develop the model. Statistical tools such as analysis of variance (ANOVA), student's t-test, correlation co-efficient etc. have been used to validate the developed model. The developed mathematical model can be effectively used to predict the tensile strength of FSW joints at 95% confidence level

  9. Characterization of Friction Stir Welded Tubes by Means of Tube Bulge Test

    International Nuclear Information System (INIS)

    D'Urso, G.; Longo, M.; Giardini, C.

    2011-01-01

    Mechanical properties of friction stir welded joints are generally evaluated by means of conventional tensile test. This testing method might provide insufficient information because maximum strain obtained in tensile test before necking is small; moreover, the application of tensile test is limited when the joint path is not linear or even when the welds are executed on curved surfaces. Therefore, in some cases, it would be preferable to obtain the joints properties from other testing methods. Tube bulge test can be a valid solution for testing circumferential or longitudinal welds executed on tubular workpieces. The present work investigates the mechanical properties and the formability of friction stir welded tubes by means of tube bulge tests. The experimental campaign was performed on tubular specimens having a thickness of 3 mm and an external diameter of 40 mm, obtained starting from two semi-tubes longitudinally friction stir welded. The first step, regarding the fabrication of tubes, was performed combining a conventional forming process and friction stir welding. Sheets in Al-Mg-Si-Cu alloy AA6060 T6 were adopted for this purpose. Plates having a dimension of 225x60 mm were bent (with a bending axis parallel to the main dimension) in order to obtain semi-tubes. A particular care was devoted to the fabrication of forming devices (punch and die) in order to minimize the springback effects. Semi-tubes were then friction stir welded by means of a CNC machine tool. Some preliminary tests were carried out by varying the welding parameters, namely feed rate and rotational speed. A very simple tool having flat shoulder and cylindrical pin was used. The second step of the research was based on testing the welded tubes by means of tube bulge test. A specific equipment having axial actuators with a conical shape was adopted for this study. Some analyses were carried out on the tubes bulged up to a certain pressure level. In particular, the burst pressure and the

  10. Structure and Mechanical Properties of Friction Stir Weld Joints of Magnesium Alloy AZ31

    Science.gov (United States)

    Nagasawa, T.; Otsuka, M.; Yokota, T.; Ueki, T.

    The applicability of friction stir welding to hot rolled sheet of commercial magnesium alloy AZ31 plates has been investigated. Friction stir weld joint showed mechanical strength comparable to that of base material, though the ductility remained at one half of that of the latter. The results are consistent with the microstructure which is characterized by a fine grained bond layer bounded by-intermediate grained base metals. It is found that both anodizing treatment and insertion of aluminum foil between batting faces do not degrade the joint properties at all. The results suggest that friction stir welding can be potentially applied to magnesium alloy.

  11. Reinforcement with alumina particles at the interface region of AA6101-T6 and AA1350 alloys during friction stir welding

    Science.gov (United States)

    Ashok Kumar, R.; Thansekhar, M. R.

    2018-04-01

    This paper deals the combinational effect of friction stir welding and friction stir processing on dissimilar AA6101-T6 and AA1350 aluminium alloys. For that, alumina particles are reinforced at interface region of AA6101-T6 and AA1350 aluminium alloys. Friction Stir Welding and Friction Stir Processing are done simultaneously for various sizes of groove. To analyze the welding quality and surface modifications, mechanical, wear and microstructural tests are carried out. Among these, smallest groove of 0.5 mm width and 1 mm depth reveals highest tensile and bending strengths and largest groove of 2 mm width and 3 mm depth gives maximum hardness and wear resistance. Taguchi technique shows that groove width is most influencing parameter. Developed second order models with interaction predict the responses with minimum error.

  12. Microstructure, mechanical properties and microtexture of friction stir welded S690QL high yield steel

    Energy Technology Data Exchange (ETDEWEB)

    Paillard, Pascal [Institut des Matériaux Jean Rouxel, UMR 6205, Polytech Nantes, Site de la Chantrerie, BP 50609, 44306 Nantes cedex 3 (France); Bertrand, Emmanuel, E-mail: emmanuel.bertrand@univ-nantes.fr [Institut des Matériaux Jean Rouxel, UMR 6205, Polytech Nantes, Site de la Chantrerie, BP 50609, 44306 Nantes cedex 3 (France); Allart, Marion; Benoit, Alexandre [Institut de Recherche Technologique Jules Verne, Chemin du Chaffault, 44340 Bouguenais (France); Ruckert, Guillaume [DCNS Research, Technocampus Ocean, 5 rue de l' Halbrane, 44340 Bouguenais (France)

    2016-12-15

    Two try-out campaigns of friction stir welding (FSW) were performed with different friction parameters to join S690QL high yield strength steel. The welds were investigated at macroscopic and microscopic scales using optical and electronic microscopy and microhardness mapping. Welds of the second campaign exhibit microstructures and mechanical properties in accordance with requirements for service use. Microtexture measurements were carried out in different zones of welds by electron backscattered diffraction (EBSD). It is shown that that texture of the bottom of the weld is similar to that of the base metal, suggesting a diffusion bonding mechanism. Finally, the mechanical properties (tensile strength, resilience, bending) were established on the most promising welds. It is shown that it is possible to weld this high yield strength steel using FSW process with satisfactory geometric, microstructural and mechanical properties. - Highlights: •1000 mm ∗ 400 mm ∗ 8 mm S690QL steel plates are joined by friction stir welding (FSW). •Maximum hardness is reduced by optimization of process parameters. •Various microstructures are formed but no martensite after process optimization. •Texture is modified in mechanically affected zones of the weld. •Texture in the bottom of the weld is preserved, suggesting diffusion bonding.

  13. Optimization of friction stir welding using space mapping and manifold mapping-an initial study of thermal aspects

    DEFF Research Database (Denmark)

    Larsen, Anders Astrup; Bendsøe, Martin P.; Hattel, Jesper Henri

    2009-01-01

    The aim of this paper is to optimize a thermal model of a friction stir welding process by finding optimal welding parameters. The optimization is performed using space mapping and manifold mapping techniques in which a coarse model is used along with the fine model to be optimized. Different...

  14. Influence of volume percentage of NanoTiB2 particles on tribological & mechanical behaviour of 6061-T6 Al alloy nano-surface composite layer prepared via friction stir process

    Directory of Open Access Journals (Sweden)

    V. Kishan

    2017-02-01

    Full Text Available The aim of present study is to analyze the influence of volume percentage (vol.% of nano-sized particles (TiB2: average size is 35 nm on microstructure, mechanical and tribological behavior of 6061-T6 Al alloy surface nano composite prepared via Friction stir process (FSP. The microstructure of the fabricated surface nanocomposites is examined using optical microscopy (OM and scanning electron microscope (SEM for distribution of TiB2 nano reinforcement particles, thickness of nano composite layer formed on the Aluminum alloy substrate and fracture features. The depth of surface nano composite layer is measured as 3683.82 μm along the cross section of stir zone of nano composite perpendicular to FSP. It was observed that increase in volume percentage of TiB2 particles, the microhardness is increased up to 132 Hv and it is greater than as-received Al alloy's microhardness (104 Hv. It is also observed that at 4 volume percentage higher tensile properties exhibited as compared with the 2 and 8 vol. %. It is found that high wear resistance exhibited at 4 volume percentage as-compared with the 2 and 8 vol. %. The observed wear and mechanical properties are interrelated with microstructure, fractography and worn morphology.

  15. Formation of Oxides in the Interior of Friction Stir Welds

    Science.gov (United States)

    Schneider, Judy; Chen, Po; Nunes, Arthur C., Jr.

    2016-01-01

    In friction stir welding (FSWing) the actual solid state joining takes place between the faying surfaces which form the weld seam. Thus the seam trace is often investigated for clues when the strength of the weld is reduced. Aluminum and its alloys are known to form a native, protective oxide on the surface. If these native surface oxides are not sufficiently broken up during the FSW process, they are reported to remain in the FSW interior and weaken the bond strength. This type of weld defect has been referred to as a lazy "S", lazy "Z", joint line defect, kissing bond, or residual oxide defect. Usually these defects are mitigated by modification of the process parameters, such as increased tool rotation rate, which causes a finer breakup of the native oxide particles. This study proposes that there may be an alternative mechanism for formation of oxides found within the weld nugget. As the oxidation rate increases at elevated temperatures above 400ºC, it may be possible for enhanced oxidation to occur on the interior surfaces during the FSW process from entrained air entering the seam gap. Normally, FSWs of aluminum alloys are made without a purge gas and it is unknown how process parameters and initial fit up could affect a potential air path into the interior during the processing. In addition, variations in FSW parameters, such as the tool rotation, are known to have a strong influence on the FSW temperature which may affect the oxidation rate if internal surfaces are exposed to entrained air. A series of FSWs were made in 3 different thickness panels of AA2219 (0.95, 1.27 and 1.56 cm) at 2 different weld pitches. As the thickness of the panels increased, there was an increased tendency for a gap to form in advance of the weld tool. If sufficient air is able to enter the workpiece gap prior to consolidation, the weld temperature can increase the oxidation rate on the interior surfaces. These oxidation rates would also be accelerated in areas of localized

  16. Effect of welding speed on microstructural and mechanical properties of friction stir welded Inconel 600

    International Nuclear Information System (INIS)

    Song, K.H.; Fujii, H.; Nakata, K.

    2009-01-01

    In order to evaluate the properties of a friction stir welded Ni base alloy, Inconel 600 (single phase type) was selected. Sound friction stir welds without weld defect were obtained at 150 and 200 mm/min in welding speed, however, a groove like defect occurred at 250 mm/min. The electron back scattered diffraction (EBSD) method was used to analyze the grain boundary character distribution. As a result, dynamic recrystallization was observed at all conditions, and the grain refinement was achieved in the stir zone, and it was gradually accelerated from 19 μm in average grain size of the base material to 3.4 μm in the stir zone with increasing the welding speed. It also has an effect on the mechanical properties so that friction stir welded zone showed 20% higher microhardness and 10% higher tensile strength than those of base material.

  17. Friction Stir Welding: Standards and Specifications in Today's U.S. Manufacturing and Fabrication

    Science.gov (United States)

    Ding, Robert Jeffrey

    2008-01-01

    New welding and technology advancements are reflected in the friction stir welding (FSW) specifications used in the manufacturing sector. A lack of publicly available specifications as one of the reasons that the FSW process has not propagate through the manufacturing sectors. FSW specifications are an integral supporting document to the legal agreement written between two entities for deliverable items. Understanding the process and supporting specifications is essential for a successful FSW manufacturing operation. This viewgraph presentation provides an overview of current FSW standards in the industry and discusses elements common to weld specifications.

  18. Nonlinear Time Reversal Acoustic Method of Friction Stir Weld Assessment, Phase I

    Data.gov (United States)

    National Aeronautics and Space Administration — The goal of the project is demonstration of the feasibility of Friction Stir Weld (FSW) assessment by novel Nonlinear Time Reversal Acoustic (TRA) method. Time...

  19. A study on microstructure and strain-hardening rate of friction stir welded Al-Mg-Si alloys using a weak beam technique

    International Nuclear Information System (INIS)

    Sukedai, E; Yokoyama, T

    2012-01-01

    Mechanical properties of a friction stir welded Al-Mg-Si (6061-T6Al) alloy are evaluated by a tensile test. It is found that the strain-hardening rate is higher than that of a base material. In order to investigate the origin, TEM observations have been performed about 4 kinds of materials; base- and friction stir welded-materials, and both materials deformed to 5 % strain by tension. There are not so large differences about dislocation density, size and density of precipitates and crystal defects between the base material and the friction stir welded-materials, but a significant decrease of grain-size in the friction stir welded-materials is recognized. These results suggest a dynamic recovery occurs during FSW process, and it is speculated that the recovery leads to the differences of yield stress and strain-hardening rate between both materials.

  20. Corrosion Behavior of Arc Weld and Friction Stir Weld in Al 6061-T6 Alloys

    International Nuclear Information System (INIS)

    Yoon, Byoung Hyun; Kim, Heung Ju; Chang, Woong Seong; Kweon, Young Gak

    2006-01-01

    For the evaluation of corrosion resistance of Al 6061-T6 Alloy, Tafel method and immersion test was performed with Friction Stir Weld(FSW) and Gas Metal Arc Weld(GMAW). The Tafel and immersion test results indicated that GMA weld was severely attacked compared with those of friction stir weld. It may be mainly due to the galvanic corrosion mechanism act on the GMA weld

  1. Friction stir spot welding of 2024-T3 aluminum alloy with SiC nanoparticles

    Energy Technology Data Exchange (ETDEWEB)

    Paidar, Moslem; Sarab, Mahsa Laali [Islamic Azad University, Tehran (Iran, Islamic Republic of)

    2016-01-15

    In this study, the Friction stir spot welding (FSSW) of 2024-T3 aluminum alloy with 1.6 mm thickness was investigated. The effects of the silicon carbide (SiC) nanoparticles on the metallurgical and mechanical properties were discussed. The effects of particles on tension shear and wear tests were also investigated. The process was conducted at a constant rotational speed of 1000 rpm. Results showed that adding SiC nanoparticles to the weld during FSSW had a major effect on the mechanical properties. In fact, the addition of nanoparticles as barriers prevented grain growth in the Stir zone (SZ). The data obtained in the tensile-shear and wear tests showed that tensile-shear load and wear resistance increased with the addition of SiC nanoparticles, which was attributed to the fine grain size produced in the SZ.

  2. Identifying Combination of Friction Stir Welding Parameters to Maximize Strength of Lap Joints of AA2014-T6 Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    Rajendrana C.

    2017-01-01

    Full Text Available AA2014 aluminum alloy (Al-Cu alloy has been widely utilized in fabrication of lightweight structures like aircraft structures, demanding high strength to weight ratio and good corrosion resistance. The fusion welding of these alloys will lead to solidification problems such as hot cracking. Friction stir welding is a new solid state welding process, in which the material being welded does not melt and recast. Lot of research works have been carried out by many researchers to optimize process parameters and establish empirical relationships to predict tensile strength of friction stir welded butt joints of aluminum alloys. However, very few investigations have been carried out on friction stir welded lap joints of aluminum alloys. Hence, in this investigation, an attempt has been made to optimize friction stir lap welding (FSLW parameters to attain maximum tensile strength using statistical tools such as design of experiment (DoE, analysis of variance (ANOVA, response graph and contour plots. By this method, it is found that maximum tensile shear fracture load of 12.76 kN can be achieved if a joint is made using tool rotational speed of 900 rpm, welding speed of 110 mm/min, tool shoulder diameter of 12 mm and tool tilt angle of 1.5°.

  3. The effect of laser surface melting on microstructure and corrosion behavior of friction stir welded aluminum alloy 2219

    Science.gov (United States)

    Ma, Shengchong; Zhao, Yong; Zou, Jiasheng; Yan, Keng; Liu, Chuan

    2017-11-01

    This study aimed to explore the electrochemical properties and microstructure of friction stir welds to understand the correlation between their properties and processing. Friction stir welding is a promising solid-state joining process for high-strength aluminum alloys (AA). Although friction stir welding (FSW) eliminates the problems of fusion welding due to the fact that it is performed below Tm, it causes severe plastic deformation in the material. Some AA welded by FSW exhibit relatively poor corrosion resistance. In this research, the corrosion resistance of such welds was enhanced through laser surface melting. A friction stir weld of AA 2219 was laser melted. The melt depth and microstructure were observed using optical and scanning electron microscopy. The melt zone exhibited epitaxially grown columnar grains. The redistribution of elemental composition was analyzed using energy-dispersive spectroscopy. The anticorrosion properties of both laser-melted and original welds were studied in aqueous 3.5% NaCl solution using cyclic potentiodynamic polarization. The results indicated a noticeable increase in the pitting corrosion resistance after the laser treatment on the surface. The repassivation potential was nobler than the corrosion potential after the laser treatment, confirming that the resistance to pitting growth improved.

  4. Thermomechanical conditions and stresses on the friction stir welding tool

    Science.gov (United States)

    Atthipalli, Gowtam

    Friction stir welding has been commercially used as a joining process for aluminum and other soft materials. However, the use of this process in joining of hard alloys is still developing primarily because of the lack of cost effective, long lasting tools. Here I have developed numerical models to understand the thermo mechanical conditions experienced by the FSW tool and to improve its reusability. A heat transfer and visco-plastic flow model is used to calculate the torque, and traverse force on the tool during FSW. The computed values of torque and traverse force are validated using the experimental results for FSW of AA7075, AA2524, AA6061 and Ti-6Al-4V alloys. The computed torque components are used to determine the optimum tool shoulder diameter based on the maximum use of torque and maximum grip of the tool on the plasticized workpiece material. The estimation of the optimum tool shoulder diameter for FSW of AA6061 and AA7075 was verified with experimental results. The computed values of traverse force and torque are used to calculate the maximum shear stress on the tool pin to determine the load bearing ability of the tool pin. The load bearing ability calculations are used to explain the failure of H13 steel tool during welding of AA7075 and commercially pure tungsten during welding of L80 steel. Artificial neural network (ANN) models are developed to predict the important FSW output parameters as function of selected input parameters. These ANN consider tool shoulder radius, pin radius, pin length, welding velocity, tool rotational speed and axial pressure as input parameters. The total torque, sliding torque, sticking torque, peak temperature, traverse force, maximum shear stress and bending stress are considered as the output for ANN models. These output parameters are selected since they define the thermomechanical conditions around the tool during FSW. The developed ANN models are used to understand the effect of various input parameters on the total

  5. Dissimilar Joining of ODS and F/M Steel Tube by Friction Stir Welding

    Energy Technology Data Exchange (ETDEWEB)

    Kang, Suk Hoon; Noh, Sanghoon; Kim, Jun Hwan; Kim, Tae Kyu [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2014-05-15

    Oxide Dispersion strengthened (ODS) steels, it is well known that uniform nano-oxide dispersoids act as pinning points to obstruct dislocation and grain boundary motion, however, those advantages will be disappeared while the material is subjected to the high temperature of conventional fusion welding. Rotary friction welding, also referred to as friction stir welding (FSW), has shown great promise as a method for welding traditionally difficult to weld materials such as aluminum alloys. This relatively new technology has more recently been applied to higher melting temperature alloys such as steels, nickel-based and titanium alloys. Friction stir processing (FSP) is a method of changing the properties of a metal through intense, localized plastic deformation. FSW is the precursor of the FSP technique. When ideally implemented, this process mixes the material without changing the phase and creates a microstructure with fine, equiaxed grains. This homogeneous grain structure, separated by high-angle boundaries, allows some alloys to take on superplastic properties. In this study, FSW is used as a substitutive welding process between FMS tube and ODS parts. The dimension of tube is 7.0 OD, 0.5 T. During the FSW, dynamic-recrystallized grains are developed; the uniform oxides Dispersion is preserved in the metal matrix. The microstructure and microtexture of the material near the stir zone is found to be influenced by the rotational behavior of the tool. The additive effect from FSP on sample surface is considered. Since the mechanical alloying (MA) and FSP commonly apply extreme shear deformation on materials, the Dispersion of oxide particle in ODS steels is very active during both processes. Friction stir welding appears to be a very promising technique for the welding of FMS and ODS steels in the form of sheet and tube. FSW could successfully produce defect-free welds on FMS tubes and ODS ring assembly. FSW produces a fine grain structure consisting of ferrite and

  6. Dissimilar Joining of ODS and F/M Steel Tube by Friction Stir Welding

    International Nuclear Information System (INIS)

    Kang, Suk Hoon; Noh, Sanghoon; Kim, Jun Hwan; Kim, Tae Kyu

    2014-01-01

    Oxide Dispersion strengthened (ODS) steels, it is well known that uniform nano-oxide dispersoids act as pinning points to obstruct dislocation and grain boundary motion, however, those advantages will be disappeared while the material is subjected to the high temperature of conventional fusion welding. Rotary friction welding, also referred to as friction stir welding (FSW), has shown great promise as a method for welding traditionally difficult to weld materials such as aluminum alloys. This relatively new technology has more recently been applied to higher melting temperature alloys such as steels, nickel-based and titanium alloys. Friction stir processing (FSP) is a method of changing the properties of a metal through intense, localized plastic deformation. FSW is the precursor of the FSP technique. When ideally implemented, this process mixes the material without changing the phase and creates a microstructure with fine, equiaxed grains. This homogeneous grain structure, separated by high-angle boundaries, allows some alloys to take on superplastic properties. In this study, FSW is used as a substitutive welding process between FMS tube and ODS parts. The dimension of tube is 7.0 OD, 0.5 T. During the FSW, dynamic-recrystallized grains are developed; the uniform oxides Dispersion is preserved in the metal matrix. The microstructure and microtexture of the material near the stir zone is found to be influenced by the rotational behavior of the tool. The additive effect from FSP on sample surface is considered. Since the mechanical alloying (MA) and FSP commonly apply extreme shear deformation on materials, the Dispersion of oxide particle in ODS steels is very active during both processes. Friction stir welding appears to be a very promising technique for the welding of FMS and ODS steels in the form of sheet and tube. FSW could successfully produce defect-free welds on FMS tubes and ODS ring assembly. FSW produces a fine grain structure consisting of ferrite and

  7. Material Flow and Oxide Particle Distributions in Friction-Stir Welded F/M-ODS Sheets

    Energy Technology Data Exchange (ETDEWEB)

    Kang, Suk Hoon; Noh, Sanghoon; Jin, Hyun Ju; Kim, Tae Kyu [Korea Atomic Energy Research Institute, Daejeon (Korea, Republic of)

    2015-05-15

    It is well known that uniform nano-oxide dispersoids act as pinning points to obstruct dislocation and grain boundary motion in ODS(Oxide dispersion strengthened) steel. However, these advantages will disappear while the material is subjected to the high temperature of conventional fusion welding. There is only limited literature available on the joining of ODS steels. Friction stir welding (FSW) is considered to be the best welding technique for welding ODS steels as the technique helps in retaining the homogeneous nano-oxide particles distributions in matrix. FSW is a solid.state, hot.shear joining process in which a rotating tool with a shoulder and terminating in a threaded pin, moves along the butting surfaces of two rigidly clamped plates placed on a backing plate. Heat generated by friction at the shoulder and to a lesser extent at the pin surface, softens the material being welded. Severe plastic deformation and flow of this plasticised metal occurs as the tool is translated along the welding direction. Material is transported from the front of the tool to the trailing edge where it is forged into a joint. Friction stir welding appears to be a very promising technique for the welding of FMS and ODS steels. This study found that, during FSW, the forward movement of the tool pin results in loose contact between the tool pin and the receding material on the advancing side.

  8. Microstructural evolution during friction stir welding of AlSi1MgMn alloy

    Directory of Open Access Journals (Sweden)

    M. Janjić

    2012-01-01

    Full Text Available This paper provides the research of the infl uence of geometric and kinematic parameters on the microstructure and mechanical properties of welded joint of aluminum alloy AlSi1MgMn (6082-T6 obtained through the Friction Stir Welding (FSW process. The experiment parameters were welding speed, rotation speed, angle of pin slope, pin diameter and shoulder diameter. On the obtained welded workpieces the dynamic testing on the impact toughness, and determination of microstructural zones were carried out.

  9. The Effect of Tool Pin Shape of Friction Stir Welding (FSW) on Polypropylene

    Science.gov (United States)

    Nik, Z. C.; Ishak, M.; Othman, N. H.

    2017-09-01

    This experiment deals with similar joining of polypropylene (PP) with thickness of 3 mm was carried out by using friction stir welding (FSW) technique. The process parameters, rotational speed, welding speed and tilt angle were fixed of experiments. The tool geometry shapes were the main parameters which were taken into consideration. The optimum designs of tool geometry shape were determined with reference to tensile strength of the joint. During the tensile testing experiment, the results show that all fractured occurs in the heat-affected zone (HAZ) on the polypropylene (PP). Results show that the optimum design can be obtained with same rotational speed, welding speed and tilt angle.

  10. Nondestructive online testing method for friction stir welding using acoustic emission

    Science.gov (United States)

    Levikhina, Anastasiya

    2017-12-01

    The paper reviews the possibility of applying the method of acoustic emission for online monitoring of the friction stir welding process. It is shown that acoustic emission allows the detection of weld defects and their location in real time. The energy of an acoustic signal and the median frequency are suggested to be used as informative parameters. The method of calculating the median frequency with the use of a short time Fourier transform is applied for the identification of correlations between the defective weld structure and properties of the acoustic emission signals received during welding.

  11. The Effect of Premixed Al-Cu Powder on the Stir Zone in Friction Stir Welding of AA3003-H18

    Science.gov (United States)

    Abnar, B.; Kazeminezhad, M.; Kokabi, A. H.

    2015-02-01

    In this research, 3-mm-thick AA3003-H18 non-heat-treatable aluminum alloy plates were joined by friction stir welding (FSW). It was performed by adding pure Cu and premixed Cu-Al powders at various rotational speeds of 800, 1000, and 1200 rpm and constant traveling speeds of 100 mm/min. At first, the powder was filled into the gap (0.2 or 0.4 mm) between two aluminum alloy plates, and then the FSW process was performed in two passes. The microstructure, mechanical properties, and formation of intermetallic compounds were investigated in both cases of using pure Cu and premixed Al-Cu powders. The results of using pure Cu and premixed Al-Cu powders were compared in the stir zone at various rotational speeds. The copper particle distribution and formation of Al-Cu intermetallic compounds (Al2Cu and AlCu) in the stir zone were desirable using premixed Al-Cu powder into the gap. The hardness values were significantly increased by formation of Al-Cu intermetallic compounds in the stir zone and it was uniform throughout the stir zone when premixed Al-Cu powder was used. Also, longitudinal tensile strength from the stir zone was higher when premixed Al-Cu powder was used instead of pure Cu powder.

  12. Design of Friction Stir Welding Tool for Avoiding Root Flaws.

    Science.gov (United States)

    Ji, Shude; Xing, Jingwei; Yue, Yumei; Ma, Yinan; Zhang, Liguo; Gao, Shuangsheng

    2013-12-12

    In order to improve material flow behavior during friction stir welding and avoid root flaws of weld, a tool with a half-screw pin and a tool with a tapered-flute pin are suggested. The effect of flute geometry in tool pins on material flow velocity is investigated by the software ANSYS FLUENT. Numerical simulation results show that high material flow velocity appears near the rotational tool and material flow velocity rapidly decreases with the increase of distance away from the axis of the tool. Maximum material flow velocity by the tool with the tapered-flute pin appears at the beginning position of flute and the velocity decreases with the increase of flow length in flute. From the view of increasing the flow velocity of material near the bottom of the workpiece or in the middle of workpiece, the tool with the half-screw pin and the tool with the tapered-flute pin are both better than the conventional tool.

  13. Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys

    Science.gov (United States)

    Grujicic, M.; Arakere, G.; Pandurangan, B.; Ochterbeck, J. M.; Yen, C.-F.; Cheeseman, B. A.; Reynolds, A. P.; Sutton, M. A.

    2012-09-01

    Workpiece material flow and stirring/mixing during the friction stir welding (FSW) process are investigated computationally. Within the numerical model of the FSW process, the FSW tool is treated as a Lagrangian component while the workpiece material is treated as an Eulerian component. The employed coupled Eulerian/Lagrangian computational analysis of the welding process was of a two-way thermo-mechanical character (i.e., frictional-sliding/plastic-work dissipation is taken to act as a heat source in the thermal-energy balance equation) while temperature is allowed to affect mechanical aspects of the model through temperature-dependent material properties. The workpiece material (AA5059, solid-solution strengthened and strain-hardened aluminum alloy) is represented using a modified version of the classical Johnson-Cook model (within which the strain-hardening term is augmented to take into account for the effect of dynamic recrystallization) while the FSW tool material (AISI H13 tool steel) is modeled as an isotropic linear-elastic material. Within the analysis, the effects of some of the FSW key process parameters are investigated (e.g., weld pitch, tool tilt-angle, and the tool pin-size). The results pertaining to the material flow during FSW are compared with their experimental counterparts. It is found that, for the most part, experimentally observed material-flow characteristics are reproduced within the current FSW-process model.

  14. Investigation of Friction Stir Welding of Al Metal Matrix Composite Materials

    Science.gov (United States)

    Diwan, Ravinder M.

    2003-01-01

    The innovative process of Friction Stir Welding (FSW) has generated tremendous interest since its inception about a decade or so ago since the first patent in 1991 by TWI of Cambridge, England. This interest has been seen in many recent international conferences and publications on the subject and relevant published literature. Still the process needs both intensive basic study of deformation mechanisms during this FSW process and analysis and feasibility study to evaluate production methods that will yield high quality strong welds from the stirring action of the appropriate pin tool into the weld plate materials. Development of production processes is a complex task that involves effects of material thickness, materials weldability, pin tool design, pin height, and pin shoulder diameter and related control conditions. The frictional heating with rotational speeds of the pin tool as it plunges into the material and the ensuing plastic flow arising during the traverse of the welding faying surfaces provide the known special advantages of the FSW process in the area of this new advanced joining technology.

  15. Microstructural characterization in dissimilar friction stir welding between 304 stainless steel and st37 steel

    International Nuclear Information System (INIS)

    Jafarzadegan, M.; Feng, A.H.; Abdollah-zadeh, A.; Saeid, T.; Shen, J.; Assadi, H.

    2012-01-01

    In the present study, 3 mm-thick plates of 304 stainless steel and st37 steel were welded together by friction stir welding at a welding speed of 50 mm/min and tool rotational speed of 400 and 800 rpm. X-ray diffraction test was carried out to study the phases which might be formed in the welds. Metallographic examinations, and tensile and microhardness tests were used to analyze the microstructure and mechanical properties of the joint. Four different zones were found in the weld area except the base metals. In the stir zone of the 304 stainless steel, a refined grain structure with some features of dynamic recrystallization was evidenced. A thermomechanically-affected zone was characterized on the 304 steel side with features of dynamic recovery. In the other side of the stir zone, the hot deformation of the st37 steel in the austenite region produced small austenite grains and these grains transformed to fine ferrite and pearlite and some products of displacive transformations such as Widmanstatten ferrite and martensite by cooling the material after friction stir welding. The heat-affected zone in the st37 steel side showed partially and fully refined microstructures like fusion welding processes. The recrystallization in the 304 steel and the transformations in the st37 steel enhanced the hardness of the weld area and therefore, improved the tensile properties of the joint. - Highlights: ► FSW produced sound welds between st37 low carbon steel and 304 stainless steel. ► The SZ of the st37 steel contained some products of allotropic transformation. ► The material in the SZ of the 304 steel showed features of dynamic recrystallization. ► The finer microstructure in the SZ increased the hardness and tensile strength.

  16. Structural Phase Evolution in Ultrasonic-Assisted Friction Stir Welded 2195 Aluminum Alloy Joints

    Science.gov (United States)

    Eliseev, A. A.; Fortuna, S. V.; Kalashnikova, T. A.; Chumaevskii, A. V.; Kolubaev, E. A.

    2017-10-01

    The authors examined the structural and phase state of fixed joints produced by method of friction stir welding (FSW) and ultrasonic-assisted friction stir welding (UAFSW) from extruded profile of aluminum alloy AA2195. In order to identify the role of ultrasonic application in the course of welding, such characteristics, as volume fraction and average size of secondary particles are compared in the base material and stir zones of FSW and UAFSW joints. By applying the methods of SEM and TEM analysis, researchers established the complex character of phase transitions as a result of ultrasonic application.

  17. Recent Developments for Ultrasonic-Assisted Friction Stir Welding: Joining, Testing, Corrosion - an Overview

    Science.gov (United States)

    Thomä, M.; Wagner, G.; Straß, B.; Conrad, C.; Wolter, B.; Benfer, S.; Fürbeth, W.

    2016-03-01

    Due to the steadily increasing demand on innovative manufacturing processes, modern lightweight construction concepts become more and more important. Especially joints of dissimilar metals offer a variety of advantages due to their high potential for lightweight construction. The focus of the investigations was Al/Mg-joints. Friction Stir Welding (FSW) is an efficient process to realize high strength joints between these materials in ductile condition. Furthermore, for a simultaneous transmission of power ultrasound during the FSW-process (US-FSW) a positive effect on the achievable tensile strength of the Al/Mg-joints was proven. In the present work the industrial used die cast alloys EN AC-48000 (AlSi12CuNiMg) and AZ80 (MgAl8Zn) were joined by a machining center modified especially for Ultrasound Supported Friction Stir Welding. The appearing welding zone and the formation of intermetallic phases under the influence of power ultrasound were examined in particular. In order to identify optimal process parameters extensive preliminary process analyzes have been carried out. Following this, an ultrasound-induced more intensive stirring of the joining zone and as a result of this a considerably modified intermetallic zone was detected. At the same time an increase of the tensile strength of about 25% for US-FSW-joints and for fatigue an up to three times higher number of cycles to failure in comparison to a conventional welding process was observed. Moreover, detailed corrosion analyzes have shown that especially the welding zone was influenced by the corrosive attack. To expand and deepen the knowledge of the US-FSW-process further material combinations such as Ti/Steel and Al/Steel will be considered in future.

  18. Recent Developments for Ultrasonic-Assisted Friction Stir Welding: Joining, Testing, Corrosion - an Overview

    International Nuclear Information System (INIS)

    Thomä, M; Wagner, G; Straß, B; Conrad, C; Wolter, B; Benfer, S; Fürbeth, W

    2016-01-01

    Due to the steadily increasing demand on innovative manufacturing processes, modern lightweight construction concepts become more and more important. Especially joints of dissimilar metals offer a variety of advantages due to their high potential for lightweight construction. The focus of the investigations was Al/Mg-joints. Friction Stir Welding (FSW) is an efficient process to realize high strength joints between these materials in ductile condition. Furthermore, for a simultaneous transmission of power ultrasound during the FSW-process (US-FSW) a positive effect on the achievable tensile strength of the Al/Mg-joints was proven. In the present work the industrial used die cast alloys EN AC-48000 (AlSi12CuNiMg) and AZ80 (MgAl8Zn) were joined by a machining center modified especially for Ultrasound Supported Friction Stir Welding. The appearing welding zone and the formation of intermetallic phases under the influence of power ultrasound were examined in particular. In order to identify optimal process parameters extensive preliminary process analyzes have been carried out. Following this, an ultrasound-induced more intensive stirring of the joining zone and as a result of this a considerably modified intermetallic zone was detected. At the same time an increase of the tensile strength of about 25% for US-FSW-joints and for fatigue an up to three times higher number of cycles to failure in comparison to a conventional welding process was observed. Moreover, detailed corrosion analyzes have shown that especially the welding zone was influenced by the corrosive attack. To expand and deepen the knowledge of the US-FSW-process further material combinations such as Ti/Steel and Al/Steel will be considered in future. (paper)

  19. Effect of tool rotational speed and penetration depth on dissimilar aluminum alloys friction stir spot welds

    Directory of Open Access Journals (Sweden)

    Joaquín M. Piccini

    2017-03-01

    Full Text Available In the last years, the automotive industry is looking for the use of aluminum parts in replace of steel parts in order to reduce the vehicles weight. These parts have to be joined, for instance, by welding processes. The more common welding process in the automotive industry is the Resistance Spot Welding (RSW technique. However, RSW of aluminum alloys has many disadvantages. Regarding this situation, a variant of the Friction Stir Welding process called Friction Stir Spot Welding (FSSW has been developed, showing a strong impact in welding of aluminum alloys and dissimilar materials in thin sheets. Process parameters affect the characteristics of the welded joints. However, the information available on this topic is scarce, particularly for dissimilar joints and thin sheets. The aim of this work was to study the effect of the rotational speed and the tool penetration depth on the characteristics of dissimilar FSS welded joints. Defects free joints have been achieved with higher mechanical properties than the ones reported. The maximum fracture load was 5800 N. It was observed that the effective joint length of the welded spots increased with the tool penetration depth, meanwhile the fracture load increased and then decreased. Finally, welding at 1200 RPM produced welded joints with lower mechanical properties than the ones achieved at 680 and 903 RPM.

  20. Application of Taguchi approach to optimize friction stir welding parameters of polyethylene

    Directory of Open Access Journals (Sweden)

    Bejaoui S.

    2010-06-01

    Full Text Available This paper presents experimental and numerical results of butt friction stir welding of high density polyethylene. The FSW designed tool insulates the welded samples and preserves the heat gained from friction thus avoiding the appearance of blisters and splits after welding. The experimental tests, conducted according to combinations of process factors such as rotation speed, welding speed, pin diameter and hold time at beginning welding, were carried out according the Taguchi orthogonal table L27 in randomized way. Temperatures in the joint during the welding operation and flow stresses from the tensile tests of welded samples were measured and variances were analyzed. Identified models were used to simulate, by finite elements, the tensile tests performed on specimens having a weld cordon in their active area. The results show coherence between the numerical predictions and experimental observations in different cases of weld cordon mechanical behaviour.

  1. Design of Friction Stir Spot Welding Tools by Using a Novel Thermal-Mechanical Approach.

    Science.gov (United States)

    Su, Zheng-Ming; Qiu, Qi-Hong; Lin, Pai-Chen

    2016-08-09

    A simple thermal-mechanical model for friction stir spot welding (FSSW) was developed to obtain similar weld performance for different weld tools. Use of the thermal-mechanical model and a combined approach enabled the design of weld tools for various sizes but similar qualities. Three weld tools for weld radii of 4, 5, and 6 mm were made to join 6061-T6 aluminum sheets. Performance evaluations of the three weld tools compared fracture behavior, microstructure, micro-hardness distribution, and welding temperature of welds in lap-shear specimens. For welds made by the three weld tools under identical processing conditions, failure loads were approximately proportional to tool size. Failure modes, microstructures, and micro-hardness distributions were similar. Welding temperatures correlated with frictional heat generation rate densities. Because the three weld tools sufficiently met all design objectives, the proposed approach is considered a simple and feasible guideline for preliminary tool design.

  2. Immersed friction stir welding of ultrafine grained accumulative roll-bonded Al alloy

    International Nuclear Information System (INIS)

    Hosseini, M.; Danesh Manesh, H.

    2010-01-01

    In this research, ultrafine grained strips of commercial pure strain hardenable aluminum (AA1050) were produced by accumulative roll-bonding (ARB) technique. These strips were joined by friction stir welding (FSW) in immersed (underwater) and conventional (in-air) conditions to investigate the effect of the immersion method on the microstructure and mechanical properties of the joint, aiming to reduce the deterioration of the mechanical properties of the joint. Transmission electron microscopy and X-ray diffraction analyses were used to evaluate the microstructure, showing smaller grains and subgrains in the stir zone of the immersed FSW condition with respect to the conventional FSW method. The hardness and tensile properties of the immersed friction stir welded sample and ARBed base metal show more similarity compared to the conventional friction stir welded sample. Moreover, the aforementioned method can result in the enhancement of the superplasticity tendency of the material.

  3. Microstructure and mechanical properties of friction stir welded SAF 2507 super duplex stainless steel

    International Nuclear Information System (INIS)

    Sato, Y.S.; Nelson, T.W.; Sterling, C.J.; Steel, R.J.; Pettersson, C.-O.

    2005-01-01

    The microstructure and mechanical properties of friction stir (FS) welded SAF 2507 super duplex stainless steel were examined. High-quality, full-penetration welds were successfully produced in the super duplex stainless steel by friction stir welding (FSW) using polycrystalline cubic boron nitride (PCBN) tool. The base material had a microstructure consisting of the ferrite matrix with austenite islands, but FSW refined grains of the ferrite and austenite phases in the stir zone through dynamic recrystallisation. Ferrite content was held between 50 and 60% throughout the weld. The smaller grain sizes of the ferrite and austenite phases caused increase in hardness and strength within the stir zone. Welded transverse tensile specimen failed near the border between the stir zone and TMAZ at the retreating side as the weld had roughly the same strengths as the base material

  4. Genesis of Microstructures in Friction Stir Welding of Ti-6Al-4V

    Science.gov (United States)

    Tchein, Gnofam Jacques; Jacquin, Dimitri; Coupard, Dominique; Lacoste, Eric; Girot Mata, Franck

    2018-03-01

    This paper is focused on the genesis of microstructures in friction stir welding (FSW) of the Ti-6Al-4V alloy. Several titanium joints, initially prepared with four different preheat treatments, were processed by FSW. Detailed microstructural analyses were performed in order to investigate change in the microstructure during the process. In this work, the FSW processing allows a controlled and stable microstructure to be produced in the stirring zone, regardless of the initial heat treatment or the welding conditions. The welded material undergoes a severe thermomechanical treatment which can be divided into two steps. First, the friction in the shoulder and the plastic strain give rise to the necessary conditions to allow a continuous dynamic recrystallization of the β phase. This operation produces a fine and equiaxed β grain structure. Second, once the pin has moved away, the temperature decreases, and the material undergoes a heat treatment equivalent to air quenching. The material thus exhibits a β → β + α transformation with germination of a fine intergranular Widmanstätten phase within the ex-fully-recrystallized-β grains.

  5. Genesis of Microstructures in Friction Stir Welding of Ti-6Al-4V

    Science.gov (United States)

    Tchein, Gnofam Jacques; Jacquin, Dimitri; Coupard, Dominique; Lacoste, Eric; Girot Mata, Franck

    2018-06-01

    This paper is focused on the genesis of microstructures in friction stir welding (FSW) of the Ti-6Al-4V alloy. Several titanium joints, initially prepared with four different preheat treatments, were processed by FSW. Detailed microstructural analyses were performed in order to investigate change in the microstructure during the process. In this work, the FSW processing allows a controlled and stable microstructure to be produced in the stirring zone, regardless of the initial heat treatment or the welding conditions. The welded material undergoes a severe thermomechanical treatment which can be divided into two steps. First, the friction in the shoulder and the plastic strain give rise to the necessary conditions to allow a continuous dynamic recrystallization of the β phase. This operation produces a fine and equiaxed β grain structure. Second, once the pin has moved away, the temperature decreases, and the material undergoes a heat treatment equivalent to air quenching. The material thus exhibits a β → β + α transformation with germination of a fine intergranular Widmanstätten phase within the ex-fully-recrystallized- β grains.

  6. Corrosion Properties of Cryorolled AA2219 Friction Stir Welded Joints Using Different Tool Pin Profiles

    Science.gov (United States)

    Kamal Babu, K.; Panneerselvam, K.; Sathiya, P.; Noorul Haq, A.; Sundarrajan, S.; Mastanaiah, P.; Srinivasa Murthy, C. V.

    The purpose of this paper is to present the corrosion behavior of the Cryorolled (CR) material and its Friction Stir Welded joints. Due to the thermal cycles of Friction Stir Welding (FSW) process, the corrosion behavior of the material gets affected. Here, the cryorolling process was carried out on AA2219 alloy and CR material was joined by FSW process using four different pin tool profiles such as cylindrical, threaded cylindrical, square and hexagonal pin. The FSW joints were analyzed by corrosion resistance with the help of potentiodynamic polarization test with 3.5% NaCl solution. From the analysis, it is found that CR AA2219 material exhibits good corrosion resistance compared to the base AA2219 material, and also a hexagonal pin profile FSW joint exhibits high corrosion resistance. Among the weld joints created by four different tools, the lowest corrosion resistance was found in the cylindrical pin tool FSW welds. Further, the corroded samples were investigated through metallurgical investigations like OM, Transmission Electron Microscopy (TEM), Energy-Dispersive X-ray Spectroscopy (EDX) and X-Ray Diffraction (XRD). It was found that the amount of dissolution of Al2Cu precipitate was present in the weld nugget. The amount of dissolution of Al2Cu precipitate is higher in the weld nugget produced by hexagonal pin tool. This is due to the enhancement of the corrosion resistance.

  7. Friction stir processing of an aluminum-magnesium alloy with pre-placing elemental titanium powder: In-situ formation of an Al{sub 3}Ti-reinforced nanocomposite and materials characterization

    Energy Technology Data Exchange (ETDEWEB)

    Khodabakhshi, F., E-mail: farzadkhodabakhshi83@gmail.com [Department of Materials Science and Engineering, School of Engineering, Shiraz University, Zand Boulevard, Shiraz (Iran, Islamic Republic of); Simchi, A. [Department of Materials Science and Engineering, Sharif University of Technology, P.O. Box 11365-9466, Azadi Avenue, 14588 Tehran (Iran, Islamic Republic of); Institute for Nanoscience and Nanotechnology, Sharif University of Technology, P.O. Box 11365-9466, Azadi Avenue, 14588 Tehran (Iran, Islamic Republic of); Kokabi, A.H. [Department of Materials Science and Engineering, Sharif University of Technology, P.O. Box 11365-9466, Azadi Avenue, 14588 Tehran (Iran, Islamic Republic of); Gerlich, A.P. [Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON (Canada)

    2015-10-15

    A fine-grained Al–Mg/Al{sub 3}Ti nanocomposite was fabricated by friction stir processing (FSP) of an aluminum-magnesium (AA5052) alloy with pre-placed titanium powder in the stirred zone. Microstructural evolutions and formation of intermetallic phases were analyzed by optical and electron microscopic techniques across the thickness section of the processed sheets. The microstructure of the nanocomposite consisted of a fine-grained aluminum matrix (1.5 µm), un-reacted titanium particles (<40 µm) and reinforcement particles of Al{sub 3}Ti (<100 nm) and Mg{sub 2}Si (<100 nm). Detailed microstructural analysis indicated solid-state interfacial reactions between the aluminum matrix and micro-sized titanium particles to form Al{sub 3}Ti intermetallic phase. The hard inclusions were then fractured and re-distributed in the metal matrix by the severe thermo-mechanical conditions imposed by FSP. Evaluation of mechanical properties by hardness measurement and uniaxial tensile test determined significant enhancement in the mechanical strength (by 2.5 order of magnetite) with a high ductility (~22%). Based on a dislocation-based model analysis, it was suggested that the strength enhancement was governed by grain refinement and the presence of hard inclusions (4 vol%) in the metal matrix. Fractographic studies also showed a ductile-brittle fracture mode for the nanocomposite compared with fully ductile rupture of the annealed alloy as well as the FSPed specimen without pre-placing titanium particles. - Highlights: • FSP was employed to fabricate in situ nanocomposite. • The AA5052 Al alloy with pre-placed micro-sized Ti particles were utilized. • The structural analysis was revealed that the in situ formation of Al{sub 3}Ti nanophase. • The SZ grain structure was refined by PSN and ZHP mechanisms during DRX. • Hardness and tensile strength were improved up to ~2.5 times with a good ductility.

  8. Effect of Pin Geometry on the Mechanical Strength of Friction-Stir-Welded Polypropylene Composite Plates

    Science.gov (United States)

    Kordestani, F.; Ashenai Ghasemi, F.; Arab, N. B. M.

    2017-09-01

    Friction stir welding (FSW) is a solid-state welding process, which has successfully been applied in aerospace and automotive industries for joining materials. The friction stir tool is the key element in the FSW process. In this study, the effect of four different tool pin geometries on the mechanical properties of two types of polypropylene composite plates, with 30% glass and carbon fiber, respectively, were investigated. For this purpose, four pins of different geometry, namely, a threaded-tapered pin, square pin, four-flute threaded pin, and threaded-tapered pin with a chamfer were made and used to carry out the butt welding of 5-mm-thick plates. The standard tensile and Izod impact tests were performed to evaluate the tensile strength and impact toughness of welded specimens. The results indicated that the threaded-tapered pin with a chamfer produced welds with a better surface appearance and higher tensile and impact strengths. The tests also showed that, with the threaded-tapered pin with a chamfer, the impact strength of the glass- and carbon-fiber composite welds were about 40 and 50%, respectively, of that of the base materials.

  9. Microstructure examination and microhardness of friction stir welded joint of (AA7020-O after PWHT

    Directory of Open Access Journals (Sweden)

    Ghada M.F. Essa

    2018-04-01

    Full Text Available This paper studies the microstructure and microhardness of the welded joints of the annealed aluminum alloy AA7020-O produced by friction stir welding (FSW technique. The material was applied to post weld heat treatment (solution treatment and artificially aged, T6. The traverse speed and the rotational speed are the most important process parameters of FSW, and have great influence on the heat input of the welding operation which governs the welded joints quality. To investigate their effect, the welding operation was performed using three traverse speeds, 20, 40 and 60 mm/s with two rotational speeds of 1125 and 1400 rpm, and other welding parameters were kept constant to produce comparable joints. It was found that the two rotational speeds are accepted with lower traverse speeds to produce sound joints. Microstructure of the welded joints was significantly affected by the FSW process parameters, and slight effect was reported for the grain size. Microhardness examination showed high weld joint quality with respect to the base metal hardness, which proves the reprecipitation of the hardening phase in the weld zone. The microhardness profile was strongly dependant on the rotational speed, and the average values of the joints hardness have increased with the decrease in the rotational speed, where it have been slightly affected by the welding speed. Keywords: Friction stir welding, Aluminum alloy, Mechanical properties, Microstructures

  10. Friction Stir Welding of GR-Cop 84 for Combustion Chamber Liners

    Science.gov (United States)

    Russell, Carolyn K.; Carter, Robert; Ellis, David L.; Goudy, Richard

    2004-01-01

    GRCop-84 is a copper-chromium-niobium alloy developed by the Glenn Research Center for liquid rocket engine combustion chamber liners. GRCop-84 exhibits superior properties over conventional copper-base alloys in a liquid hydrogen-oxygen operating environment. The Next Generation Launch Technology program has funded a program to demonstrate scale-up production capabilities of GR-Cop 84 to levels suitable for main combustion chamber production for the prototype rocket engine. This paper describes a novel method of manufacturing the main combustion chamber liner. The process consists of several steps: extrude the GR-Cop 84 powder into billets, roll the billets into plates, bump form the plates into cylinder halves and friction stir weld the halves into a cylinder. The cylinder is then metal spun formed to near net liner dimensions followed by finish machining to the final configuration. This paper describes the friction stir weld process development including tooling and non-destructive inspection techniques, culminating in the successful production of a liner preform completed through spin forming.

  11. Stir Friction Welding Used in Ares I Upper Stage Fabrication

    Science.gov (United States)

    2007-01-01

    Under the goals of the Vision for Space Exploration, Ares I is a chief component of the cost-effective space transportation infrastructure being developed by NASA's Constellation Program. This transportation system will safely and reliably carry human explorers back to the moon, and then onward to Mars and other destinations in the solar system. The Ares I effort includes multiple project element teams at NASA centers and contract organizations around the nation, and is managed by the Exploration Launch Projects Office at NASA's Marshall Space Flight Center (MFSC). ATK Launch Systems near Brigham City, Utah, is the prime contractor for the first stage booster. ATK's subcontractor, United Space Alliance of Houston, is designing, developing and testing the parachutes at its facilities at NASA's Kennedy Space Center in Florida. NASA's Johnson Space Center in Houston hosts the Constellation Program and Orion Crew Capsule Project Office and provides test instrumentation and support personnel. Together, these teams are developing vehicle hardware, evolving proven technologies, and testing components and systems. Their work builds on powerful, reliable space shuttle propulsion elements and nearly a half-century of NASA space flight experience and technological advances. Ares I is an inline, two-stage rocket configuration topped by the Crew Exploration Vehicle, its service module, and a launch abort system. This HD video image depicts friction stir welding used in manufacturing aluminum panels that will fabricate the Ares I upper stage barrel. The panels are subjected to confidence tests in which the bent aluminum is stressed to breaking point and thoroughly examined. The panels are manufactured by AMRO Manufacturing located in El Monte, California. (Highest resolution available)

  12. Study of the joining of polycarbonate panels in butt joint configuration through friction stir welding

    Science.gov (United States)

    Astarita, Antonello; Boccarusso, Luca; Carrino, Luigi; Durante, Massimo; Minutolo, Fabrizio Memola Capece; Squillace, Antonino

    2018-05-01

    Polycarbonate sheets, 3 mm thick, were successfully friction stir welded in butt joint configuration. Aiming to study the feasibility of the process and the influence of the process parameters joints under different processing conditions, obtained by varying the tool rotational speed and the tool travel speed, were realized. Tensile tests were carried out to characterize the joints. Moreover the forces arising during the process were recorded and carefully studied. The experimental outcomes proved the feasibility of the process when the process parameters are properly set, joints retaining more than 70% of the UTS of the base material were produced. The trend of the forces was described and explained, the influence of the process parameters was also introduced.

  13. Enabling high speed friction stir welding of aluminum tailor welded blanks

    Science.gov (United States)

    Hovanski, Yuri

    Current welding technologies for production of aluminum tailor-welded blanks (TWBs) are utilized in low-volume and niche applications, and have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high-volumes. While friction stir welding (FSW) has traditionally been applied at linear velocities less than one meter per minute, high volume production applications demand the process be extended to higher velocities more amenable to cost sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low to moderate welding velocities do not directly translate to high speed linear friction stir welding. Therefore, in order to facilitate production of high volume aluminum FSW components, parameters were developed with a minimum welding velocity of three meters per minute. With an emphasis on weld quality, welded blanks were evaluated for post-weld formability using a combination of numerical and experimental methods. Evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum tailor-welded blanks, which provided validation of the numerical and experimental analysis of laboratory scale tests.

  14. Nondestructive Evaluation of Friction Stir-Welded Aluminum Alloy to Coated Steel Sheet Lap Joint

    Science.gov (United States)

    Das, H.; Kumar, A.; Rajkumar, K. V.; Saravanan, T.; Jayakumar, T.; Pal, Tapan Kumar

    2015-11-01

    Dissimilar lap joints of aluminum sheet (AA 6061) of 2 mm thickness and zinc-coated steel sheet of 1 mm thickness were produced by friction stir welding with different combinations of rotational speed and travel speed. Ultrasonic C- and B-scanning, and radiography have been used in a complementary manner for detection of volumetric (cavity and flash) and planar (de bond) defects as the defects are in micron level. Advanced ultrasonic C-scanning did not provide any idea about the defects, whereas B-scanning cross-sectional image showed an exclusive overview of the micron-level defects. A digital x-ray radiography methodology is proposed for quality assessment of the dissimilar welds which provide three-fold increase in signal-to-noise ratio with improved defect detection sensitivity. The present study clearly shows that the weld tool rotational speed and travel speed have a decisive role on the quality of the joints obtained by the friction stir welding process. The suitability of the proposed NDE techniques to evaluate the joint integrity of dissimilar FSW joints is thus established.

  15. Friction stir welding of SiCp/2009Al composite plate

    International Nuclear Information System (INIS)

    Wang, D.; Xiao, B.L.; Wang, Q.Z.; Ma, Z.Y.

    2013-01-01

    Highlights: ► SiCp/2009Al plates were successfully friction stir welded using an ultra-hard tool. ► Under T4 temper condition, the joint coefficient of tensile strength was 95.9%. ► Coarsen Al 2 Cu in the nugget zone dissolved and precipitated after T4. - Abstract: Six milimeter thick hot-rolled SiCp/2009Al composite plates were successfully joined by friction stir welding (FSW) using an ultra-hard material tool. After FSW, the distribution of the SiC particles in the nugget zone (NZ) was more homogeneous than that in the base material (BM). Scanning electron microscopic examinations (SEM) and X-ray analysis (XRD) indicated that part of the Al 2 Cu was dissolved into the aluminum matrix in the NZ due to intense plastic deformation and high temperature during FSW. The undissolved Al 2 Cu particles remained in the NZ and coarsened during the cooling process after FSW. The ultimate tensile strength (UTS) of the as-welded joint is only 321 MPa and failed in the BM zone due to the low strength of the BM. After T4 heat treatment, the strength of the joint increased and became close to that of the BM with T4 temper, because most of the Al 2 Cu particles were dissolved into the matrix and re-precipitated homogeneously as the GP zones, which are the major strengthening precipitates for T4-tempered 2009Al alloy

  16. A preliminary investigation on microstructure and mechanical properties of dissimilar Al to Cu friction stir welds prepared using silver interlayer

    Directory of Open Access Journals (Sweden)

    Shailesh N. Pandya

    2018-04-01

    Full Text Available Due to its solid-state nature, friction stir welding (FSW process can be considered a better alternative for dissimilar welding metals. However, like fusion welding techniques, in friction stir welding growth of thick layers of brittle intermetallics - Cu9Al4 and CuAl2 is a significant issue. One solution to this problem is the use of the suitable interlayer material. Use of interlayer material modifies the joint microstructure with the replacement of thick, brittle intermetallics by more ductile intermetallics in a thin layer or particle form. The present study is a preliminary investigation about joining of AA6082-O to pure copper joints with and without silver (Ag wire interlayer. Friction stir welded joints were characterized regarding optical microscopy, X-Ray Diffraction (XRD analysis, microhardness measurement, tensile testing and Scanning Electron Microscopy (SEM based fractography. The Al-Cu weld prepared using silver interlayer was stronger than without it. The higher strength of the weld with silver interlayer is attributed to the formation of a composite type of structure with intercalation of more ductile Ag2Al intermetallics along with dispersion of Ag particles in stir zone.

  17. Effect of Friction Stir Welding Parameters on the Mechanical and Microstructure Properties of the Al-Cu Butt Joint

    Directory of Open Access Journals (Sweden)

    Sare Celik

    2016-05-01

    Full Text Available Friction Stir Welding (FSW is a solid-state welding process used for welding similar and dissimilar materials. FSW is especially suitable to join sheet Al alloys, and this technique allows different material couples to be welded continuously. In this study, 1050 Al alloys and commercially pure Cu were produced at three different tool rotation speeds (630, 1330, 2440 rpm and three different tool traverse speeds (20, 30, 50 mm/min with four different tool position (0, 1, 1.5, 2 mm by friction stir welding. The influence of the welding parameters on the microstructure and mechanical properties of the joints was investigated. Tensile and bending tests and microhardness measurements were used to determine the mechanical properties. The microstructures of the weld zone were investigated by optical microscope and scanning electron microscope (SEM and were analyzed in an energy dispersed spectrometer (EDS. Intermetallic phases were detected based on the X-ray diffraction (XRD analysis results that evaluated the formation of phases in the weld zone. When the welding performance of the friction stir welded butt joints was evaluated, the maximum value obtained was 89.55% with a 1330 rpm tool rotational speed, 20 mm/min traverse speed and a 1 mm tool position configuration. The higher tensile strength is attributed to the dispersion strengthening of the fine Cu particles distributed over the Al material in the stir zone region.

  18. Mitigating Abnormal Grain Growth for Friction Stir Welded Al-Li 2195 Spun Formed Domes

    Science.gov (United States)

    Chen, Po-Shou; Russell, Carolyn

    2012-01-01

    Formability and abnormal grain growth (AGG) are the two major issues that have been encountered for Al alloy spun formed dome development using friction stir welded blanks. Material properties that have significant influence on the formability include forming range and strain hardening exponent. In this study, tensile tests were performed for two 2195 friction stir weld parameter sets at 400 F to study the effects of post weld anneal on the forming range and strain hardening exponent. It was found that the formability can be enhanced by applying a newly developed post weld anneal to heat treat the friction stir welded panels. This new post weld anneal leads to a higher forming range and much improved strain hardening exponent. AGG in the weld nugget is known to cause a significant reduction of ductility and fracture toughness. This study also investigated how AGG may be influenced by the heating rate to the solution heat treatment temperature. After post-weld annealing, friction stir welds were strained to 15% and 39% by compression at 400 F before they were subjected to SHT at 950 F for 1 hour. Salt bath SHT is very effective in reducing the grain size as it helps arrest the onset of AGG and promote normal recrystallization and grain growth. However, heat treating a 18 ft dome using a salt bath is not practical. Efforts are continuing at Marshall Space Flight Center to identify the welding parameters and heat treating parameters that can help mitigate the AGG in the friction stir welds.

  19. Microstructural characterization and formation of α′ martensite phase in Ti–6Al–4V alloy butt joints produced by friction stir and gas tungsten arc welding processes

    International Nuclear Information System (INIS)

    Esmaily, M.; Nooshin Mortazavi, S.; Todehfalah, P.; Rashidi, M.

    2013-01-01

    Highlights: ► A fusion (GTAW) and a solid state method (FSW) are used to weld Ti–6Al–4V alloy. ► Optimal parameters yielding defects-free weldments are identified. ► A very careful microstructural quantification of the FSW and GTAW weldments are performed. ► α′ Martensite formed only in FSWed samples and avoided in GTAWed samples. ► FSW process produced joints with considerably smaller HAZ and higher hardness values. - Abstract: The obtained microstructures of a Ti–6Al–4V alloy welded by Gas Tungsten Arc Welding (GTAW) and Friction Stir Welding (FSW) were investigated and evaluated quantitatively. In the GTAW method, the effect of current was examined so that the samples were subjected to various currents between 90 and 120 A. In the FSW process, samples were welded by different rotational speeds (450–850 rpm). Non-destructive tests including Visual and Radiography Tests (VT and RT) were used to identify defect-free samples. The microstructural studies by electron microscopes revealed formation of different phases in the weld area of the samples welded via mentioned methods. The recorded peak temperatures in the weld regions compared favorably with the expectations about the evolved microstructures. A bi-modal microstructure was just obtained in the FSWed sample with a peak temperature below β transus temperature (T < 995 °C). α′ martensite phase, which is an acicular and strengthening phase in this alloy, was only observed in FSWed specimens

  20. Friction Stir Welding Development at NASA-Marshall Space Flight Center

    Science.gov (United States)

    Bhat, Biliyar N.; Carter, Robert W.; Ding, Robert J.; Lawless, Kirby G.; Nunes, Arthur C., Jr.; Russell, Carolyn K.; Shah, Sandeep R.

    2001-01-01

    This paper presents an overview of friction stir welding (FSW) process development and applications at Marshall Space Flight Center (MSFC). FSW process development started as a laboratory curiosity but soon found support from many users. The FSW process advanced very quickly and has found many applications both within and outside the aerospace industry. It is currently being adapted for joining key elements of the Space Shuttle External Tank for improved producibility and reliability. FSW process modeling is done to better understand and improve the process. Special tools have been developed to weld variable thickness materials including thin and thick materials. FSW is now being applied to higher temperature materials such as copper and to advanced materials such as metal matrix composites. FSW technology is being successfully transferred from MSFC laboratory to shop floors of many commercial companies.

  1. Friction Stir Welding Development at National Aeronautics and Space Administration-Marshall Space Flight Center

    Science.gov (United States)

    Bhat, Biliyar N.; Carter, Robert W.; Ding, Robert J.; Lawless, Kirby G.; Nunes, Arthur C., Jr.; Russell, Carolyn K.; Shah, Sandeep R.; Munafo, Paul M. (Technical Monitor)

    2001-01-01

    This paper presents an over-view of friction stir welding (FSW) process development and applications at Marshall Space Flight Center (MSFC). FSW process development started as a laboratory curiosity but soon found support from many users. The FSW process advanced very quickly and has found many applications both within and outside the aerospace industry. It is currently being adapted for joining key elements of the Space Shuttle External Tank for improved producibility and reliability. FSW process modeling is done to better understand and improve the process. Special tools have been developed to weld variable thickness materials including very thin and very thick materials. FSW is now being applied to higher temperature materials such as copper and to advanced materials such as metal matrix composites. FSW technology is being successfully transferred from MSFC laboratory to shop floors of many commercial companies.

  2. Optimization in Friction Stir Welding - With Emphasis on Thermo-mechanical Aspects

    DEFF Research Database (Denmark)

    Tutum, Cem Celal

    combined with classical single-objective and evolutionary multi-objective optimization algorithms (i.e. SQP and NSGA-II), to find the optimum process parameters (heat input, rotational and traverse welding speeds) that would result in favorable thermo-mechanical conditions for the process.......This book deals with the challenging multidisciplinary task of combining variant thermal and thermo-mechanical simulations for the manufacturing process of friction stir welding (FSW) with numerical optimization techniques in the search for optimal process parameters. The FSW process...... is characterized by multiphysics involving solid material flow, heat transfer, thermal softening, recrystallization and the formation of residual stresses. Initially, the thermal models were addressed since they in essence constitute the basis of all other models of FSW. Following this, several integrated thermo-mechanical...

  3. Effects of mechanical force on grain structures of friction stir welded oxide dispersion strengthened ferritic steel

    International Nuclear Information System (INIS)

    Han, Wentuo; Kimura, Akihiko; Tsuda, Naoto; Serizawa, Hisashi; Chen, Dongsheng; Je, Hwanil; Fujii, Hidetoshi; Ha, Yoosung; Morisada, Yoshiaki; Noto, Hiroyuki

    2014-01-01

    The weldability of oxide dispersion strengthened (ODS) ferritic steels is a critical obstructive in the development and use of these steels. Friction stir welding has been considered to be a promising way to solve this problem. The main purpose of this work was to reveal the effects of mechanical force on grain structures of friction stir welded ODS ferritic steel. The grain appearances and the misorientation angles of grain boundaries in different welded zones were investigated by the electron backscatter diffraction (EBSD). Results showed that the mechanical force imposed by the stir tool can activate and promote the recrystallization characterized by the transformation of boundaries from LABs to HABs, and contribute to the grain refinement. The type of recrystallization in the stir zone can be classified as the continuous dynamic recrystallization (CDRX)

  4. Effects of mechanical force on grain structures of friction stir welded oxide dispersion strengthened ferritic steel

    Energy Technology Data Exchange (ETDEWEB)

    Han, Wentuo, E-mail: hanwentuo@hotmail.com [Institute of Advanced Energy, Kyoto University, Gokasho, Uji, Kyoto 611-0011 (Japan); Kimura, Akihiko [Institute of Advanced Energy, Kyoto University, Gokasho, Uji, Kyoto 611-0011 (Japan); Tsuda, Naoto [Graduate School of Energy Science, Kyoto University, Gokasho, Uji, Kyoto 611-0011 (Japan); Serizawa, Hisashi [Joining and Welding Research Institute, Osaka University, Ibaraki, Osaka 567-0047 (Japan); Chen, Dongsheng [Graduate School of Energy Science, Kyoto University, Gokasho, Uji, Kyoto 611-0011 (Japan); Je, Hwanil [Institute of Advanced Energy, Kyoto University, Gokasho, Uji, Kyoto 611-0011 (Japan); Fujii, Hidetoshi [Joining and Welding Research Institute, Osaka University, Ibaraki, Osaka 567-0047 (Japan); Ha, Yoosung [Graduate School of Energy Science, Kyoto University, Gokasho, Uji, Kyoto 611-0011 (Japan); Morisada, Yoshiaki [Joining and Welding Research Institute, Osaka University, Ibaraki, Osaka 567-0047 (Japan); Noto, Hiroyuki [Graduate School of Energy Science, Kyoto University, Gokasho, Uji, Kyoto 611-0011 (Japan)

    2014-12-15

    The weldability of oxide dispersion strengthened (ODS) ferritic steels is a critical obstructive in the development and use of these steels. Friction stir welding has been considered to be a promising way to solve this problem. The main purpose of this work was to reveal the effects of mechanical force on grain structures of friction stir welded ODS ferritic steel. The grain appearances and the misorientation angles of grain boundaries in different welded zones were investigated by the electron backscatter diffraction (EBSD). Results showed that the mechanical force imposed by the stir tool can activate and promote the recrystallization characterized by the transformation of boundaries from LABs to HABs, and contribute to the grain refinement. The type of recrystallization in the stir zone can be classified as the continuous dynamic recrystallization (CDRX)

  5. Microstructure of Multi-Pass Friction-Stir-Processed Al-Zn-Mg-Cu Alloys Reinforced by Nano-Sized TiB2 Particles and the Effect of T6 Heat Treatment

    Directory of Open Access Journals (Sweden)

    Xiaofei Ju

    2017-11-01

    Full Text Available In this work, a fine-grained structure with a uniform distribution of TiB2 particles and precipitates was achieved in TiB2 particle-reinforced (PR Al-Zn-Mg-Cu alloys by friction stir processing (FSP. The effects of multi-pass FSP on the microstructure, and TiB2 particle distribution, as well as the microstructural evolution in the following T6 treatment, were investigated by X-ray diffraction, scanning electron microscopy and associated electron backscattered diffraction. The results showed that the distribution of TiB2 particles and alloy precipitates was further improved with an increase in the FSP passes. Moreover, compared with alloy segregation in the as-cast PR alloys during T6 treatment, a complete solution of the precipitates was achieved in the FSP-treated PR alloys. The fine-grained structure of the FSP-treated PR alloys was thermally stable without any abnormal growth at the high temperature of T6 treatment due to the pinning effect of dispersed TiB2 particles. The strength and ductility of the PR alloys were simultaneously improved by the combination of FSP and T6 treatment.

  6. Role of hybrid ratio in microstructural, mechanical and sliding wear properties of the Al5083/Graphitep/Al2O3p a surface hybrid nanocomposite fabricated via friction stir processing method

    International Nuclear Information System (INIS)

    Mostafapour Asl, A.; Khandani, S.T.

    2013-01-01

    Hybrid ratio of each reinforcement phase in hybrid composite can be defined as proportion of its volume to total reinforcement volume of the composite. The hybrid ratio is an important factor which controls the participation extent of each reinforcement phase in overall properties of hybrid composites. Hence, in the present work, surface hybrid nanocomposites of Al5083/Graphite p /Al 2 O 3p with different hybrid ratios were fabricated by friction stir processing method. Subsequently, effect of hybrid ratio on microstructural, mechanical and tribological properties of the nanocomposite was investigated. Optical microscopy and scanning electron microscopy were utilized to perform microstructural observation on the samples. Hardness value measurements, tensile and pin on disk dry sliding wear tests were carried out to investigate effect of hybrid ratio on mechanical and tribological properties of the nanocomposites. Microstructural investigations displayed better distribution with less agglomeration of reinforcement for lower volume fraction of reinforcement for both alumina and graphite particles. Hardness value, yield strength, ultimate tensile strength and wear rate of the nanocomposites revealed a two stage form along with hybrid ratio variation. The results are discussed based on microstructural observations of the nanocomposites and worn surface analyses.

  7. Effect of tool geometry on friction stir spot welding of polypropylene sheets

    Directory of Open Access Journals (Sweden)

    M. K. Bilici

    2012-10-01

    Full Text Available The effects of tool geometry and properties on friction stir spot welding properties of polypropylene sheets were studied. Four different tool pin geometries, with varying pin angles, pin lengths, shoulder diameters and shoulder angles were used for friction stir spot welding. All the welding operations were done at the room temperature. Lap-shear tensile tests were carried out to find the weld static strength. Weld cross section appearance observations were also done. From the experiments the effect of tool geometry on friction stir spot weld formation and weld strength were determined. The optimum tool geometry for 4 mm thick polypropylene sheets were determined. The tapered cylindrical pin gave the biggest and the straight cylindrical pin gave the lowest lap-shear fracture load.

  8. The Influence of Friction Stir Weld Tool Form and Welding Parameters on Weld Structure and Properties: Nugget Bulge in Self-Reacting Friction Stir Welds

    Science.gov (United States)

    Schneider, Judy; Nunes, Arthur C., Jr.; Brendel, Michael S.

    2010-01-01

    Although friction stir welding (FSW) was patented in 1991, process development has been based upon trial and error and the literature still exhibits little understanding of the mechanisms determining weld structure and properties. New concepts emerging from a better understanding of these mechanisms enhance the ability of FSW engineers to think about the FSW process in new ways, inevitably leading to advances in the technology. A kinematic approach in which the FSW flow process is decomposed into several simple flow components has been found to explain the basic structural features of FSW welds and to relate them to tool geometry and process parameters. Using this modelling approach, this study reports on a correlation between the features of the weld nugget, process parameters, weld tool geometry, and weld strength. This correlation presents a way to select process parameters for a given tool geometry so as to optimize weld strength. It also provides clues that may ultimately explain why the weld strength varies within the sample population.

  9. Modeling of AA5083 Material-Microstructure Evolution During Butt Friction-Stir Welding

    Science.gov (United States)

    Grujicic, M.; Arakere, G.; Yalavarthy, H. V.; He, T.; Yen, C.-F.; Cheeseman, B. A.

    2010-07-01

    A concise yet a fairly comprehensive overview of the friction stir welding (FSW) process is provided. This is followed by a computational investigation in which FSW behavior of a prototypical solution-strengthened and strain-hardened aluminum alloy, AA5083-H131, is modeled using a fully coupled thermo-mechanical finite-element procedure developed in our prior study. Particular attention is given to proper modeling of the welding work-piece material behavior during the FSW process. Specifically, competition and interactions between plastic-deformation and dynamic-recrystallization processes are considered to properly account for the material-microstructure evolution in the weld nugget zone. The results showed that with proper modeling of the material behavior under high-temperature/severe-plastic-deformation conditions, significantly improved agreement can be attained between the computed and measured post-FSW residual-stress and material-strength distribution results.

  10. Experimental investigations of tungsten inert gas assisted friction stir welding of pure copper plates

    Science.gov (United States)

    Constantin, M. A.; Boșneag, A.; Nitu, E.; Iordache, M.

    2017-10-01

    Welding copper and its alloys is usually difficult to join by conventional fusion welding processes because of high thermal diffusivity of the copper, alloying elements, necessity of using a shielding gas and a clean surface. To overcome this inconvenience, Friction Stir Welding (FSW), a solid state joining process that relies on frictional heating and plastic deformation, is used as a feasible welding process. In order to achieve an increased welding speed and a reduction in tool wear, this process is assisted by another one (WIG) which generates and adds heat to the process. The aim of this paper is to identify the influence of the additional heat on the process parameters and on the welding joint properties (distribution of the temperature, hardness and roughness). The research includes two experiments for the FSW process and one experiment for tungsten inert gas assisted FSW process. The outcomes of the investigation are compared and analysed for both welding variants. Adding a supplementary heat source, the plates are preheated and are obtain some advantages such as reduced forces used in process and FSW tool wear, faster and better plasticization of the material, increased welding speed and a proper weld quality.

  11. Friction stir welding of F/M ODS steel plug and F/M steel tube

    Energy Technology Data Exchange (ETDEWEB)

    Kang, Suk Hoon, E-mail: shkang77@kaeri.re.kr [Nuclear Materials Division, Korea Atomic Energy Research Institute (Korea, Republic of); Vasudevan, M. [Materials Technology Division, Indira Gandhi Centre for Atomic Research, Kalpakkam (India); Noh, Sanghoon; Jin, Hyun Ju; Jang, Jinsung; Kim, Tae Kyu [Nuclear Materials Division, Korea Atomic Energy Research Institute (Korea, Republic of)

    2016-11-01

    Highlights: • Friction stir welding (FSW) was used for joining of oxide dispersion strengthened (ODS) steel plug and F/M steel tube. • The curvature and smaller thickness of tube was the major limitation for applying FSW method, it was solved using specially designed jig. • Considerable hardening occurs in the joint because the cooling rate was sufficient to reproduce a martensitic microstructure. • The measured hoop strength of the FSWed joint was 70–90 MPa, the value was at around 70% of the tube. - Abstract: Friction stir welding (FSW) was used for joining of oxide dispersion strengthened (ODS) steel plug and F/M steel tube. The dimensions of the tube included outer diameter of 7 mm, wall thickness of 0.5 mm. The objective was to find suitable process variables for gaining enough frictional heat from those thin and curved pieces. A specially designed jig was used for stabilization and slow rotation of tube during FSW. Additionally, the plug was designed to overlap the tube. Inconel 718 was used as FSW tool, the diameter was 3.5 mm. The adequate rotation speed of the tool and jig were 1200 rpm and 1.5 rpm, respectively. The joining was successfully accomplished using above combination, showing a good possibility. The hoop stress tests of joint were conducted by blowing Ar gas into the tube, the flow rate of gas was 10 MPa/min. The measured hoop stress was 70–90 MPa, the value was at around 70% of the tube.

  12. Friction stir welding of F/M ODS steel plug and F/M steel tube

    International Nuclear Information System (INIS)

    Kang, Suk Hoon; Vasudevan, M.; Noh, Sanghoon; Jin, Hyun Ju; Jang, Jinsung; Kim, Tae Kyu

    2016-01-01

    Highlights: • Friction stir welding (FSW) was used for joining of oxide dispersion strengthened (ODS) steel plug and F/M steel tube. • The curvature and smaller thickness of tube was the major limitation for applying FSW method, it was solved using specially designed jig. • Considerable hardening occurs in the joint because the cooling rate was sufficient to reproduce a martensitic microstructure. • The measured hoop strength of the FSWed joint was 70–90 MPa, the value was at around 70% of the tube. - Abstract: Friction stir welding (FSW) was used for joining of oxide dispersion strengthened (ODS) steel plug and F/M steel tube. The dimensions of the tube included outer diameter of 7 mm, wall thickness of 0.5 mm. The objective was to find suitable process variables for gaining enough frictional heat from those thin and curved pieces. A specially designed jig was used for stabilization and slow rotation of tube during FSW. Additionally, the plug was designed to overlap the tube. Inconel 718 was used as FSW tool, the diameter was 3.5 mm. The adequate rotation speed of the tool and jig were 1200 rpm and 1.5 rpm, respectively. The joining was successfully accomplished using above combination, showing a good possibility. The hoop stress tests of joint were conducted by blowing Ar gas into the tube, the flow rate of gas was 10 MPa/min. The measured hoop stress was 70–90 MPa, the value was at around 70% of the tube.

  13. Friction stir welding of F82H steel for fusion applications

    Energy Technology Data Exchange (ETDEWEB)

    Noh, Sanghoon, E-mail: shnoh@kaeri.re.kr [Fusion Structural Materials Division, Japan Atomic Energy Agency, Rokkasho, Aomori (Japan); Nuclear Materials Division, Korea Atomic Energy Research Institute, Yuseong-gu, Daejeon (Korea, Republic of); Ando, Masami; Tanigawa, Hiroyasu [Fusion Structural Materials Division, Japan Atomic Energy Agency, Rokkasho, Aomori (Japan); Fujii, Hidetoshi [Joining and Welding Research Institute, Osaka University, Ibaraki, Osaka (Japan); Kimura, Akihiko [Institute of Advanced Energy, Kyoto University, Gokasho, Uji, Kyoto (Japan)

    2016-09-15

    In the present study, friction stir welding was employed to join F82H steels and develop a potential joining technique for a reduced activation ferritic/martensitic steel. The microstructures and mechanical properties on the joint region were investigated to evaluate the applicability of friction stir welding. F82H steel sheets were successfully butt-joined with various welding parameters. In welding conditions, 100 rpm and 100 mm/min, the stirred zone represented a comparable hardness distribution with a base metal. Stirred zone induced by 100 rpm reserved uniformly distributed precipitates and very fine ferritic grains, whereas the base metal showed a typical tempered martensite with precipitates on the prior austenite grain boundary and lath boundary. Although the tensile strength was decreased at 550 °C, the stirred zone treated at 100 rpm showed comparable tensile behavior with base metal up to 500 °C. Therefore, friction stir welding is considered a potential welding method to preserve the precipitates of F82H steel.

  14. Friction stir welding of F82H steel for fusion applications

    International Nuclear Information System (INIS)

    Noh, Sanghoon; Ando, Masami; Tanigawa, Hiroyasu; Fujii, Hidetoshi; Kimura, Akihiko

    2016-01-01

    In the present study, friction stir welding was employed to join F82H steels and develop a potential joining technique for a reduced activation ferritic/martensitic steel. The microstructures and mechanical properties on the joint region were investigated to evaluate the applicability of friction stir welding. F82H steel sheets were successfully butt-joined with various welding parameters. In welding conditions, 100 rpm and 100 mm/min, the stirred zone represented a comparable hardness distribution with a base metal. Stirred zone induced by 100 rpm reserved uniformly distributed precipitates and very fine ferritic grains, whereas the base metal showed a typical tempered martensite with precipitates on the prior austenite grain boundary and lath boundary. Although the tensile strength was decreased at 550 °C, the stirred zone treated at 100 rpm showed comparable tensile behavior with base metal up to 500 °C. Therefore, friction stir welding is considered a potential welding method to preserve the precipitates of F82H steel.

  15. Microstructure, mechanical behavior and corrosion properties of friction stir welded aluminum alloys used in the aerospace industry

    OpenAIRE

    Alfaro Mercado, Ulises

    2011-01-01

    Friction stir welding (FSW) has been identified as “key” technology for the production of primary aerospace structures, being able to substitute conventional riveted airframes. FSW is a solid state welding process that avoids any problems caused by the solidification of the melted weld pool. Besides the production of high quality similar joints from high strength aluminum alloys, it allows for joining materials of different metallurgical characteristics. However, problems concerning the corro...

  16. The investigation of typical welding defects for 5456 aluminum alloy friction stir welds

    International Nuclear Information System (INIS)

    Chen Huabin; Yan Keng; Lin Tao; Chen Shanben; Jiang Chengyu; Zhao Yong

    2006-01-01

    The external factors on the friction stir welding defects are so abundant that the experiments of friction stir welding were conducted for 5456 aluminum alloy. With the changes of the tool tilt angle and material condition, defects can be generated. These defects can be conventional ones (lack of penetration or voids), or lazy S, which are unique to friction stir welding. However, the origin of the defects remains an area of uncertainty. In this study, an attempt has been made to investigate the formation of these defects. The typical welding defects of friction stir welding joint for 5456 aluminum alloy were analyzed and discussed, respectively, by using optical microscopy (OM), energy-dispersive X-ray spectroscopy (EDS) and scanning electron microscope (SEM). The microscopic examination of the nugget zone and fracture location of the weld confirms that the tilt angle can change the plastic material flow patterns in the stir zone and accordingly control the weld properties. In addition, the oxide layer from the initial butt surface during FSW is dispersed at the grain boundary. These A1 2 O 3 particles are actually the major cause of failure of the joint

  17. Computational Analysis of Material Flow During Friction Stir Welding of AA5059 Aluminum Alloys

    Science.gov (United States)

    2011-01-01

    structures in Finland; (b) manufacture of Al-Mg-Si-based alloy 181 FSW-joined bullet- train cabins in Japan; (c) fabrication of 182 Al-Cu-based alloy...Simonsen, Visualisation of Material 857Flow in an Autogenous Friction Stir Weld, Proc. 1st International 858Symp. FSW, Thousand Oaks, CA, 1999 85928...A.P. Reynolds, Visualization of Material Flow in an Autogenous 860Friction Stir Weld, Sci. Technol. Weld. Join., 2000, 5, p 120–124 86129. T.U. Seidel

  18. Effect of Water Cooling on the Performances of Friction Stir Welding Heat-Affected Zone

    Science.gov (United States)

    Zhang, H. J.; Liu, H. J.; Yu, L.

    2012-07-01

    The heat-affected zone (HAZ) is generally the intrinsic weakest location of the normal friction stir welded precipitate hardened aluminum alloys. In order to improve the mechanical properties of the HAZ by controlling the temperature level, underwater friction stir welding (FSW) of an Al-Cu aluminum alloy was conducted in the present study. The results indicate that the hardness of the HAZ can be improved through underwater FSW. Microstructural analysis reveals that the hardness improvement is attributed to the lowering of precipitate coarsening level and the narrowing of precipitate free zone, which are essentially induced by the variations of welding thermal cycles under the cooling effect of water.

  19. TEM analysis of a friction stir-welded butt joint of Al-Si-Mg alloys

    International Nuclear Information System (INIS)

    Cabibbo, M.; Meccia, E.; Evangelista, E.

    2003-01-01

    The microstructure evolution of a joint of Al-Si-Mg alloys A6056-T4 and A6056-T6 has been characterized by transmission electron microscopy (TEM). Metallurgical investigations, hardness and mechanical tests were also performed to correlate the TEM investigations to the mechanical properties of the produced friction stir-welded butt joint. After friction stir-welding thermal treatment has been carried out at 530 deg. C followed by ageing at 160 deg. C (T6). The base material (T4) and the heat-treated one (T6) were put in comparison showing a remarkable ductility reduction of the joint after T6 treatment

  20. Microstructural and mechanical properties of pure aluminum, 5083 and 7075 alloys joined by friction stir welding

    Energy Technology Data Exchange (ETDEWEB)

    Yilmaz, Selim Sarper [Celal Bayar Univ., Manisa, Muradiye (Turkey)

    2012-07-01

    In this study, microstructural and mechanical properties of pure aluminum, 5083 and 7075 alloys joined by friction stir welding were investigated. Hardness, tensile, bending and impact tests were applied to the welded samples. In addition, optical and SEM tests were carried out. The effects of welding speed on microstructure and mechanical properties were investigated in these materials. Then, the optimal conditions for friction stir welding were determined for pure aluminum, 5083 and 7075 alloys. The maximum hardness was observed for 7075 while the minimum hardness was observed for pure aluminum. (orig.)

  1. Characterization of microstructure and mechanical properties of friction stir welded AlMg5- Al_2O_3 nanocomposites

    International Nuclear Information System (INIS)

    Babu, N. Kishore; Kallip, Kaspar; Leparoux, Marc; AlOgab, Khaled A.; Reddy, G.M.; Talari, M.K.

    2016-01-01

    In the present study, powder metallurgy processed unmilled AlMg5, milled AlMg5 and milled AlMg5-0.5 vol% Al_2O_3 nanocomposite have been successfully friction stir welded (FSW). The effect of friction stir welding on the evolution of weld microstructures; hardness and tensile properties were studied and discussed in detail. FSW of unmilled AlMg5 resulted in significant grain refinement and strain hardening in the nugget zone induced by the thermo-mechanical processing, thereby increasing the stir zone hardness and tensile strengths to 100 HV and 324 MPa when compared to 80 HV and 300 MPa of base metal, respectively. In contrast, the FSW of milled AlMg5 and milled AlMg5-0.5 vol% Al_2O_3 samples showed a reduction in UTS values to 375 MPa and 401 MPa in the stir zone compared to 401 MPa and 483 MPa of respective base metal values. Transmission electron microscopic (TEM) investigation of weld stir zones revealed the homogenous distribution of Al_4C_3 nanophases in milled AlMg5 and Al_2O_3 nanoparticles in milled AlMg5-0.5 vol% Al_2O_3 samples throughout the aluminium matrix. It was revealed that the pre-stored energy from the prior ball milling and hot pressing processes, higher deformation energy and grain boundary pinning effect due to the presence of reinforcement particles has resulted in a higher recrystallization tendency and retarded grain growth during FSW of milled samples. The welds prepared with milled AlMg5-0.5 vol% Al_2O_3 exhibited higher hardness and tensile strength in the stir zone when compared to all other conditions which was attributed to Hall Petch effect due to fine grain size and Orowan strengthening effect due to Al_2O_3 reinforcements.

  2. Effect of tool shape and welding parameters on mechanical properties and microstructure of dissimilar friction stir welded aluminium alloys

    Directory of Open Access Journals (Sweden)

    Chetan Aneja

    2016-07-01

    Full Text Available In the present experimental study, dissimilar aluminum alloy AA5083 and AA6082 were friction stir welded by varying tool shape, welding speed and rotary speed of the tool in order to investigate the effect of varying tool shape and welding parameters on the mechanical properties as well as microstructure. The friction stir welding (FSW process parameters have great influence on heat input per unit length of weld. The outcomes of experimental study prove that mechanical properties increases with decreasing welding speed. Furthermore mechanical properties were also found to improve as the rotary speed increases and the same phenomenon was found to happen while using straight cylindrical threaded pin profile tool. The microstructure of the dissimilar joints revealed that at low welding speeds, the improved material mixing was observed. The similar phenomenon was found to happen at higher rotational speeds using straight cylindrical threaded tool.

  3. Effect of Trailing Intensive Cooling on Residual Stress and Welding Distortion of Friction Stir Welded 2060 Al-Li Alloy

    Science.gov (United States)

    Ji, Shude; Yang, Zhanpeng; Wen, Quan; Yue, Yumei; Zhang, Liguo

    2018-04-01

    Trailing intensive cooling with liquid nitrogen has successfully applied to friction stir welding of 2 mm thick 2060 Al-Li alloy. Welding temperature, plastic strain, residual stress and distortion of 2060 Al-Li alloy butt-joint are compared and discussed between conventional cooling and trailing intensive cooling using experimental and numerical simulation methods. The results reveal that trailing intensive cooling is beneficial to shrink high temperature area, reduce peak temperature and decrease plastic strain during friction stir welding process. In addition, the reduction degree of plastic strain outside weld is smaller than that inside weld. Welding distortion presents an anti-saddle shape. Compared with conventional cooling, the reductions of welding distortion and longitudinal residual stresses of welding joint under intense cooling reach 47.7 % and 23.8 %, respectively.

  4. Influence of friction stir welding parameters on titanium-aluminum heterogeneous lap joining configuration

    Science.gov (United States)

    Picot, Florent; Gueydan, Antoine; Hug, Éric

    2017-10-01

    Lap joining configuration for Friction Stir Welding process is a methodology mostly dedicated to heterogeneous bonding. This welding technology was applied to join pure titanium with pure aluminum by varying the rotation speed and the movement speed of the tool. Regardless of the process parameters, it was found that the maximum strength of the junction remains almost constant. Microstructural observations by means of Scanning Electron Microscopy and Energy Dispersive Spectrometry analysis enable to describe the interfacial join and reveal asymmetric Cold Lap Defects on the sides of the junction. Chemical analysis shows the presence of one exclusive intermetallic compound through the interface identified as TiAl3. This compound is responsible of the crack spreading of the junction during the mechanical loading. The original version of this article supplied to AIP Publishing contained an accidental inversion of the authors, names. An updated version of this article, with the authors names formatted correctly was published on 20 October 2017.

  5. Development of mathematical model to predict the mechanical properties of friction stir

    Directory of Open Access Journals (Sweden)

    R. Palanivel

    2011-01-01

    Full Text Available This paper presents a systematic approach to develop the mathematical model for predicting the ultimate tensile strength,yield strength, and percentage of elongation of AA6351 aluminum alloy which is widely used in automotive, aircraft anddefense Industries by incorporating (FSW friction stir welding process parameter such as tool rotational speed, weldingspeed, and axial force. FSW has been carried out based on three factors five level central composite rotatable design withfull replications technique. Response surface methodology (RSM is employed to develop the mathematical model. Analysisof variance (ANOVA Technique is used to check the adequacy of the developed mathematical model. The developedmathematical model can be used effectively at 95% confidence level. The effect of FSW process parameter on mechanicalproperties of AA6351 aluminum alloy has been analyzed in detail.

  6. Microstructural evolution and properties of friction stir welded aluminium alloy AA2219

    International Nuclear Information System (INIS)

    Gupta, R. K.; Biju, S.; Ghosh, B. R.; Sinha, P. P.

    2007-01-01

    Low weld strength of fusion welded joints of aluminium alloy AA2219 is a concern in fabrication of pressure vessels and is attributable to the presence of weld defects, as well as various metallurgical factors. Friction stir welding (FSW), being a solid state joining process has obvious advantages over fusion welding. Results of preliminary FSW experiments conducted on 10 mm thick plate using a particular tool configuration are presented here. Microscopic studies show the presence of very fine equiaxed recrystallised grain at the weld nugget and a flow pattern of grains due to heavy deformation in defect-free weld coupons. Mechanical properties are correlated with the microstructure and process variables. Fractographic analysis complements the observations of optical microscopy and mechanical properties

  7. Laser beam welding and friction stir welding of 6013-T6 aluminium alloy sheet

    International Nuclear Information System (INIS)

    Braun, R.; Dalle Donne, C.; Staniek, G.

    2000-01-01

    Butt welds of 1.6 mm thick 6013-T6 sheet were produced using laser beam welding and friction stir welding processes. Employing the former joining technique, filler powders of the alloys Al-5%Mg and Al-12%Si were used. Microstructure, hardness profiles, tensile properties and the corrosion behaviour of the welds in the as-welded condition were investigated. The hardness in the weld zone was lower compared to that of the base material in the peak-aged temper. Hardness minima were measured in the fusion zone and in the thermomechanically affected zone for laser beam welded and friction stir welded joints, respectively. Metallographic and fractographic examinations revealed pores in the fusion zone of the laser beam welds. Porosity was higher in welds made using the filler alloy Al-5%Mg than using the filler metal Al-12%Si. Transmission electron microscopy indicated that the β '' (Mg 2 Si) hardening precipitates were dissolved in the weld zone due to the heat input of the joining processes. Joint efficiencies achieved for laser beam welds depended upon the filler powders, being about 60 and 80% using the alloys Al-5%Mg and Al-12%Si, respectively. Strength of the friction stir weld approached over 80% of the ultimate tensile strength of the 6013-T6 base material. Fracture occurred in the region of hardness minima unless defects in the weld zone led to premature failure. The heat input during welding did not cause a degradation of the corrosion behaviour of the welds, as found in continuous immersion tests in an aqueous chloride-peroxide solution. In contrast to the 6013-T6 parent material, the weld zone was not sensitive to intergranular corrosion. Alternate immersion tests in 3.5% NaCl solution indicated high stress corrosion cracking resistance of the joints. For laser beam welded sheet, the weld zone of alternately immersed specimens suffered severe degradation by pitting and intergranular corrosion, which may be associated with galvanic coupling of filler metal and

  8. Optimizing friction stir weld parameters of aluminum and copper using conventional milling machine

    Science.gov (United States)

    Manisegaran, Lohappriya V.; Ahmad, Nurainaa Ayuni; Nazri, Nurnadhirah; Noor, Amirul Syafiq Mohd; Ramachandran, Vignesh; Ismail, Muhammad Tarmizizulfika; Ahmad, Ku Zarina Ku; Daruis, Dian Darina Indah

    2018-05-01

    The joining of two of any particular materials through friction stir welding (FSW) are done by a rotating tool and the work piece material that generates heat which causes the region near the FSW tool to soften. This in return will mechanically intermix the work pieces. The first objective of this study is to join aluminum plates and copper plates by means of friction stir welding process using self-fabricated tools and conventional milling machine. This study also aims to investigate the optimum process parameters to produce the optimum mechanical properties of the welding joints for Aluminum plates and Copper plates. A suitable tool bit and a fixture is to be fabricated for the welding process. A conventional milling machine will be used to weld the aluminum and copper. The most important parameters to enable the process are speed and pressure of the tool (or tool design and alignment of the tool onto the work piece). The study showed that the best surface finish was produced from speed of 1150 rpm and tool bit tilted to 3°. For a 200mm × 100mm Aluminum 6061 with plate thickness of 2 mm at a speed of 1 mm/s, the time taken to complete the welding is only 200 seconds or equivalent to 3 minutes and 20 seconds. The Copper plates was successfully welded using FSW with tool rotation speed of 500 rpm, 700 rpm, 900 rpm, 1150 rpm and 1440 rpm and with welding traverse rate of 30 mm/min, 60 mm/min and 90 mm/min. As the conclusion, FSW using milling machine can be done on both Aluminum and Copper plates, however the weld parameters are different for the two types of plates.

  9. Microstructural features of friction stir welded dissimilar Aluminium alloys AA2219-AA7475

    Science.gov (United States)

    Zaman Khan, Noor; Ubaid, Mohammed; Siddiquee, Arshad Noor; Khan, Zahid A.; Al-Ahmari, Abdulrahman; Chen, Xizhang; Haider Abidi, Mustufa

    2018-05-01

    High strength, good corrosion resistance, light weight make aluminium alloys a material of choice in many industrial sectors like aerospace, marine etc. Problems associated with welding of these alloys by fusion welding processes restricted their use in various industries. Friction stir welding (FSW), a clean solid-state joining process, easily overcomes various difficulties encountered during conventional fusion welding processes. In the present work, the effect of rotational speed (710 rpm, 900 rpm and 1120 rpm) on micro-hardness distribution and microstructure of FSWed dissimilar aluminium alloy joints were analyzed. Plates of AA7475-T761 and AA2219-O having thickness of 2.5 mm were welded by fixing AA7475 on retreating side (RS) and AA2219 on advancing side (AS). Welded joints were characterized by Vickers micro-hardness testing, scanning electron microscopy (SEM) and optical microscopy (OM). Results revealed that rotational speed significantly affects the micro-hardness due to increase in grain size, coarsening and dissolution of strengthening precipitates and re-precipitation. Higher micro-hardness values were observed in stir zone due to grain refinement and re-precipitation. Minimum micro-hardness value was observed at the TMAZ/HAZ of advancing side due to thermal softening.

  10. Microstructure Characterization and Stress Corrosion Evaluation of Autogenous and Hybrid Friction Stir Welded Al-Cu-Li 2195 Alloy

    Science.gov (United States)

    Li, Zhixian; Arbegast, William J.; Meletis, Efstathios I.

    1997-01-01

    Friction stir welding process is being evaluated for application on the Al-Cu-Li 2195 Super-Light Weight External Tank of the Space Transportation System. In the present investigation Al-Cu-Li 2195 plates were joined by autogenous friction stir welding (FSW) and hybrid FSW (friction stir welding over existing variable polarity plasma arc weld). Optical microscopy and transmission electron microscopy (TEM) were utilized to characterize microstructures of the weldments processed by both welding methods. TEM observations of autogenous FSW coupons in the center section of the dynamically-recrystallized zone showed an equiaxed recrystallized microstructure with an average grain size of approx. 3.8 microns. No T(sub 1), precipitates were present in the above-mentioned zone. Instead, T(sub B) and alpha precipitates were found in this zone with a lower population. Alternate immersion, anodic polarization, constant load, and slow strain tests were carried out to evaluate the general corrosion and stress-corrosion properties of autogenous and hybrid FSW prepared coupons. The experimental results will be discussed.

  11. Microstructure and mechanical characterization of friction stir welded high strength low alloy steels

    Energy Technology Data Exchange (ETDEWEB)

    Ramesh, R., E-mail: rameshsmit@gmail.com [Department of Mechanical Engineering, PSG College of Technology, Coimbatore 641004, Tamilnadu (India); Dinaharan, I., E-mail: dinaweld2009@gmail.com [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park Kingsway Campus, Johannesburg 2006, Gauteng (South Africa); Kumar, Ravi, E-mail: nvrk@iitm.ac.in [Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras, Chennai 600036, Tamilnadu (India); Akinlabi, E.T., E-mail: etakinlabi@uj.ac.za [Department of Mechanical Engineering Science, University of Johannesburg, Auckland Park Kingsway Campus, Johannesburg 2006, Gauteng (South Africa)

    2017-02-27

    Friction stir welding (FSW) is a promising technique to join HSLA steels without the problems encountered during fusion based welding processes. In the present work, 3 mm thick HSLA plates were successfully welded using FSW. A tool made of tungsten-rhenium alloy was used in this work. The relationship between microstructure and tensile strength was studied under various welding conditions i.e. change in traverse speed (57–97 mm/min). The microstructure of the weld nugget revealed the presence of upper bainite and fine ferrite phases. The amount of upper bainite reduced with increase in traverse speed. EBSD images showed a reducing trend for grain size. The details of hardness, tensile strength and bending test were reported.

  12. Microstructure and mechanical characterization of friction stir welded high strength low alloy steels

    International Nuclear Information System (INIS)

    Ramesh, R.; Dinaharan, I.; Kumar, Ravi; Akinlabi, E.T.

    2017-01-01

    Friction stir welding (FSW) is a promising technique to join HSLA steels without the problems encountered during fusion based welding processes. In the present work, 3 mm thick HSLA plates were successfully welded using FSW. A tool made of tungsten-rhenium alloy was used in this work. The relationship between microstructure and tensile strength was studied under various welding conditions i.e. change in traverse speed (57–97 mm/min). The microstructure of the weld nugget revealed the presence of upper bainite and fine ferrite phases. The amount of upper bainite reduced with increase in traverse speed. EBSD images showed a reducing trend for grain size. The details of hardness, tensile strength and bending test were reported.

  13. Effects of Friction Stir Welding on Corrosion Behaviors of AA2024-T4 Aluminum Alloy

    Directory of Open Access Journals (Sweden)

    Ales Steve Korakan

    2017-01-01

    Full Text Available In this work, the corrosion behavior of welded joints of AA2024-T4 Al alloy produced by friction stir welding process has been investigated. Tests were performed in an aerated 3.5% NaCl aqueous solution with pH = 7 at 20±2°C. Corrosion rate and corrosion morphology of weld regions were evaluated and compared to those of the parent metal. The microstructure of weld nugget, thermomechanical affected zone, heated affected zone, and parent metal were analyzed using scanning electron microscopy and energy dispersive spectroscopy. It was observed that corrosion initiated at FSW related spots and the sizes of local corrosion increased with time.

  14. Microstructure and Mechanical Characterization of Friction-Stir-Welded Dual-Phase Brass

    Science.gov (United States)

    Ramesh, R.; Dinaharan, I.; Akinlabi, E. T.; Murugan, N.

    2018-03-01

    Friction stir welding (FSW) is an ideal process to join brass to avoid the evaporation of zinc. In the present investigation, 6-mm-thick dual-phase brass plates were joined efficiently using FSW at various tool rotational speeds. The microstructures were studied using optical microscopy, electron backscattered diffraction and transmission electron microscopy. The optical micrographs revealed the evolution of various zones across the joint line. The microstructure of the heat-affected zone was similar to that of base metal. The weld zone exhibited finer grains due to dynamic recrystallization. The recrystallization was inhomogeneous and the inhomogeneity reduced with increased tool rotational speed. The dual phase was preserved in the weld zone due to the retention of zinc. The severe plastic deformation created a lot of dislocations in the weld zone. The weld zone was strengthened after welding. The role of tool rotational speed on the joint strength is further reported.

  15. Influence of tool shape on lattice rearrangement under loading conditions reproducing friction stir welding

    Energy Technology Data Exchange (ETDEWEB)

    Konovalenko, Ivan S., E-mail: ivkon@ispms.tsc.ru [Institute of Strength Physics and Materials Science SB RAS, Tomsk, 634055 (Russian Federation); Konovalenko, Igor S., E-mail: igkon@ispms.tsc.ru [Institute of Strength Physics and Materials Science SB RAS, Tomsk, 634055 (Russian Federation); National Research Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation)

    2015-10-27

    Metal behavior under loading conditions that reproduce friction stir welding was studied on the atomic scale. Calculations were conducted based on molecular dynamics simulation with potentials calculated within the embedded atom method. The loading of the interface between two crystallites, whose structure corresponded to aluminum alloy 2024, was simulated by the motion of a cone-shaped tool along the interface with constant angular and translational velocities. The motion of the rotating tool causes fracture of the workpiece crystal structure with subsequent mixing of surface atoms of the interfacing crystallites. It is shown that the resistance force acting on the moving tool from the workpiece and the process of structural defect formation in the workpiece depend on the tool shape.

  16. Analysing the strength of friction stir welded dissimilar aluminium alloys using Sugeno Fuzzy model

    Science.gov (United States)

    Barath, V. R.; Vaira Vignesh, R.; Padmanaban, R.

    2018-02-01

    Friction stir welding (FSW) is a promising solid state joining technique for aluminium alloys. In this study, FSW trials were conducted on two dissimilar plates of aluminium alloy AA2024 and AA7075 by varying the tool rotation speed (TRS) and welding speed (WS). Tensile strength (TS) of the joints were measured and a Sugeno - Fuzzy model was developed to interconnect the FSW process parameters with the tensile strength. From the developed model, it was observed that the optimum heat generation at WS of 15 mm.min-1 and TRS of 1050 rpm resulted in dynamic recovery and dynamic recrystallization of the material. This refined the grains in the FSW zone and resulted in peak tensile strength among the tested specimens. Crest parabolic trend was observed in tensile strength with variation of TRS from 900 rpm to 1200 rpm and TTS from 10 mm.min-1 to 20 mm.min-1.

  17. Role of Tool Shoulder End Features on Friction Stir Weld Characteristics of 6082 Aluminum Alloy

    Science.gov (United States)

    Mugada, Krishna Kishore; Adepu, Kumar

    2018-03-01

    Understanding the temperature generation around the tool shoulder contact is one of the important aspects of the friction stir welding process. In the present study, the effects of various tool shoulder end feature on the temperature and mechanical properties of the 6082 aluminum alloy were investigated. The experimental results show that the axial force during the welding is considerably reduced by using tools with shoulder end features. The detailed observation revealed that around the tool shoulder contact, the amount of heat generation is higher between trialing edge (TE) to retreating side-leading edge corner (RS-LE) counter clockwise direction and lower between RS-LE to TE clockwise direction. Out of the four shoulder end featured tools, the welds produced with ridges shoulder tool resulted in superior properties with significantly lower axial force (approximately 32%) compared to plane shoulder tool.

  18. Microstructure and Mechanical Performance of Friction Stir Spot-Welded Aluminum-5754 Sheets

    Science.gov (United States)

    Pathak, N.; Bandyopadhyay, K.; Sarangi, M.; Panda, Sushanta Kumar

    2013-01-01

    Friction stir spot welding (FSSW) is a recent trend of joining light-weight sheet metals while fabricating automotive and aerospace body components. For the successful application of this solid-state welding process, it is imperative to have a thorough understanding of the weld microstructure, mechanical performance, and failure mechanism. In the present study, FSSW of aluminum-5754 sheet metal was tried using tools with circular and tapered pin considering different tool rotational speeds, plunge depths, and dwell times. The effects of tool design and process parameters on temperature distribution near the sheet-tool interface, weld microstructure, weld strength, and failure modes were studied. It was found that the peak temperature was higher while welding with a tool having circular pin compared to tapered pin, leading to a bigger dynamic recrystallized stir zone (SZ) with a hook tip bending towards the upper sheet and away from the keyhole. Hence, higher lap shear separation load was observed in the welds made from circular pin compared to those made from tapered pin. Due to influence of size and hardness of SZ on crack propagation, three different failure modes of weld nugget were observed through optical cross-sectional micrograph and SEM fractographs.

  19. Microstructure-based modeling of tensile deformation of a friction stir welded AZ31 Mg alloy

    Energy Technology Data Exchange (ETDEWEB)

    He, Weijun, E-mail: weijun.he@cqu.edu.cn [College of Materials Science and Engineering, Chongqing University, Chongqing 400044 (China); Zheng, Li [College of Materials Science and Engineering, Shenyang University of Technology, Shenyang 110870 (China); Xin, Renlong, E-mail: rlxin@cqu.edu.cn [College of Materials Science and Engineering, Chongqing University, Chongqing 400044 (China); Liu, Qing [College of Materials Science and Engineering, Chongqing University, Chongqing 400044 (China)

    2017-02-27

    The deformation and fracture behaviors of friction stir welded (FSWed) Mg alloys are topics under investigation. The microstructure and texture of a FSWed Mg alloy were characterized by electron back scattered diffraction. Four characteristic sub-zones with different orientations in the FSWed Mg alloy joint were identified. The texture distribution across the stir zones and transition zone were obviously inhomogeneous. For comparison, four sub-regions in the base material were also characterized. Based on the experimental microstructure and texture, a crystal plasticity finite element model was developed to represent the friction stir welded Mg alloy. Simulations were carried out to study the effect of texture variation on the deformation behaviors during transverse tension. Compared with the base material case, strong macroscopic strain localization was observed for the FSWed joint case after transverse tension. Strain localization may have contributed to the decayed elongation of the FSWed joint in the transverse tension. Texture variation in the thermal-mechanical affected zone did not change the deformation mechanism in the stir zones, while it did decrease the strain localization, thus assuming to improve the elongation of the friction stir welded Mg alloy.

  20. Microstructure-based modeling of tensile deformation of a friction stir welded AZ31 Mg alloy

    International Nuclear Information System (INIS)

    He, Weijun; Zheng, Li; Xin, Renlong; Liu, Qing

    2017-01-01

    The deformation and fracture behaviors of friction stir welded (FSWed) Mg alloys are topics under investigation. The microstructure and texture of a FSWed Mg alloy were characterized by electron back scattered diffraction. Four characteristic sub-zones with different orientations in the FSWed Mg alloy joint were identified. The texture distribution across the stir zones and transition zone were obviously inhomogeneous. For comparison, four sub-regions in the base material were also characterized. Based on the experimental microstructure and texture, a crystal plasticity finite element model was developed to represent the friction stir welded Mg alloy. Simulations were carried out to study the effect of texture variation on the deformation behaviors during transverse tension. Compared with the base material case, strong macroscopic strain localization was observed for the FSWed joint case after transverse tension. Strain localization may have contributed to the decayed elongation of the FSWed joint in the transverse tension. Texture variation in the thermal-mechanical affected zone did not change the deformation mechanism in the stir zones, while it did decrease the strain localization, thus assuming to improve the elongation of the friction stir welded Mg alloy.

  1. Microstructure Stability During Creep of Friction Stir Welded AA2024-T3 Alloy

    Science.gov (United States)

    Regev, Michael; Rashkovsky, Tal; Cabibbo, Marcello; Spigarelli, Stefano

    2018-01-01

    The poor weldability of the AA2024 aluminum alloy limits its use in industrial applications. Because friction stir welding (FSW) is a non-fusion welding process, it seems to be a promising solution for welding this alloy. In the current study, FSW was applied to butt weld AA2024-T3 aluminum alloy plates. Creep tests were conducted at 250 and at 315 °C on both the parent material and the friction stir welded specimens. The microstructures of the welded and non-welded AA2024-T3 specimens before and after the creep tests were studied and compared. A comprehensive transmission electron microscopy study together with a high-resolution scanning electron microscopy study and energy-dispersive x-ray spectroscopy analysis was conducted to investigate the microstructure stability. The parent material seems to contain two kinds of Cu-rich precipitates—coarse precipitates of a few microns each and uniformly dispersed fine nanosized precipitates. Unlike the parent material, the crept specimens were found to contain the two kinds of precipitates mentioned above together with platelet-like precipitates. In addition, extensive decoration of the grain boundaries with precipitates was clearly observed in the crept specimens. Controlled aging experiments for up to 280 h at the relevant temperatures were conducted on both the parent material and the welded specimens in order to isolate the contribution of exposure to high temperatures to the microstructure changes. TEM study showed the development of dislocation networks into a cellular dislocation structure in the case of the parent metal. Changes in the dislocation structure as a function of the creep strain and the FSW process were recorded. A detailed creep data analysis was conducted, taking into account the instability of the microstructure.

  2. Ductile damage development in friction stir welded aluminum (AA2024) joints

    DEFF Research Database (Denmark)

    Nielsen, Kim Lau

    2008-01-01

    Ductile damage development in a friction stir welded aluminum joint subjected to tension is analyzed numerically by FE-analysis, based on a total Lagrangian formulation. An elastic-viscoplastic constitutive relation that accounts for nucleation and growth of microvoids is applied. Main focus...

  3. Heat input effect of friction stir welding on aluminum alloy AA 6061-T6 welded joint

    Czech Academy of Sciences Publication Activity Database

    Sedmak, A.; Kumar, R.; Chattopadhyaya, S.; Hloch, Sergej; Tadić, S.; Djurdjević, A. A.; Čeković, I. R.; Dončeva, E.

    2016-01-01

    Roč. 20, č. 2 (2016), s. 637-641 ISSN 0354-9836 Institutional support: RVO:68145535 Keywords : friction stir welding * defect * heat input * maximum temperature Subject RIV: JQ - Machines ; Tools Impact factor: 1.093, year: 2016 http://www.doiserbia.nb.rs/img/doi/0354-9836/2016/0354-98361500147D.pdf

  4. Structure and properties of fixed joints formed by ultrasonic-assisted friction-stir welding

    Energy Technology Data Exchange (ETDEWEB)

    Fortuna, S. V., E-mail: s-fortuna@ispms.ru; Ivanov, K. V., E-mail: ikv@ispms.ru; Eliseev, A. A., E-mail: alan@ispms.ru [Institute of Strength Physics and Materials ScienceTomsk, 634055 (Russian Federation); Tarasov, S. Yu., E-mail: tsy@ispms.ru; Ivanov, A. N., E-mail: ivan@ispms.ru; Rubtsov, V. E., E-mail: rvy@ispms.ru; Kolubaev, E. A., E-mail: eak@ispms.ru [Institute of Strength Physics and Materials ScienceTomsk, 634055 (Russian Federation); National Research Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation)

    2015-10-27

    This paper deals with structure and properties of aluminum alloy 7475 and its joints obtained by friction stir welding including under ultrasonic action. Microhardness measurements show that ultrasonic action increases strength properties of the joints. Optical and transmission electron microscopy reveals that this effect is related to the precipitation of tertiary coherent S-and T-phase particles.

  5. Effects of welding parameters on friction stir spot welding of high density polyethylene sheets

    International Nuclear Information System (INIS)

    Bilici, Mustafa Kemal; Yukler, Ahmet Irfan

    2012-01-01

    Graphical abstract: (a) Schematic illustration of the cross section of a friction stir spot weld and (b) Geometry of the weld bonded area, x: nugget thickness and y: the thickness of the upper sheet. Highlights: → Welding parameters affect the FSSW nugget formation and the strength of the joint. → Melting of polyethylene occurred in the vicinity of the tool pin. → The joint that fractures with a pull nugget failure mode has a higher strength. -- Abstract: Friction stir spot welding parameters affect the weld strength of thermoplastics, such as high density polyethylene (HDPE) sheets. The effects of the welding parameters on static strength of friction stir spot welds of high density polyethylene sheets were investigated. For maximizing the weld strength, the selection of welding parameters is very important. In lap-shear tests two fracture modes were observed; cross nugget failure and pull nugget failure. The tool rotational speed, tool plunge depth and dwell time were determined to be important in the joint formation and its strength. The joint which had a better strength fails with a pull nugget failure morphology. Weld cross section image analysis of the joints were done with a video spectral comparator. The plunge rate of the tool was determined to have a negligible effect on friction stir spot welding.

  6. An analytical model for the heat generation in friction stir welding

    DEFF Research Database (Denmark)

    Schmidt, Henrik Nikolaj Blich; Hattel, Jesper; Wert, John

    2004-01-01

    The objective of this work is to establish an analytical model for heat generation by friction stir welding (FSW), based on different assumptions of the contact condition between the rotating tool surface and the weld piece. The material flow and heat generation are characterized by the contact...

  7. Wear characteristics and defects analysis of friction stir welded joint of aluminium alloy 6061-t6

    Czech Academy of Sciences Publication Activity Database

    Kumar, R.; Chattopadhyaya, S.; Hloch, Sergej; Krolczyk, G.; Legutko, S.

    2016-01-01

    Roč. 18, č. 1 (2016), s. 128-135 ISSN 1507-2711 Institutional support: RVO:68145535 Keywords : Friction stir welding (FSW) * grinding machine * Field Emission Scanning Electron Microscope (FESEM) Subject RIV: JQ - Machines ; Tools Impact factor: 1.145, year: 2016 http://www.ein.org.pl/2016-01-17

  8. Effect of friction stirring on microstructure in equal channel angular pressed aluminum alloys

    Energy Technology Data Exchange (ETDEWEB)

    Sato, Y.S.; Urata, M.; Kokawa, H.; Ikeda, K. [Dept. of Materials Processing, Graduate School of Engineering, Tohoku Univ., Aoba-yama, Sendai (Japan)

    2003-07-01

    Friction stir welding (FSW) was applied to equal channel angular (ECA) pressed aluminum (Al) alloys with high strength and toughness, and the effect of FSW on microstructure and the hardness profile in ECA-pressed alloys was examined. In the weld of ECA-pressed Al alloy 1050 and 5083, the stir zone had roughly the same hardness as the ECA-pressed material, while the hardness was slightly reduced in the thermo-mechanically affected zone (TMAZ). The reduction of hardness in the TMAZ was due to dynamic recovery of dislocation cells of the ECA-pressed material. The addition of Zr to Al suppressed the reduction of hardness in the TMAZ. Consequently, friction stir (FS) weld of Al-Zr alloy retained the hardness of the ECA-pressed material throughout the weld. (orig.)

  9. Emission of nanoparticles during friction stir welding (FSW) of aluminium alloys.

    Science.gov (United States)

    Gomes, J F; Miranda, R M; Santos, T J; Carvalho, P A

    2014-01-01

    Friction stir welding (FSW) is now well established as a welding process capable of joining some different types of metallic materials, as it was (1) found to be a reliable and economical way of producing high quality welds, and (2) considered a "clean" welding process that does not involve fusion of metal, as is the case with other traditional welding processes. The aim of this study was to determine whether the emission of particles during FSW in the nanorange of the most commonly used aluminum (Al) alloys, AA 5083 and AA 6082, originated from the Al alloy itself due to friction of the welding tool against the item that was being welded. Another goal was to measure Al alloys in the alveolar deposited surface area during FSW. Nanoparticles dimensions were predominantly in the 40- and 70-nm range. This study demonstrated that microparticles were also emitted during FSW but due to tool wear. However, the biological relevance and toxic manifestations of these microparticles remain to be determined.

  10. Computer Tomography 3-D Imaging of the Metal Deformation Flow Path in Friction Stir Welding

    Science.gov (United States)

    Schneider, Judy; Beshears, Ronald; Nunes, Arthur C., Jr.

    2004-01-01

    In friction stir welding, a rotating threaded pin tool is inserted into a weld seam and literally stirs the edges of the seam together. This solid-state technique has been successfully used in the joining of materials that are difficult to fusion weld such as aluminum alloys. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path is required. Marker studies are the principal method of studying the metal deformation flow path around the FSW pin tool. In our study, we have used computed tomography (CT) scans to reveal the flow pattern of a lead wire embedded in a FSW weld seam. At the welding temperature of aluminum, the lead becomes molten and thus tracks the aluminum deformation flow paths in a unique 3-dimensional manner. CT scanning is a convenient and comprehensive way of collecting and displaying tracer data. It marks an advance over previous more tedious and ambiguous radiographic/metallographic data collection methods.

  11. Computed Tomography 3-D Imaging of the Metal Deformation Flow Path in Friction Stir Welding

    Science.gov (United States)

    Schneider, Judy; Beshears, Ronald; Nunes, Arthur C., Jr.

    2005-01-01

    In friction stir welding (FSW), a rotating threaded pin tool is inserted into a weld seam and literally stirs the edges of the seam together. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path is required. Marker studies are the principal method of studying the metal deformation flow path around the FSW pin tool. In our study, we have used computed tomography (CT) scans to reveal the flow pattern of a lead wire embedded in a FSW weld seam. At the welding temperature of aluminum, the lead becomes molten and is carried with the macro-flow of the weld metal. By using CT images, a 3-dimensional (3D) image of the lead flow pattern can be reconstructed. CT imaging was found to be a convenient and comprehensive way of collecting and displaying tracer data. It marks an advance over previous more tedious and ambiguous radiographic/metallographic data collection methods.

  12. Microhardness and Strain Field Characterization of Self-Reacting Friction Stir and Plug Welds of Dissimilar Aluminum Alloys

    Science.gov (United States)

    Horton, Karla Renee

    2011-01-01

    Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. This work reports on material properties and strain patterns developed in a SR-FSW with a friction plug weld. Specifically, this study examines the behavior of a SR-FSW formed between an AA 2014-T6 plate on the advancing side and an AA 2219-T87 plate on the retreating side and a SR-FSW (AA 2014-T6 to AA 2219-T87) with a 2219-T87 plug weld. This study presents the results of a characterization of the micro-hardness, joint strength, and strain field characterization of SR-FSW and FPW joints tested at room temperature and cryogenic temperatures.

  13. Welding parameter optimization of alloy material by friction stir welding using Taguchi approach and design of experiments

    Science.gov (United States)

    Karwande, Amit H.; Rao, Seeram Srinivasa

    2018-04-01

    Friction stir welding (FSW) a welding process in which metals are joint by melting them at their solid state. In different engineering areas such as civil, mechanical, naval and aeronautical engineering beams are widely used of the magnesium alloys for different applications and that are joined by conventional inert gas welding process. Magnesium metal has less density and low melting point for that reason large heat generation in the common welding process so its necessity to adapt new welding process. FSW process increases the weld quality which observed under various mechanical testing by using different tool size.

  14. Effect of water-cooling treatment times on properties of friction stir welded joints of 7N01-T4 aluminum alloy

    Science.gov (United States)

    Zhang, T. H.; Wang, Y.; Fang, X. F.; Liang, P.; Zhao, Y.; Li, Y. H.; Liu, X. M.

    2018-02-01

    Due to the deformation caused by residual stress in the welding process, welded components need treatment to reduce welding distortion. In this paper, several different times of flame-heating and water-cooling treatment were subjected to the friction stir welding joints of 15mm thick 7N01P-T4 aluminum alloy sheets to study the microstructure variation of friction stir welding joints of 7N01P-T4 aluminum alloy, and to analyze the effect on micro-hardness, tensile and fracture mechanical properties. This investigation will be helpful to optimize treatment methods and provide instruction on industrial production.

  15. An integrated multiphysics model for friction stir welding of 6061 Aluminum alloy

    Directory of Open Access Journals (Sweden)

    M Nourani

    2016-09-01

    Full Text Available This article presents a new, combined ‘integrated’- ‘multiphysics’ model of friction stir welding (FSW where a set of governing equations from non-Newtonian incompressible fluid dynamics, conductive and convective heat transfer, and plain stress solid mechanics have been coupled for calculating the process variables and material behaviour both during and after welding. More specifically, regarding the multiphysics feature, the model is capable of simultaneously predicting the local distribution, location and magnitude of maximum temperature, strain, and strain rate fields around the tool pin during the process; while for the integrated (post-analysis part, the above predictions have been used to study the microstructure and residual stress field of welded parts within the same developed code. A slip/stick condition between the tool and workpiece, friction and deformation heat source, convection and conduction heat transfer in the workpiece, a solid mechanics-based viscosity definition, and the Zener-Hollomon- based rigid-viscoplastic material properties with solidus cut-off temperature and empirical softening regime have been employed. In order to validate all the predicted variables collectively, the model has been compared to a series of published case studies on individual/limited set of variables, as well as in-house experiments on FSW of aluminum 6061.

  16. Influence of groove size and reinforcements addition on mechanical properties and microstructure of friction stir welded joints

    Science.gov (United States)

    Reddy Baridula, Ravinder; Ibrahim, Abdullah Bin; Yahya, Che Ku Mohammad Faizal Bin Che Ku; Kulkarni, Ratnakar; Varma Ramaraju, Ramgopal

    2018-03-01

    The butt joints fabricated by friction stir welding were found to have more strength than the joints obtained by conventional joining process. The important outcome of this process is the successful fabrication of surface composites with improved properties. Thus in order to further enhance the strength of the dissimilar alloy joints the reinforcements can be deposited in to the aluminium matrix during the process of friction stir welding. In the present study the multi-walled carbon nanotubes were embedded in to the groove by varying the width during joining of dissimilar alloys AA2024 and AA7075. Four widths were selected with constant depth and optimum process parameters were selected to fabricate the sound welded joints. The results show that the mechanical properties of the fabricated butt joints were influenced by the size of the groove, due to variation in the deposition of reinforcement in the stir zone. The microstructural study and identification of the elements of the welded joints show that the reinforcements deposition is influenced by the size of the groove. It has also been observed that the groove with minimum width is more effective than higher width. The mechanical properties are found to be improved due to the pinning of grain boundaries.

  17. Analysing the Friction Stir Welded Joints of AA2219 Al-Cu Alloy in Different Heat-Treated-State

    Science.gov (United States)

    Venkateswarlu, D.; Cheepu, Muralimohan; Kranthi kumar, B.; Mahapatra, M. M.

    2018-03-01

    Aluminium alloy AA2219 is widely used in light weight structural applications where the good corrosion resistance and specific weight required. The fabrication of this alloy using friction stir welding process is gaining interest towards finding the characteristics of the weld metal properties, since this process involved in the welded materials does not melt and recast. In the present investigation, friction stir welding process was used for different heat treated conditions of 2219-T87 and 2219-T62 aluminium alloys to find the influence of base metal on characteristics of the joints. The experimental output results exhibited that, mechanical properties, weld metal characteristics and joint failure locations are significantly affected by the different heat treatment conditions of the substrate. The joints tensile and yield strength of the 2219-T87 welds was higher than the 2219-T62 welds. Hardness distribution in the stir zone was significantly varied between two different heat treaded material conditions. The microstructural features of the 2219-T62 welds reveal the coarse grains formation in the thermo-mechanically affected zone and heat affected zone. The joint efficiency of the 2219- T82 welds is 59.87%, while that of 2219-T62 welds is 39.10%. In addition, the elongation of the joint also varied and the joints failure location characteristics are different for two different types heat treated condition joints.

  18. The Effect of Friction Stir Welding on Corrosion Behavior of Ti-6Al-4V

    Science.gov (United States)

    Nasresfahani, Ali Reza; Soltanipur, Abdol Reza; Farmanesh, Khosro; Ghasemi, Ali

    2017-09-01

    Fusion welding can deteriorate corrosion behavior of Ti-6Al-4V alloy. However, the use of friction stir welding leads to a more appropriate corrosion resistance. In this study, the corrosion resistance of welded zones of Ti-6Al-4V alloy using friction stir welding technique is evaluated. For these purposes, the study of structural characteristics using SEM and FESEM equipped with EDS micro-analyses was conducted. Micro-hardness test was also employed to estimate the hardness of welded zones. Corrosion behavior was investigated by a potentiostat instrument. SEM micrographs, EDS and XRD analyses confirmed non-uniformity of chemical composition within the welded zones. The results reveal that the stir zone contains typical alpha and prior beta phases. Nevertheless, thermomechanical zone included equiaxed and bimodal lamellae structure. Furthermore, the presence of different types of phases and microstructure in the thermomechanical zone led to reduced corrosion resistance. The corresponding values of corrosion current density in the stir zone, thermomechanical zone and base metal were 0.048, 0.55 and 0.032 µA, respectively. Corresponding corrosion potential for these zones was estimated as -207, -110 and -157 mV. Evidently, the results show that corrosion resistance of thermomechanical zone is less than that of the stir zone and both zones have lower value than the base metal.

  19. A Study on Tooling and Its Effect on Heat Generation and Mechanical Properties of Welded Joints in Friction Stir Welding

    Science.gov (United States)

    Tikader, Sujoy; Biswas, Pankaj; Puri, Asit Baran

    2018-04-01

    Friction stir welding (FSW) has been the most attracting solid state welding process as it serves numerous advantages like good mechanical, metallurgical properties etc. Non weldable aluminium alloys like 5XXX, 7XXX series can be simply joined by this process. In this present study a mathematical model has been developed and experiments were successfully performed to evaluate mechanical properties of FSW on similar aluminium alloys i.e. AA1100 for different process parameters and mainly two kind of tool geometry (straight cylindrical and conical or cylindrical tapered shaped pin with flat shoulder). Tensile strength and micro hardness for different process parameters are reported of the welded plate sample. It was noticed that in FSW of similar alloy with tool made of SS-310 tool steel, friction is the major contributor for the heat generation. It was seen that tool geometry, tool rotational speed, plunging force by the tool and traverse speed have significant effect on tensile strength and hardness of friction stir welded joints.

  20. Influence of tool pin in friction stir welding on activated carbon reinforced aluminium metal matrix composite

    Science.gov (United States)

    DijuSamuel, G.; Raja Dhas, J. Edwin

    2017-10-01

    This paper focus on impact of tool pin in friction stir welding on activated carbon reinforced aluminium metal matrix composite. For fabrication of metal matrix composite AA6061 is used as matrix and activated carbon is used as reinforcement and it is casted using modified stir casting technique. After casting metal matrix composite has undergone various microstructure tests like SEM,EDAX and XRD. FSW is carried out in this metal matrix composite by choosing various tool pin profile like square,round,Threaded round, hexagon and taper. The quality of welded plates is measured in terms of ultimate tensile strength and hardness.

  1. Optimization and Characterization of the Friction Stir Welded Sheets of AA 5754-H111: Monitoring of the Quality of Joints with Thermographic Techniques.

    Science.gov (United States)

    De Filippis, Luigi Alberto Ciro; Serio, Livia Maria; Palumbo, Davide; De Finis, Rosa; Galietti, Umberto

    2017-10-11

    Friction Stir Welding (FSW) is a solid-state welding process, based on frictional and stirring phenomena, that offers many advantages with respect to the traditional welding methods. However, several parameters can affect the quality of the produced joints. In this work, an experimental approach has been used for studying and optimizing the FSW process, applied on 5754-H111 aluminum plates. In particular, the thermal behavior of the material during the process has been investigated and two thermal indexes, the maximum temperature and the heating rate of the material, correlated to the frictional power input, were investigated for different process parameters (the travel and rotation tool speeds) configurations. Moreover, other techniques (micrographs, macrographs and destructive tensile tests) were carried out for supporting in a quantitative way the analysis of the quality of welded joints. The potential of thermographic technique has been demonstrated both for monitoring the FSW process and for predicting the quality of joints in terms of tensile strength.

  2. A Microstructural Evaluation of Friction Stir Welded 7075 Aluminum Rolled Plate Heat Treated to the Semi-Solid State

    Directory of Open Access Journals (Sweden)

    Ava Azadi Chegeni

    2018-01-01

    Full Text Available Two rolled plates of 7075 aluminum alloy were used as starting material. The plates were welded using a simultaneous double-sided friction stir welding (FSW process. One way of obtaining feedstock materials for Semi-solid processing or thixoforming is via deformation routes followed by partial melting in the semi-solid state. As both the base plate materials and the friction weld area have undergone extensive deformation specimens were subjected to a post welding heat-treatment in the semi-solid range at a temperature of 628 °C, for 3 min in order to observe the induced microstructural changes. A comparison between the microstructural evolution and mechanical properties of friction stir welded plates was performed before and after the heat-treatment in the Base Metal (BM, the Heat Affected Zone (HAZ, the Thermomechanically Affected Zone (TMAZ and the Nugget Zone (NZ using optical microscopy, Scanning Electron microscopy (SEM and Vickers hardness tests. The results revealed that an extremely fine-grained structure, obtained in the NZ after FSW, resulted in a rise of hardness from the BM to the NZ. Furthermore, post welding heat-treatment in the semi-solid state gave rise to a consistent morphology throughout the material which was similar to microstructures obtained by the thixoforming process. Moreover, a drop of hardness was observed after heat treatment in all regions as compared to that in the welded microstructure.

  3. Characterization of friction stir welded joint of low nickel austenitic stainless steel and modified ferritic stainless steel

    Science.gov (United States)

    Mondal, Mounarik; Das, Hrishikesh; Ahn, Eun Yeong; Hong, Sung Tae; Kim, Moon-Jo; Han, Heung Nam; Pal, Tapan Kumar

    2017-09-01

    Friction stir welding (FSW) of dissimilar stainless steels, low nickel austenitic stainless steel and 409M ferritic stainless steel, is experimentally investigated. Process responses during FSW and the microstructures of the resultant dissimilar joints are evaluated. Material flow in the stir zone is investigated in detail by elemental mapping. Elemental mapping of the dissimilar joints clearly indicates that the material flow pattern during FSW depends on the process parameter combination. Dynamic recrystallization and recovery are also observed in the dissimilar joints. Among the two different stainless steels selected in the present study, the ferritic stainless steels shows more severe dynamic recrystallization, resulting in a very fine microstructure, probably due to the higher stacking fault energy.

  4. Friction Stir Welding of three dissimilar aluminium alloy used in aeronautics industry

    Science.gov (United States)

    Boşneag, A.; Constantin, M. A.; Niţu, E.; Iordache, M.

    2017-10-01

    Friction Stir Welding (FSW) is an innovative solid-state joining process. This process was, in first time, develop to join the similar aluminum plates but now the technology can be used to weld a large area of materials similar or dissimilar. Taking these into account FSW process, for dissimilar materials are increasingly required, more than traditional arc welding, in industrial environment. More than that FSW is used in aeronautics industry because of very good result and very good weldability between aluminum alloy used at building of airplanes, where the body of airplane are 20% aluminum alloy and this percent can be increaser in future. In this paper is presented an experimental study which includes welding three dissimilar aluminum alloy, with different properties, used in aeronautics industry, this materials are: AA 2024, AA6061 and AA7075. After welding with different parameters, the welding join and welding process will be analyzed considering process temperature, process vertical force, and roughnessof welding seams, visual aspect and microhardness.

  5. Magnesium Based Composite via Friction Stir Processing

    Science.gov (United States)

    2013-04-01

    study. FSP was carried out with a stepped spiral conical tool with a featureless shoulder and a pin length of 6.5 mm, which was made of H13 tool ...of a high strength rotating tool to locally heat the work piece and produce intense plastic deformation. The interplay between temperature and strain... steel . A set of holes with a depth of about 6 mm were drilled into the plate in the pattern shown in Fig.1 (a) and the B4C powder was then filled into

  6. Peak Stir Zone Temperature During Friction Stir Processing

    Science.gov (United States)

    2010-03-01

    jii reprecipitation. The nonequilibrium trans- formation products of b may include fine Widmanstät- ten a as well as bainite and martensite, depending... bainite , reflecting cooling at 2 to 3 9 101 C/s (Table II), i.e., rates ~104 times that of the as-cast condition. In region 2, the microstructure...Shepard, and O.D. Sherby: J. Iron Steel Inst., 1964, vol. 202, pp. 804–07. 26. O.D. Sherby, B. Walser, C.M. Young, and E.M. Cady: Scripta Metall

  7. Effect of microstructure on properties of friction stir welded Inconel Alloy 600

    International Nuclear Information System (INIS)

    Sato, Y.S.; Arkom, P.; Kokawa, H.; Nelson, T.W.; Steel, R.J.

    2008-01-01

    Friction stir welding (FSW) has been widely used to metals with moderate melting temperatures, primarily Al alloys. Recently, tool materials that withstand high stresses and temperatures necessary for FSW of materials with high melting temperatures have been developed. In the present study, polycrystalline cubic boron nitride (PCBN) tool was used for partially penetrated FSW of Inconel Alloy 600, and a defect-free weld was successfully produced. Microstructural characteristics, mechanical and corrosion properties in the weld were examined. The weld had better mechanical properties than the base material due to formation of fine grain structure in the stir zone, but exhibited slightly the lower corrosion resistance in a part of the stir zone and heat-affected zone (HAZ)

  8. Microstructure and mechanical properties of similar and dissimilar joints of aluminium alloy and pure copper by friction stir welding

    Directory of Open Access Journals (Sweden)

    V.C. Sinha

    2016-09-01

    Full Text Available In the present study, the microstructure and mechanical properties of similar and dissimilar friction stir welded joints of aluminium alloy (AlA and pure copper (Cu were evaluated at variable tool rotational speeds from 150 to 900 rpm in steps of 150 rpm at 60 mm/min travel speed and constant tilt angle 2°. The interfacial microstructures of the joints were characterised by optical and scanning electron microscopy. The Al4Cu9, AlCu, Al2Cu and Al2Cu3 intermetallic compounds have been observed at the interface and stir zone region of dissimilar Al/Cu FSWed joints. Variation in the grain size was observed in the stir zone depending upon the heat input value. Axial force, traverse force and torque value were analysed with variation in tool rotational speed. Residual stresses were measured at the stir zone by X-ray diffraction technique. Maximum ultimate tensile strength of ∼75% of AlA strength for AlA–AlA joints has been obtained at 750 rpm and for Cu–Cu joint tensile strength of ∼100% of tensile strength of Cu was obtained at 300 rpm. However, for Cu–AlA joint when processed at 600 rpm tool rotational speed achieved maximum ultimate tensile strength of ∼77% of AlA.

  9. Evolution of microstructure and mechanical properties in naturally aged 7050 and 7075 Al friction stir welds

    Energy Technology Data Exchange (ETDEWEB)

    Fuller, Christian B., E-mail: christian.fuller@yahoo.com [Rockwell Scientific, 1049 Camino Dos Rios, Thousand Oaks, CA 93021 (United States); Mahoney, Murray W., E-mail: murraymahoney@comcast.net [Rockwell Scientific, 1049 Camino Dos Rios, Thousand Oaks, CA 93021 (United States); Calabrese, Mike [Rockwell Scientific, 1049 Camino Dos Rios, Thousand Oaks, CA 93021 (United States); Micona, Leanna [The Boeing Company, P.O. Box 3707 MC 19-HP, Seattle, WA 98124 (United States)

    2010-04-15

    The microstructural and mechanical property evolution of friction stir welded 7050-T7651 and 7075-T651 Al alloys were examined as a function of room temperature (natural) aging for up to 67,920 h. During the range of aging times studied, transverse tensile strengths continuously increased, and are still increasing, with improvements of 24% and 29% measured for the 7050-T7651 and 7075-T651 Al alloy friction stir welds, respectively. Microstructural evolution within the weld nugget and heat-affected zone was evaluated with both transmission electron microscopy (TEM) and differential scanning calorimetry (DSC). Formation of a high volume fraction of GP(II) zones produced a majority of the strength improvement within the weld nugget and HAZ regions. The rational for the microstructural changes are discussed in light of the mechanical properties.

  10. Material Characterization of Dissimilar Friction Stir Spot Welded Aluminium and Copper Alloy

    Science.gov (United States)

    Sanusi, K. O.; Akinlabi, E. T.

    2017-08-01

    In this research study, material characterization of dissimilar friction stir spot welded Aluminium and Copper was evaluated. Rotational speeds of 800 rpm and transverse speeds of 50 mm/min, 150 mm/min and 250 mm/min were used. The total numbers of samples evaluated were nine altogether. The spot welds were characterised by microstructure characterization using optical microscope (OEM) and scanning electron microscopy technique (SEM) by observing the evolution of the microstructure across the weld’s cross-section. lap-shear test of the of the spot weld specimens were also done. From the results, it shows that welding of metals and alloys using Friction stir spot welding is appropriate and can be use in industrial applications.

  11. A study on heat-flow analysis of friction stir welding on a rotation affected zone

    International Nuclear Information System (INIS)

    Kang, Sung Wook; Jang, Beom Seon; Kim, Jae Woong

    2014-01-01

    In recent years, as interest in environmental protection and energy conservation rose, technological development for lightweight efficiency of transport equipment, such as aircrafts, railcars, automobiles and vessels, have been briskly proceeding. This has led to an expansion of the application of lightweight alloys such as aluminum and magnesium. For the welding of these lightweight alloys, friction stir welding has been in development by many researchers. Heat-flow analysis of friction stir welding is one such research. The flow and energy equation is solved using the computational fluid dynamic commercial program 'Fluent'. In this study, a rotation affected zone concept is imposed. The rotation affected zone is a constant volume. In this volume, flow is rotated the same as the tool rotation speed and so plastic dissipation occurs. Through this simulation, the temperature distribution results are calculated and the simulation results are compared with the experimental results.

  12. Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in ODS Steel MA956

    Science.gov (United States)

    2013-06-01

    dispersion strengthened - Eurofer steel ,” J. Nucl. Mater., vol. 416 , pp. 2229, Sep 1, 2011. [10] H. J. K. Lemmen and K. J. Sudmeijer, I, “Laser beam...Reynolds and W. Tang, “Structure, properties, and residual stress of 304L stainless steel friction stir welds,” Scr. Mater., vol. 48, pp. 12891294...OF RESIDUAL STRESS AS A FUNCTION OF FRICTION STIR WELDING PARAMETERS IN ODS STEEL MA956 by Martin S. Bennett June 2013 Thesis Advisor

  13. In-situ neutron diffraction measurements of temperature and stresses during friction stir welding of 6061-T6 aluminum alloy

    International Nuclear Information System (INIS)

    Woo, Wan Chuck; Feng, Zhili; Wang, Xun-Li; Brown, D.W.; Clausen, B.; An, Ke; Choo, Hahn; Hubbard, Camden R.; David, Stan A.

    2007-01-01

    The evolution of temperature and thermal stresses during friction stir welding of Al6061-T6 was investigated by means of in-situ, time-resolved neutron diffraction technique. A method is developed to deconvolute the temperature and stress from the lattice spacing changes measured by neutron diffraction. The deep penetration capability of neutrons made it possible for the first time to obtain the temperature and thermal stresses inside a friction stir weld

  14. Residual strains and microstructure development in single and sequential double sided friction stir welds in RQT-701 steel

    Energy Technology Data Exchange (ETDEWEB)

    Barnes, S.J. [School of Materials, University of Manchester, Grosvenor Street, Manchester M1 7HS (United Kingdom)], E-mail: simon.barnes-2@manchester.ac.uk; Steuwer, A. [FaME38, ILL ESRF, 6 rue J.Horowitz, 38042 Grenoble, Cedex (France); University of Plymouth, Drake Circus, Plymouth PL4 8AA (United Kingdom); Mahawish, S. [School of Materials, University of Manchester, Grosvenor Street, Manchester M1 7HS (United Kingdom); Johnson, R. [TWI Yorkshire, Wallis Way, Catcliffe, Rotherham S60 5TZ (United Kingdom); Withers, P.J. [School of Materials, University of Manchester, Grosvenor Street, Manchester M1 7HS (United Kingdom)

    2008-09-25

    Single and double sided partial penetration friction stir butt welds, in a rolled, quenched and tempered steel (RQT-701), were produced at The Welding Institute (TWI) under controlled process conditions. The residual strain distributions in the longitudinal and transverse directions have been measured using energy dispersive synchrotron X-ray diffraction. The measured strains were indicative of longitudinal tensile residual stresses at levels greater than the 0.2% yield stress of the parent metal in both the single and double pass welds. In both cases, the maximum tensile strain was found in the parent metal at the boundary of the heat affected zone (HAZ). Microstructural analysis of the welds was carried out using optical microscopy and hardness variations were also mapped across the weld-plate cross-section. The maximum hardness was observed in the mixed bainite/martensite structure of the weld nugget on the advancing side of the stir zone. The minimum hardness was observed in the HAZ.

  15. Residual strains and microstructure development in single and sequential double sided friction stir welds in RQT-701 steel

    International Nuclear Information System (INIS)

    Barnes, S.J.; Steuwer, A.; Mahawish, S.; Johnson, R.; Withers, P.J.

    2008-01-01

    Single and double sided partial penetration friction stir butt welds, in a rolled, quenched and tempered steel (RQT-701), were produced at The Welding Institute (TWI) under controlled process conditions. The residual strain distributions in the longitudinal and transverse directions have been measured using energy dispersive synchrotron X-ray diffraction. The measured strains were indicative of longitudinal tensile residual stresses at levels greater than the 0.2% yield stress of the parent metal in both the single and double pass welds. In both cases, the maximum tensile strain was found in the parent metal at the boundary of the heat affected zone (HAZ). Microstructural analysis of the welds was carried out using optical microscopy and hardness variations were also mapped across the weld-plate cross-section. The maximum hardness was observed in the mixed bainite/martensite structure of the weld nugget on the advancing side of the stir zone. The minimum hardness was observed in the HAZ

  16. Texture analysis of a friction stir welded ultrafine grained Al–Al{sub 2}O{sub 3} composite produced by accumulative roll-bonding

    Energy Technology Data Exchange (ETDEWEB)

    Shamanian, Morteza, E-mail: shamanian@cc.iut.ac.ir [Department of Materials Engineering, Isfahan University of Technology, Isfahan 84156-83111 (Iran, Islamic Republic of); Mohammadnezhad, Mahyar [Department of Materials Engineering, Isfahan University of Technology, Isfahan 84156-83111 (Iran, Islamic Republic of); Szpunar, Jerzy [Department of Mechanical Engineering, University of Saskatchewan, Saskatoon, SK S7N5A9 (Canada)

    2014-12-05

    Highlights: • Aluminum matrix composite was successfully bonded using friction stir welding. • After welding process the fraction of low angle boundary area rapidly decreases. • The grain growth in the NZ is related the increase of temperature during the FSW. • The aluminum matrix composite has a strong Rotated Cube texture. • The weld nugget has a Rotated Cube and shear texture. - Abstract: In recent years, several studies have been focused on friction stir welding of aluminum alloys, and some researchers have also been reported on welding of aluminum-based composites. In the present research, ultrafine grained sheets of aluminum matrix composite (Al–Al{sub 2}O{sub 3}) were produced by accumulative roll-bonding (ARB) technique. The aluminum composite sheets were then joined by friction stir welding. The present work describes the effect of the FSW process on the microstructure and crystallographic textures in the base metal and weld nugget. Electron backscattered diffraction (EBSD) results demonstrated the existence of different grain orientations within the weld nugget as compared to the base metal. Al composite plates have a Rotated Cube texture component. Moreover, in the nugget, grain structure with Rotated Cube and shear texture developed. Friction stir welding coarsened the grain size in the weld zone from the original grain size of 3–17 μm.

  17. Texture analysis of a friction stir welded ultrafine grained Al–Al2O3 composite produced by accumulative roll-bonding

    International Nuclear Information System (INIS)

    Shamanian, Morteza; Mohammadnezhad, Mahyar; Szpunar, Jerzy

    2014-01-01

    Highlights: • Aluminum matrix composite was successfully bonded using friction stir welding. • After welding process the fraction of low angle boundary area rapidly decreases. • The grain growth in the NZ is related the increase of temperature during the FSW. • The aluminum matrix composite has a strong Rotated Cube texture. • The weld nugget has a Rotated Cube and shear texture. - Abstract: In recent years, several studies have been focused on friction stir welding of aluminum alloys, and some researchers have also been reported on welding of aluminum-based composites. In the present research, ultrafine grained sheets of aluminum matrix composite (Al–Al 2 O 3 ) were produced by accumulative roll-bonding (ARB) technique. The aluminum composite sheets were then joined by friction stir welding. The present work describes the effect of the FSW process on the microstructure and crystallographic textures in the base metal and weld nugget. Electron backscattered diffraction (EBSD) results demonstrated the existence of different grain orientations within the weld nugget as compared to the base metal. Al composite plates have a Rotated Cube texture component. Moreover, in the nugget, grain structure with Rotated Cube and shear texture developed. Friction stir welding coarsened the grain size in the weld zone from the original grain size of 3–17 μm

  18. Microstructure feature of friction stir butt-welded ferritic ductile iron

    International Nuclear Information System (INIS)

    Chang, Hung-Tu; Wang, Chaur-Jeng; Cheng, Chin-Pao

    2014-01-01

    Highlights: • Defect-free ferritic ductile iron joints is fabricated by FSW. • The welding nugget is composed of graphite, martensite, and recrystallized ferrite. • The graphite displays a striped pattern in the surface and advancing side. • The ferritic matrix transforms into martensite structure during welding. • High degree of plastic deformation is found on the advancing side. - Abstract: This study conducted friction stir welding (FSW) by using the butt welding process to join ferritic ductile iron plates and investigated the variations of microsturcture in the joined region formed after welding. No defects appeared in the resulting experimental weld, which was formed using a 3-mm thick ductile iron plate and tungsten carbide alloy stir rod to conduct FSW at a rotational speed of 982 rpm and traveling speed of 72 mm/min. The welding region was composed of deformed graphite, martensite phase, and dynamically recrystallized ferrite structures. In the surface region and on the advancing side (AS), the graphite displayed a striped configuration and the ferritic matrix transformed into martensite. On the retreating side (RS), the graphite surrounded by martensite remained as individual granules and the matrix primarily comprised dynamically recrystallized ferrite. After welding, diffusion increased the carbon content of the austenite around the deformed graphite nodules, which transformed into martensite during the subsequent cooling process. A micro Vickers hardness test showed that the maximum hardness value of the martensite structures in the weld was approximately 800 HV. An analysis using an electron probe X-ray microanalyzer (EPMA) indicated that its carbon content was approximately 0.7–1.4%. The peak temperature on the RS, 8 mm from the center of the weld, measured 630 °C by the thermocouple. Overall, increased severity of plastic deformation and process temperature near the upper stir zone (SZ) resulted in distinct phase transformation

  19. The Evolution of Friction Stir Welding Theory at Marshall Space Flight Center

    Science.gov (United States)

    Nunes, Arthur C.

    2012-01-01

    From 1995 to the present the friction stir welding (FSW) process has been under study at Marshall Space Flight Center (MSFC). This is an account of the progressive emergence of a set of conceptual tools beginning with the discovery of the shear surface, wiping metal transfer, and the invention of a kinematic model and making possible a treatment of both metallurgical structure formation and process dynamics in friction stir welding from a unified point of view. It is generally observed that the bulk of the deformation of weld metal around the FSW pin takes place in a very narrow, almost discontinuous zone with high deformation rates characteristic of metal cutting. By 1999 it was realized that this zone could be treated as a shear surface like that in simple metal cutting models. At the shear surface the seam is drawn out and compressed and pressure and flow conditions determine whether or not a sound weld is produced. The discovery of the shear surface was followed by the synthesis of a simple 3- flow kinematic model of the FSW process. Relative to the tool the flow components are: (1) an approaching translational flow at weld speed V, (2) a rotating cylindrical plug flow with the angular velocity of the tool , and (3) a relatively slow ring vortex flow (like a smoke ring) encircling the tool and driven by shoulder scrolls and pin threads. The rotating plug flow picks up an element of weld metal, rotates it around with the tool, and deposits it behind the tool ( wiping metal transfer ); it forms plan section loops in tracers cut through by the tool. Radially inward flow from the ring vortex component retains metal longer in the rotating plug and outward flow expels metal earlier; this interaction forms the looping weld seam trace and the tongue and groove bimetallic weld contour. The radial components of the translational and ring vortex flows introduce parent metal intrusions into the small grained nugget material close to the tool shoulder; if this feature is

  20. The microstructure of aluminum A5083 butt joint by friction stir welding

    International Nuclear Information System (INIS)

    Jasri, M. A. H. M.; Afendi, M.; Ismail, A.; Ishak, M.

    2015-01-01

    This study presents the microstructure of the aluminum A5083 butt joint surface after it has been joined by friction stir welding (FSW) process. The FSW process is a unique welding method because it will not change the chemical properties of the welded metals. In this study, MILKO 37 milling machine was modified to run FSW process on 4 mm plate of aluminum A5083 butt joint. For the experiment, variables of travel speed and tool rotational speed based on capability of machine were used to run FSW process. The concentrated heat from the tool to the aluminum plate changes the plate form from solid to plastic state. Two aluminum plates is merged to become one plate during plastic state and return to solid when concentrated heat is gradually further away. After that, the surface and cross section of the welded aluminum were investigated with a microscope by 400 x multiplication zoom. The welding defect in the FSW aluminum was identified. Then, the result was compared to the American Welding Society (AWS) FSW standard to decide whether the plate can be accepted or rejected

  1. Joining of AZ31 and AZ91 Mg alloys by friction stir welding

    Directory of Open Access Journals (Sweden)

    B. Ratna Sunil

    2015-12-01

    Full Text Available Two dissimilar magnesium (Mg alloy sheets, one with low aluminium (AZ31 and another with high aluminium (AZ91 content, were successfully joined by friction stir welding (FSW. The effect of process parameters on the formation of hot cracks was investigated. A sound metallurgical joint was obtained at optimized process parameters (1400 rpm with 25 mm/min feed which contained fine grains and distributed β (Mg17Al12 phase within the nugget zone. An increasing trend in the hardness measurements has also confirmed more amount of dissolution of aluminium within the nugget zone. A sharp interface between nugget zone and thermo mechanical affected zone (TMAZ was clearly noticed at the AZ31 Mg alloy side (advancing but not on the AZ91 Mg alloy side (retreating. From the results it can be concluded that FSW can be effectively used to join dissimilar metals, particularly difficult to process metals such as Mg alloys, and hot cracking can be completely eliminated by choosing appropriate process parameters to achieve sound joint.

  2. The microstructure of aluminum A5083 butt joint by friction stir welding

    Energy Technology Data Exchange (ETDEWEB)

    Jasri, M. A. H. M.; Afendi, M. [School of Mechatronic Engineering, Universiti Malaysia Perlis, Pauh, 02600, Arau, Perlis (Malaysia); Ismail, A. [UniKL MIMET, JalanPantaiRemis, 32200, Lumut, Perak (Malaysia); Ishak, M. [Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 02600, Pekan, Pahang (Malaysia)

    2015-05-15

    This study presents the microstructure of the aluminum A5083 butt joint surface after it has been joined by friction stir welding (FSW) process. The FSW process is a unique welding method because it will not change the chemical properties of the welded metals. In this study, MILKO 37 milling machine was modified to run FSW process on 4 mm plate of aluminum A5083 butt joint. For the experiment, variables of travel speed and tool rotational speed based on capability of machine were used to run FSW process. The concentrated heat from the tool to the aluminum plate changes the plate form from solid to plastic state. Two aluminum plates is merged to become one plate during plastic state and return to solid when concentrated heat is gradually further away. After that, the surface and cross section of the welded aluminum were investigated with a microscope by 400 x multiplication zoom. The welding defect in the FSW aluminum was identified. Then, the result was compared to the American Welding Society (AWS) FSW standard to decide whether the plate can be accepted or rejected.

  3. Heat input effect of friction stir welding on aluminium alloy AA 6061-T6 welded joint

    Directory of Open Access Journals (Sweden)

    Sedmak Aleksandar

    2016-01-01

    Full Text Available This paper deals with the heat input and maximum temperature developed during friction stir welding with different parameters. Aluminium alloy (AA 6061-T6 has been used for experimental and numerical analysis. Experimental analysis is based on temperature measurements by using infrared camera, whereas numerical analysis was based on empirical expressions and finite element method. Different types of defects have been observed in respect to different levels of heat input.

  4. Influence of vibrational treatment on thermomechanical response of material under conditions identical to friction stir welding

    Energy Technology Data Exchange (ETDEWEB)

    Konovalenko, Ivan S., E-mail: ivkon@ispms.tsc.ru [Institute of Strength Physics and Materials Science SB RAS, Tomsk, 634055 (Russian Federation); Konovalenko, Igor S., E-mail: igkon@ispms.tsc.ru; Kolubaev, Evgeniy A., E-mail: eak@ispms.tsc.ru [Institute of Strength Physics and Materials Science SB RAS, Tomsk, 634055 (Russian Federation); National Research Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation); Dmitriev, Andrey I., E-mail: dmitr@ispms.tsc.ru [Institute of Strength Physics and Materials Science SB RAS, Tomsk, 634055 (Russian Federation); National Research Tomsk Polytechnic University, Tomsk, 634050 (Russian Federation); National Research Tomsk State University, Tomsk, 634050 (Russian Federation); Psakhie, Sergey G., E-mail: sp@ms.tsc.ru [Institute of Strength Physics and Materials Science SB RAS, Tomsk, 634055 (Russian Federation); National Research Tomsk State University, Tomsk, 634050 (Russian Federation)

    2015-10-27

    A molecular dynamics model was constructed to describe material loading on the atomic scale by the mode identical to friction stir welding. It was shown that additional vibration applied to the tool during the loading mode provides specified intensity values and continuous thermomechanical action during welding. An increase in additional vibration intensity causes an increase both in the force acting on the workpiece from the rotating tool and in temperature within the welded area.

  5. Effect of shoulder to pin ratio on magnesium alloy Friction Stir Welding

    Science.gov (United States)

    Othman, N. H.; Ishak, M.; Shah, L. H.

    2017-09-01

    This study focuses on the effect of shoulder to pin diameter ratio on friction stir welding of magnesium alloy AZ31. Two pieces of AZ31 alloy with thickness of 2 mm were friction stir welded by using conventional milling machine. The shoulder to pin diameter ratio used in this experiment are 2.25, 2.5, 2.75, 3, 3.33, 3.66, 4.5, 5 and 5.5. The rotational speed and welding speed used in this study are 1000 rpm and 100 mm/min, respectively. Microstructure observation of welded area was studied by using optical microscope. Equiaxed grains were observed at the TMAZ and stir zone indicating fully plastic deformation. The grain size of stir zone increased with decreasing shoulder to pin ratio from ratio 3.33 to 5.5 due to higher heat input. It is observed that, surface galling and faying surface defect is produced when excessive heat input is applied. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Shoulder to pin ratio 5.5 shows lowest tensile strength while shoulder to pin diameter ratio 3.33 shows highest tensile strength with weld efficiency 91 % from based metal.

  6. Friction Stir Welding of Tapered Thickness Welds Using an Adjustable Pin Tool

    Science.gov (United States)

    Adams, Glynn; Venable, Richard; Lawless, Kirby

    2003-01-01

    Friction stir welding (FSW) can be used for joining weld lands that vary in thickness along the length of the weld. An adjustable pin tool mechanism can be used to accomplish this in a single-pass, full-penetration weld by providing for precise changes in the pin length relative to the shoulder face during the weld process. The difficulty with this approach is in accurately adjusting the pin length to provide a consistent penetration ligament throughout the weld. The weld technique, control system, and instrumentation must account for mechanical and thermal compliances of the tooling system to conduct tapered welds successfully. In this study, a combination of static and in-situ measurements, as well as active control, is used to locate the pin accurately and maintain the desired penetration ligament. Frictional forces at the pin/shoulder interface were a source of error that affected accurate pin position. A traditional FSW pin tool design that requires a lead angle was used to join butt weld configurations that included both constant thickness and tapered sections. The pitch axis of the tooling was fixed throughout the weld; therefore, the effective lead angle in the tapered sections was restricted to within the tolerances allowed by the pin tool design. The sensitivity of the FSW process to factors such as thickness offset, joint gap, centerline offset, and taper transition offset were also studied. The joint gap and the thickness offset demonstrated the most adverse affects on the weld quality. Two separate tooling configurations were used to conduct tapered thickness welds successfully. The weld configurations included sections in which the thickness decreased along the weld, as well as sections in which the thickness increased along the weld. The data presented here include weld metallography, strength data, and process load data.

  7. Improvement of Weldment Properties by Hot Forming Quenching of Friction Stir Welded TWB Sheet

    Directory of Open Access Journals (Sweden)

    Dae-Hoon Ko

    2014-04-01

    Full Text Available The purpose of this study is to improve the mechanical properties and formability of friction stir welded tailor-welded blanks (TWBs of Al6061 alloy with a new forming method called hot forming quenching (HFQ in which solid-solution heat-treated aluminum sheets are formed at elevated temperature. Forming and quenching during HFQ are simultaneously performed with the forming die for the solid-solution heat-treated sheet. In this study, specimens of aluminum TWBs were prepared by friction stir welding (FSW with a butt joint. The effectiveness of FSW joining was evaluated by observation of the macrostructure for different sheet thicknesses. In order to evaluate the formability of TWBs by HFQ, a hemisphere dome stretching test of the limit dome height achieved without specimen failure was performed with various tool temperatures. A Vickers test was also performed to measure weldment hardness as a function of position. The formability and mechanical properties of products formed by HFQ are compared with those formed by conventional forming methods, demonstrating the suitability of HFQ for sheet metal forming of friction stir welded TWBs.

  8. INVESTIGATION OF SINGLE-PASS/DOUBLE-PASS TECHNIQUES ON FRICTION STIR WELDING OF ALUMINIUM

    Directory of Open Access Journals (Sweden)

    N.A.A. Sathari

    2014-12-01

    Full Text Available The aim of this research is to study the effects of single-pass/ double-pass techniques on friction stir welding of aluminium. Two pieces of AA1100 with a thickness of 6.0 mm were friction stir welded using a CNC milling machine at rotational speeds of 1400 rpm, 1600 rpm and 1800 rpm respectively for single-pass and double-pass. Microstructure observations of the welded area were studied using an optical microscope. The specimens were tested by using a tensile test and Vickers hardness test to evaluate their mechanical properties. The results indicated that, at low rotational speed, defects such as ‘surface lack of fill’ and tunnels in the welded area contributed to a decrease in mechanical properties. Welded specimens using double-pass techniques show increasing values of tensile strength and hardness. From this investigation it is found that the best parameters of FSW welded aluminium AA1100 plate were those using double-pass techniques that produce mechanically sound joints with a hardness of 56.38 HV and 108 MPa strength at 1800 rpm compared to the single-pass technique. Friction stir welding, single-pass/ double-pass techniques, AA1100, microstructure, mechanical properties.

  9. Microstructure and failure mechanisms of refill friction stir spot welded 7075-T6 aluminum alloy joints

    International Nuclear Information System (INIS)

    Shen, Zhikang; Yang, Xinqi; Zhang, Zhaohua; Cui, Lei; Li, Tielong

    2013-01-01

    Highlights: ► There is a correlation between the void in the weld and the joint strength. ► The preferable mechanical properties can be obtained by lowering rotational speed. ► The alclad has an adverse effect on the mechanical properties. -- Abstract: In this paper, the microstructure and mechanical properties of 7075-T6 aluminum alloy joints joined by refill friction stir spot welding (RFSSW) were investigated. The keyhole was refilled successfully, and the microstructure of the weld exhibited variations in the grain sizes in the width and the thickness directions. There existed defects (hook, voids, bonding ligament, etc.) associated to the material flow in the weld. Mechanical properties of the joint have been investigated in terms of hardness and tensile/shear and cross-tension test, and the fracture mechanisms were observed by SEM (scanning electron microscope). The hardness profile of the weld exhibited a W-shaped appearance in the macroscopic level, which reached the minimum at the boundary of the sleeve and the clamping ring. The variation laws between tensile/shear and cross-tension strength and processing parameters were rather complicated. The void in the weld played an important role in determining the strength of the joint. On the whole, the preferable strength can be obtained at lower rotational speed. Shear fracture mode was observed under tensile–shear loadings, and nugget debonding, plug type fracture (on the upper sheet) and plug type fracture (on the lower sheet) modes were observed under cross-tension loadings. It was also observed that the main feature affecting the mechanical properties of the joint is the alclad between the upper and lower sheets and the connecting qualities between the stir zone and thermo-mechanically affected zone.

  10. Metallurgical characterization of pulsed current gas tungsten arc, friction stir and laser beam welded AZ31B magnesium alloy joints

    International Nuclear Information System (INIS)

    Padmanaban, G.; Balasubramanian, V.

    2011-01-01

    This paper reports the influences of welding processes such as friction stir welding (FSW), laser beam welding (LBW) and pulsed current gas tungsten arc welding (PCGTAW) on mechanical and metallurgical properties of AZ31B magnesium alloy. Optical microscopy, scanning electron microscopy, transmission electron microscopy and X-Ray diffraction technique were used to evaluate the metallurgical characteristics of welded joints. LBW joints exhibited superior tensile properties compared to FSW and PCGTAW joints due to the formation of finer grains in weld region, higher fusion zone hardness, the absence of heat affected zone, presence of uniformly distributed finer precipitates in weld region.

  11. Detection and assessment of flaws in friction stir welded joints using ultrasonic guided waves: experimental and finite element analysis

    Science.gov (United States)

    Fakih, Mohammad Ali; Mustapha, Samir; Tarraf, Jaafar; Ayoub, Georges; Hamade, Ramsey

    2018-02-01

    Ultrasonic guided waves (GWs), e.g. Lamb waves, have been proven effective in the detection of defects such as corrosion, cracking, delamination, and debonding in both composite and metallic structures. They are a significant tool employed in structural health monitoring. In this study, the ability of ultrasonic GWs to assess the quality of friction stir welding (FSW) was investigated. Four friction stir welded AZ31B magnesium plates processed with different welding parameters and a non-welded plate were used. The fundamental symmetric (S0) Lamb wave mode was excited using piezoelectric wafers (PZTs). Further, the S0 mode was separated using the "Improved complete ensemble empirical mode decomposition with adaptive noise (Improved CEEMDAN)" technique. A damage index (DI) was defined based on the variation in the amplitude of the captured wave signals in order to detect the presence and asses the severity of damage resulting from the welding process. As well, computed tomography (CT) scanning was used as a non-destructive testing (NDT) technique to assess the actual weld quality and validate predictions based on the GW approach. The findings were further confirmed using finite element analysis (FEA). To model the actual damage profile in the welds, "Mimics" software was used for the 3D reconstruction of the CT scans. The built 3D models were later used for evaluation of damage volume and for FEA. The damage volumes were correlated to the damage indices computed from both experimental and numerical data. The proposed approach showed high sensitivity of the S0 mode to internal flaws within the friction stir welded joints. This methodology has great potential as a future classification method of FSW quality.

  12. Numerically Based Phase Transformation Maps for Dissimilar Aluminum Alloys Joined by Friction Stir-Welding

    Directory of Open Access Journals (Sweden)

    Carter Hamilton

    2018-05-01

    Full Text Available Sheets of aluminum 2017A-T451 and 7075-T651 were friction stir-welded in a butt-weld configuration. An existing computational model of the welding process for temperature distribution and material flow was adapted to estimate the phase transformations that occur across the weld zone. Near the weld center, process temperatures are sufficient to fully dissolve the equilibrium η phase in 7075 and partially dissolve the equilibrium S phase in 2017A. Upon cooling, Guinier–Preston (GP and Guinier–Preston–Bagaryatsky (GPB zones re-precipitate, and hardness recovers. Due to the more complete dissolution of the equilibrium phase in 7075, the hardness recovery skews toward whichever side of the weld, i.e., the advancing or retreating side, represents the 7075 workpiece. Phase transformation maps generated by the numerical simulation align not only with the hardness profiles taken across the weld zone, but also with positron lifetimes obtained through positron annihilation lifetime spectroscopy (PALS. Boundaries between the aluminum matrix and the secondary phases provide open volumes to trap positrons; therefore, positron lifetimes across the weld correspond with the phase transformations that occur in 7075 and 2017A during processing.

  13. Microstructural Evolution in Friction Stir Welding of Ti-6Al-4V

    Science.gov (United States)

    Rubisoff, H.; Querin, J.; Magee, D.; Schneider, J.

    2008-01-01

    Friction stir welding (FSW) is a thermo-mechanical process that utilizes a nonconsumable rotating pin tool to consolidate a weld joint. In the conventional FSW process, the pin tool is responsible for generating both the heat required to soften the material and the forces necessary to deform and combine the weld seam. As such, the geometry of the pin tool is important to the quality of the weld and the process parameters required to produce the weld. Because the geometry of the pin tool is limitless, a reduced set of pin tools was formed to systematically study their effect on the weldment with respect to mechanical properties and resultant microstructure. In this study 0deg, 15deg, 30deg, 45deg, and 60deg tapered, microwave sintered, tungsten carbide (WC) pin tools were used to FSW Ti-6Al-4V. Transverse sections of the weld were used to test for mechanical properties and to document the microstructure using optical microscopy. X-ray diffraction (XRD) was also used to characterize the microstructure in the welds. FSW results for the 45deg and 60deg pin tools are reported in this paper.

  14. Simulated Service and Stress Corrosion Cracking Testing for Friction Stir Welded Spun Formed Domes

    Science.gov (United States)

    Stewart, Thomas J.; Torres, Pablo D.; Caratus, Andrei A.; Curreri, Peter A.

    2010-01-01

    Simulated service testing (SST) development was required to help qualify a new 2195 aluminum lithium (Al-Li) alloy spin forming dome fabrication process for the National Aeronautics and Space Administration (NASA) Exploration Development Technology Program. The application for the technology is to produce high strength low weight tank components for NASA s next generation launch vehicles. Since plate material is not currently manufactured large enough to fabricate these domes, two plates are joined by means of friction stir welding. The plates are then pre-contour machined to near final thicknesses allowing for a thicker weld land and anticipating the level of stretch induced by the spin forming process. The welded plates are then placed in a spin forming tool and hot stretched using a trace method producing incremental contours. Finally the dome receives a room temperature contour stretch to final dimensions, heat treatment, quenching, and artificial aging to emulate a T-8 condition of temper. Stress corrosion cracking (SCC) tests were also performed by alternate immersion in a sodium chloride (NaCl) solution using the typical double beam assembly and with 4-point loaded specimens and use of bent-beam stress-corrosion test specimens under alternate immersion conditions. In addition, experiments were conducted to determine the threshold stress intensity factor for SCC (K(sub ISCC)) which to our knowledge has not been determined previously for Al-Li 2195 alloy. The successful simulated service and stress corrosion testing helped to provide confidence to continue to Ares 1 scale dome fabrication

  15. Microstructure and mechanical properties of friction stir welded 9Cr ODS steel

    International Nuclear Information System (INIS)

    Min, Hyoung Kee; Kang, Suk Hoon; Noh, Sanghoon; Lee, Jung Gu; Jang, Jinsung; Kim, Tae Kyu

    2013-01-01

    It is well known that the welding of ODS steel with a conventional melting.solidification process is not adequate to reserve nano-oxide particles in the matrix homogeneously. To reserve nano-oxide particles in the matrix homogeneously, friction stir welding (FSW) is the most promising technique to join ODS alloys. In this study, the effects of FSW on the microstructure and mechanical properties of a ODS steel were studied to apply the FSW process to 9Cr ODS steels. Microstructures were observed by means of optical microscopy, electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM). A tensile test and hardness test were carried out to the investigate mechanical properties. FSW could successfully produce defect-free welds on ODS plates. FSW produced a fine grain structure consisting of ferrite and martensite. Tensile strengths and elongations of the SZs were excellent at 298 K, compared to those of the BM. This study suggests that FSW might be an appropriate welding method of ODS steels. Oxide dispersion strengthened (ODS) ferritic-martensitic (FM) steel containing 9 wt%Cr is a promising candidate material for high temperature components operating in aggressive environments such as nuclear fusion and fission systems because of the excellent elevated temperature strength, corrosion and radiation resistance. These characteristics come from microstructures consisting of fine grains and nano-oxide particles dispersed in high number density. However, for more applications of ODS steel in nuclear systems, its weldability is the one of the barrier to be solved

  16. Mechanical Behaviour Investigation Of Aluminium Alloy Tailor Welded Blank Developed By Using Friction Stir Welding Technique

    Science.gov (United States)

    Dwi Anggono, Agus; Sugito, Bibit; Hariyanto, Agus; Subroto; Sarjito

    2017-10-01

    The objective on the research was to investigate the mechanical properties and microstructure of tailor welded blank (TWB) made from AA6061-T6 and AA1100 using friction stir welding (FSW) process. Due to the dissimilar mechanical properties of the two aluminium alloys, microhardness test was conducted to measure the hardness distribution across the weld nugget. The mixing of two distinct materials was influenced by tool rotation speed. Therefore, microstructure analysis was carried out to investigate the grain size and shape. The grain size of AA6061-T6 has increased in the heat affected zone (HAZ) while for AA1100 has decreased. In the weld nugget, it has found a hook defects in the dissimilar aluminium joining. By using monotonic tensile load, the different weld line direction was observed with the expansion in tool rotation. The joints failure were consistently on the area of AA1100 series. Furthermore, two specimens were investigated, one through the dissimilar aluminium and the other through similiar material. Inspection of the weld nugget hardness was shown that nonhomogen material intermixing during the stiring process as confirmed by microhardness measurement.

  17. A Finite Element Model to Simulate Defect Formation during Friction Stir Welding

    Directory of Open Access Journals (Sweden)

    Zhi Zhu

    2017-07-01

    Full Text Available In this study, a 3D coupled thermo-mechanical finite element model is developed to predict and analyze the defect formation during friction stir welding based on coupled Eulerian Lagrangian method. The model is validated by comparing the estimated welding temperature, processed zone shape and void size with those obtained experimentally. The results compared indicate that the simulated temperature and the data measured are in good agreement with each other. In addition, the model can predict the plasticized zone shape and the presence of a void in the weld quite accurately. However, the void size is overestimated. The effects of welding parameters and tool pin profile are also analyzed. The results reveal that welding at low welding speed or high tool rotational speed could produce a smaller void. Moreover, compared to a smooth tool pin, a featured tool pin can enhance plastic flow in the weld and achieve defect-free weldment. The results are helpful for the optimization of the welding process and the design of welding tools.

  18. Microstructure and microtexture studies of a friction stir welded Al 6061 alloy

    International Nuclear Information System (INIS)

    Kumbhar, N.T.; Tewari, R.; Dey, G.K.; Bhanumurthy, K.; Sahoo, S.K.; Samajdar, I.

    2009-01-01

    Friction stir welding is a solid state joining technique used extensively for the joining of various metals and alloys and also has been applied to the joining of steels. The friction stir welding of Al and its alloys has been extensively delt with over a period exceeding the last decade and a half due to its numerous advantages over other conventional fusion welding techniques in terms of weld quality, efficiency, cost effectiveness etc. to name a few. This technique is being increasingly seeked by industries in mass production/engineering such as the railways, marine and aerospace industries. The friction stir welding of a precipitation hardened Al 6061 alloy plates of 6 mm. thickness was performed at various tool rotation speeds and tool traverse speeds with a constant tilt of 3 deg using a high strength steel (HSS) tool of appropriate dimensions. The cross section of the weld perpendicular to the welding direction was analyzed for a detailed microstructural investigation using electron probe microanalysis, orientation imaging microscopy and transmission electron microscopy. Various microstructural changes are observed in the various regions of the friction stir welded AA 6061. The nugget region which is highly deformed is characterized by the dissolution and reprecipitation of the coarse precipitates, grain size refinement and recrystallization. The adjoining regions near the nugget viz the thermomechanically affected zone (TMAZ) and the heat affected zone (HAZ) also show heterogeneous microstructure in terms of grain size and precipitation which is mainly attributed to the heating cycle experienced during welding. This heterogeneity is also evident from the plot of microhardness distribution across the cross section of the weld region. However, the electron probe microanalysis studies do not show any significant pickup of oxygen in the weld interior as compared to a little oxygen pickup upto 30 μm from the top surface. Further, using orientation imaging

  19. Artificial neural networks application for modeling of friction stir welding effects on mechanical properties of 7075-T6 aluminum alloy

    Science.gov (United States)

    Maleki, E.

    2015-12-01

    Friction stir welding (FSW) is a relatively new solid-state joining technique that is widely adopted in manufacturing and industry fields to join different metallic alloys that are hard to weld by conventional fusion welding. Friction stir welding is a very complex process comprising several highly coupled physical phenomena. The complex geometry of some kinds of joints makes it difficult to develop an overall governing equations system for theoretical behavior analyse of the friction stir welded joints. Weld quality is predominantly affected by welding effective parameters, and the experiments are often time consuming and costly. On the other hand, employing artificial intelligence (AI) systems such as artificial neural networks (ANNs) as an efficient approach to solve the science and engineering problems is considerable. In present study modeling of FSW effective parameters by ANNs is investigated. To train the networks, experimental test results on thirty AA-7075-T6 specimens are considered, and the networks are developed based on back propagation (BP) algorithm. ANNs testing are carried out using different experimental data that they are not used during networks training. In this paper, rotational speed of tool, welding speed, axial force, shoulder diameter, pin diameter and tool hardness are regarded as inputs of the ANNs. Yield strength, tensile strength, notch-tensile strength and hardness of welding zone are gathered as outputs of neural networks. According to the obtained results, predicted values for the hardness of welding zone, yield strength, tensile strength and notch-tensile strength have the least mean relative error (MRE), respectively. Comparison of the predicted and the experimental results confirms that the networks are adjusted carefully, and the ANN can be used for modeling of FSW effective parameters.

  20. Artificial neural networks application for modeling of friction stir welding effects on mechanical properties of 7075-T6 aluminum alloy

    International Nuclear Information System (INIS)

    Maleki, E

    2015-01-01

    Friction stir welding (FSW) is a relatively new solid-state joining technique that is widely adopted in manufacturing and industry fields to join different metallic alloys that are hard to weld by conventional fusion welding. Friction stir welding is a very complex process comprising several highly coupled physical phenomena. The complex geometry of some kinds of joints makes it difficult to develop an overall governing equations system for theoretical behavior analyse of the friction stir welded joints. Weld quality is predominantly affected by welding effective parameters, and the experiments are often time consuming and costly. On the other hand, employing artificial intelligence (AI) systems such as artificial neural networks (ANNs) as an efficient approach to solve the science and engineering problems is considerable. In present study modeling of FSW effective parameters by ANNs is investigated. To train the networks, experimental test results on thirty AA-7075-T6 specimens are considered, and the networks are developed based on back propagation (BP) algorithm. ANNs testing are carried out using different experimental data that they are not used during networks training. In this paper, rotational speed of tool, welding speed, axial force, shoulder diameter, pin diameter and tool hardness are regarded as inputs of the ANNs. Yield strength, tensile strength, notch-tensile strength and hardness of welding zone are gathered as outputs of neural networks. According to the obtained results, predicted values for the hardness of welding zone, yield strength, tensile strength and notch-tensile strength have the least mean relative error (MRE), respectively. Comparison of the predicted and the experimental results confirms that the networks are adjusted carefully, and the ANN can be used for modeling of FSW effective parameters. (paper)

  1. Friction stir welding - an alternative method for sealing nuclear waste storage canisters

    Energy Technology Data Exchange (ETDEWEB)

    Andrews, R.E. [TWI Ltd, Cambridge (United Kingdom)

    2004-12-01

    When welding 50 mm thick copper a very high heat input is required to combat the high thermal diffusivity and only the Electron Beam Welding (EBW) process had this capability when this copper canister concept was conceived. Despite the encouraging results achieved using EBW with thick section copper, SKB felt that it would be prudent to assess other joining methods. This assessment concluded that friction welding, could also provide very high quality welds to satisfy the service life requirements of the SKB canister design. A friction welding variant called Friction Stir Welding (FSW) was shown to have the capability of welding 3 mm thick copper sheet with excellent integrity and reproducibility. This later provided sufficient encouragement for SKB to consider the potential of FSW as a method for joining thick section copper, using relatively simple machine tool based technology. It was thought that FSW might provide an alternative or complementary method for welding lids, or bases to canisters. In 1997 an FSW development programme started at TWI, focussed on the feasibility of welding 10 mm thick copper plate. Once this task was successfully completed, work continued to demonstrate that progressively thicker plate, up to 50 mm thick, could be joined. At this stage, with process viability established, a full size experimental FSW canister machine was designed and built. Work with this machine finished in January 2003, when it had been shown that FSW could definitely be used to weld lids to full size canisters. This report summarises the TWI development of FSW for SKB from 1997 to January 2003. It also highlights the important aspects of the process and the project milestones that will help to ensure that SKB has a welding technology that can be used with confidence for production fabrication of copper waste storage canisters in the future. The overall conclusion to this FSW development is that there is no doubt that the FSW process could be used to produce full

  2. Friction stir welding - an alternative method for sealing nuclear waste storage canisters

    International Nuclear Information System (INIS)

    Andrews, R.E.

    2004-12-01

    When welding 50 mm thick copper a very high heat input is required to combat the high thermal diffusivity and only the Electron Beam Welding (EBW) process had this capability when this copper canister concept was conceived. Despite the encouraging results achieved using EBW with thick section copper, SKB felt that it would be prudent to assess other joining methods. This assessment concluded that friction welding, could also provide very high quality welds to satisfy the service life requirements of the SKB canister design. A friction welding variant called Friction Stir Welding (FSW) was shown to have the capability of welding 3 mm thick copper sheet with excellent integrity and reproducibility. This later provided sufficient encouragement for SKB to consider the potential of FSW as a method for joining thick section copper, using relatively simple machine tool based technology. It was thought that FSW might provide an alternative or complementary method for welding lids, or bases to canisters. In 1997 an FSW development programme started at TWI, focussed on the feasibility of welding 10 mm thick copper plate. Once this task was successfully completed, work continued to demonstrate that progressively thicker plate, up to 50 mm thick, could be joined. At this stage, with process viability established, a full size experimental FSW canister machine was designed and built. Work with this machine finished in January 2003, when it had been shown that FSW could definitely be used to weld lids to full size canisters. This report summarises the TWI development of FSW for SKB from 1997 to January 2003. It also highlights the important aspects of the process and the project milestones that will help to ensure that SKB has a welding technology that can be used with confidence for production fabrication of copper waste storage canisters in the future. The overall conclusion to this FSW development is that there is no doubt that the FSW process could be used to produce full

  3. Pengaruh Kecepatan Putar Indentor Las Gesek Puntir (Friction Stir Welding Terhadap Kualitas Hasil Pengelasan Alumunium 1100-H18

    Directory of Open Access Journals (Sweden)

    Irza Sukmana

    2016-03-01

    Full Text Available Aluminum and their alloys have been applied in many industrial sectors. Although it shows a good corrosion properties, however welding process of aluminum still a challenge as it covered by oxide layer on the surface. Friction Stir Welding (FSW technology gives a potential chance to be used for joining process of aluminum. In this study, we use a vertical milling machine Milko-12 that has been utilized with indentor of FSW process for Aluminum 1100-H18 at 4 (four different rotation speed (Rt, i.e.: 352, 490, 653, and 910 rpm and constant transversal speed (V 20mm/minutes. Based on mechanical properties and metallography data of welded materials, the higher the Rt the higher the tensile strength. Rt of 653 rpm results the highest tensile strength of 107 MPa. The crack areas of all welded metals are at base metal (BM concluded that our vertical milling machine Milko-12 can be utilized for friction stir welding (FSW process for Aluminum.

  4. Ultrasonic Stir Welding

    Science.gov (United States)

    Nabors, Sammy

    2015-01-01

    NASA Marshall Space Flight Center (MSFC) developed Ultrasonic Stir Welding (USW) to join large pieces of very high-strength metals such as titanium and Inconel. USW, a solid-state weld process, improves current thermal stir welding processes by adding high-power ultrasonic (HPU) energy at 20 kHz frequency. The addition of ultrasonic energy significantly reduces axial, frictional, and shear forces; increases travel rates; and reduces wear on the stir rod, which results in extended stir rod life. The USW process decouples the heating, stirring, and forging elements found in the friction stir welding process allowing for independent control of each process element and, ultimately, greater process control and repeatability. Because of the independent control of USW process elements, closed-loop temperature control can be integrated into the system so that a constant weld nugget temperature can be maintained during welding.

  5. Fatigue crack growth rate behaviour of friction-stir aluminium alloy AA2024-T3 welds under transient thermal tensioning

    International Nuclear Information System (INIS)

    Ilman, M.N.; Kusmono,; Iswanto, P.T.

    2013-01-01

    Highlights: • FSW enables unweldable aircraft material AA2024-T3 to be welded without cracking. • FSW applied to aircraft structure is required to have superior fatigue resistance. • Transient thermal tensioning (TTT) is being developed for stress relieving in FSW. • The fatigue crack growth rates of FSW joints under TTT are studied. - Abstract: Friction stir welding (FSW) has become a serious candidate technology to join metallic fuselage panels for the next generation of civil aircrafts. However, residual stress introduced during welding which subsequently affects fatigue performance is still a major problem that needs to be paid attention. The present investigation aims to improve fatigue crack growth resistance of friction stir aluminium alloy AA2024-T3 welds using transient thermal tensioning (TTT) treatment. In this investigation, aluminium alloy AA2024-T3 plates were joined using FSW process with and without TTT. The welding parameters used including tool rotation speed (Rt) and the plate travelling speed (v) were 1450 rpm and 30 mm/min respectively. The TTT treatments were carried out by heating both sides of friction stir weld line using moving electric heaters ahead of, beside and behind the tool at a heating temperature of 200 °C. Subsequently, a sequence of tests was carried out including microstructural examination, hardness measurement, tensile test and fatigue crack growth rate (FCGR) test in combination with fractography using scanning electron microscopy (SEM). The FCGR test was carried out using a constant amplitude fatigue experiment with stress ratio (R) of 0.1 and frequency (f) of 11 Hz whereas specimens used were centre-crack tension (CCT) type with the initial crack located at the weld nugget. Results of this investigation showed that at low ΔK, typically below 9 MPa m 0.5 , the friction stir welds under TTT treatments lowered fatigue crack growth rate (da/dN) and the lowest (da/dN) was achieved as the heaters were located ahead of

  6. Modelling residual stresses in friction stir welding of Al alloys - a review of possibilities and future trends

    DEFF Research Database (Denmark)

    Hattel, Jesper Henri; Sonne, Mads Rostgaard; Tutum, Cem C.

    2015-01-01

    Residual stresses are very important in any joining process of materials since they act as pre-stresses in the loading situation of the joint, thereby affecting the final mechanical performance of the component. This is also the case for friction stir welding (FSW) which is a complex solid-state ......, numerical framework and application as well as putting them into proper context with respect to some of the new trends in the field, e.g. coupling with subsequent load analyses of the in-service situation or applying residual stress models of FSWin numerical optimization.......Residual stresses are very important in any joining process of materials since they act as pre-stresses in the loading situation of the joint, thereby affecting the final mechanical performance of the component. This is also the case for friction stir welding (FSW) which is a complex solid......-state joining process characterized by a pronounced multiphysical behaviour involving phenomena such as change of temperature, material flow, change of microstructures and formation of residual stresses. Thus, models of FSWare typically divided into thermal models, flow models, residual stress models...

  7. Experimental and numerical investigation on under-water friction stir welding of armour grade AA2519-T87 aluminium alloy

    Directory of Open Access Journals (Sweden)

    S. Sree Sabari

    2016-08-01

    Full Text Available Friction stir welding (FSW is a promising welding process that can join age hardenable aluminium alloys with high joint efficiency. However, the thermal cycles experienced by the material to be joined during FSW resulted in the deterioration of mechanical properties due to the coarsening and dissolution of strengthening precipitates in the thermo-mechanical affected zone (TMAZ and heat affected zone (HAZ. Under water friction stir welding (UWFSW is a variant of FSW process which can maintain low heat input as well as constant heat input along the weld line. The heat conduction and dissipation during UWFSW controls the width of TMAZ and HAZ and also improves the joint properties. In this investigation, an attempt has been made to evaluate the mechanical properties and microstructural characteristics of AA2519-T87 aluminium alloy joints made by FSW and UWFSW processes. Finite element analysis has been used to estimate the temperature distribution and width of TMAZ region in both the joints and the results have been compared with experimental results and subsequently correlated with mechanical properties.

  8. Mechanical Property Analysis in the Retracted Pin-Tool (RPT) Region of Friction Stir Welded (FSW) Aluminum Lithium 2195

    Science.gov (United States)

    Ding, R. Jeffrey; Oelgoetz, Peter A.

    1999-01-01

    The "Auto-Adjustable Pin Tool for Friction Stir Welding", was developed at The Marshall Space Flight Center to address process deficiencies unique to the FSW process. The auto-adjustable pin tool, also called the retractable pin-tool (R.PT) automatically withdraws the welding probe of the pin-tool into the pin-tool's shoulder. The primary function of the auto-adjustable pin-tool is to allow for keyhole closeout, necessary for circumferential welding and localized weld repair, and, automated pin-length adjustment for the welding of tapered material thickness. An overview of the RPT hardware is presented. The paper follows with studies conducted using the RPT. The RPT was used to simulate two capabilities; welding tapered material thickness and closing out the keyhole in a circumferential weld. The retracted pin-tool regions in aluminum- lithium 2195 friction stir weldments were studied through mechanical property testing and metallurgical sectioning. Correlation's can be =de between retractable pin-tool programmed parameters, process parameters, microstructure, and resulting weld quality.

  9. Effect of rotation speed and welding speed on Friction Stir Welding of AA1100 Aluminium alloy

    Science.gov (United States)

    Raja, P.; Bojanampati, S.; Karthikeyan, R.; Ganithi, R.

    2018-04-01

    Aluminum AA1100 is the most widely used grade of Aluminium due to its excellent corrosion resistance, high ductility and reflective finish, the selected material was welded with Friction Stir Welding (FSW) process on a CNC machine, using a combination of different tool rotation speed (1500 rpm, 2500 rpm, 3500 rpm) and welding speed (10 mm/min, 30 mm/min, 50 mm/min) as welding parameters. The effect of FSW using this welding parameter was studied by measuring the ultimate tensile strength of the welded joints. A high-speed steel tool was prepared for welding the Aluminium AA1100 alloy having an 8mm shoulder diameter and pin dimension of 4mm diameter and 2.8 mm length. The welded joints were tested using the universal testing machine. It was found that Ultimate Tensile Strength of FSW specimen was highest with a value of 98.08 MPa when the weld was performed at rotation speed of 1500 RPM and welding speed of 50 mm/min.

  10. Influence of friction stir welding parameters on properties of 2024 T3 aluminium alloy joints

    Directory of Open Access Journals (Sweden)

    Eramah Abdsalam M.

    2014-01-01

    Full Text Available The aim of this work is to analyse the process of friction stir welding (FSW of 3mm thick aluminium plates made of high strength aluminium alloy - 2024 T3, as well as to assess the mechanical properties of the produced joints. FSW is a modern procedure which enables joining of similar and dissimilar materials in the solid state, by the combined action of heat and mechanical work. This paper presents an analysis of the experimental results obtained by testing the butt welded joints. Tensile strength of the produced joints is assessed, as well as the distribution of hardness, micro-and macrostructure through the joints (in the base material, nugget, heat affected zone and thermo-mechanically affected zone. Different combinations of the tool rotation speed and the welding speed are used, and the dependence of the properties of the joints on these parameters of welding technology is determined. [Projekat Ministarstva nauke Republike Srbije, br. TR 34018 i br. TR 35006

  11. High-Speed Friction-Stir Welding to Enable Aluminum Tailor-Welded Blanks

    Science.gov (United States)

    Hovanski, Yuri; Upadhyay, Piyush; Carsley, John; Luzanski, Tom; Carlson, Blair; Eisenmenger, Mark; Soulami, Ayoub; Marshall, Dustin; Landino, Brandon; Hartfield-Wunsch, Susan

    2015-05-01

    Current welding technologies for production of aluminum tailor-welded blanks (TWBs) are utilized in low-volume and niche applications, and they have yet to be scaled for the high-volume vehicle market. This study targeted further weight reduction, part reduction, and cost savings by enabling tailor-welded blank technology for aluminum alloys at high volumes. While friction-stir welding (FSW) has been traditionally applied at linear velocities less than 1 m/min, high-volume production applications demand the process be extended to higher velocities more amenable to cost-sensitive production environments. Unfortunately, weld parameters and performance developed and characterized at low-to-moderate welding velocities do not directly translate to high-speed linear FSW. Therefore, to facilitate production of high-volume aluminum FSW components, parameters were developed with a minimum welding velocity of 3 m/min. With an emphasis on weld quality, welded blanks were evaluated for postweld formability using a combination of numerical and experimental methods. An evaluation across scales was ultimately validated by stamping full-size production door inner panels made from dissimilar thickness aluminum TWBs, which provided validation of the numerical and experimental analysis of laboratory-scale tests.

  12. Characterization of Residual Stress Effects on Fatigue Crack Growth of a Friction Stir Welded Aluminum Alloy

    Science.gov (United States)

    Newman, John A.; Smith, Stephen W.; Seshadri, Banavara R.; James, Mark A.; Brazill, Richard L.; Schultz, Robert W.; Donald, J. Keith; Blair, Amy

    2015-01-01

    An on-line compliance-based method to account for residual stress effects in stress-intensity factor and fatigue crack growth property determinations has been evaluated. Residual stress intensity factor results determined from specimens containing friction stir weld induced residual stresses are presented, and the on-line method results were found to be in excellent agreement with residual stress-intensity factor data obtained using the cut compliance method. Variable stress-intensity factor tests were designed to demonstrate that a simple superposition model, summing the applied stress-intensity factor with the residual stress-intensity factor, can be used to determine the total crack-tip stress-intensity factor. Finite element, VCCT (virtual crack closure technique), and J-integral analysis methods have been used to characterize weld-induced residual stress using thermal expansion/contraction in the form of an equivalent delta T (change in local temperature during welding) to simulate the welding process. This equivalent delta T was established and applied to analyze different specimen configurations to predict residual stress distributions and associated residual stress-intensity factor values. The predictions were found to agree well with experimental results obtained using the crack- and cut-compliance methods.

  13. Intergranular corrosion following friction stir welding of aluminum alloy 7075-T651

    Energy Technology Data Exchange (ETDEWEB)

    Lumsden, J.B.; Mahoney, M.W.; Pollock, G.; Rhodes, C.G.

    1999-12-01

    Friction stir welding (FSW), a relatively new solid-state joining process, is used to join Al alloys of all compositions, including alloys essentially considered unweldable. This study focused on microstructures in FSW Al alloy 7075-T651 (AA 7075-T651 [UNS 97075-T651]), an alloy not commonly fusion welded, and the resultant corrosion susceptibility. Although the heat input associated with FSW was relatively low and the time at temperature was short compared to fusion welding, localized microstructures, chemical segregation, and precipitate distributions were created that generally are not present in parent metal AA 7075-T651. Typically, in the weld and heat affected zone (HAZ), the times at peak temperature were short, cooling was relatively rapid, and peak temperatures were {lt} {approx}500 C. Accordingly, a corresponding microstructural gradient developed from the weld nugget into the unaffected parent metal with the precipitate distribution in and around grain boundaries reflecting this temperature excursion. Some of these microstructures, when exposed to a corrosive environment, showed selective grain boundary attack and a decrease in the pitting potential relative to the parent metal. A characterization of the microstructure and localized chemistry differences within the weld zones suggested that the decrease in corrosion resistance correlated with a depletion of Cu within the grain boundaries and precipitate-free zones. These results provided evidence that the lowered resistance to intergranular corrosion following FSW of AA 7075-T651 was caused by a difference in pitting potentials.

  14. Effect of friction stir lap welding conditions on joint strength of aluminium alloy 6060

    International Nuclear Information System (INIS)

    Yazdanian, S; Chen, Z W

    2009-01-01

    Strength of lap joints made by friction stir welding (FSW) depends strongly on how material flows forming the weld nugget zone during FSW and also on how the joint is loaded during testing. Understanding of this processing-property relationship is currently inadequate. In this study, the effects of pin length, welding speed and rotation rate on weld strength using aluminium alloy 6060 were investigated. It has been found that the pin length needed to be slightly greater than the thickness of the sheet for an adequate joint to be established. However, further increase in pin length did not benefit the joint strength. The major factor affecting joint strength has been found to be the rotation speed. An increase in rotation speed resulted in lowering the joint strength. Various modes of fracture have been observed and these modes relate to the degree of hooking and softening. Explanation of how the speed values relate to heat input and material flow and then to the joint strength is given.

  15. Study of the feasibility of friction STIR welding applied to the fabrication of monolithic fuel elements

    International Nuclear Information System (INIS)

    Cabot, Pedro J.; Moglioni, A.; Mirandou, Marcela; Balart, Silvia N.

    2004-01-01

    The monolithic U-Mo fuel elements consist in a foil of a U-Mo alloy encased in Al. One of the techniques that is being tried to apply in their fabrication is Friction Stir Welding in the 'no contact at the interface' mode. The Laboratory of Welding at the National Atomic Energy Commission (Argentina) has a great experience in the conventional form of this technique so has started working on this new application. This paper describes the experiments performed to obtain the operative parameters. In the first experiments AA6061 T6 (Al) plates and sheets of AISI 316 (SS) were used to obtain the optimal operative parameters of the process. Welds were performed and evaluated for different operative variables such speed, angle and diameter of the tool and tool-interface gap keeping the rotation speed constant. Tensile test, pressure leak-proof test, bending test, non-destructive test and metallography were used to characterize the welds. Finally, SS and U-Mo foils were encased using the parameters selected from the first experiments. The samples prepared with U-Mo alloy will be used as diffusion couples and for the studies of interdiffusion under irradiation. (author)

  16. Joining aluminum to titanium alloy by friction stir lap welding with cutting pin

    International Nuclear Information System (INIS)

    Wei, Yanni; Li, Jinglong; Xiong, Jiangtao; Huang, Fu; Zhang, Fusheng; Raza, Syed Hamid

    2012-01-01

    Aluminum 1060 and titanium alloy Ti–6Al–4V plates were lap joined by friction stir welding. A cutting pin of rotary burr made of tungsten carbide was employed. The microstructures of the joining interface were observed by scanning electron microscopy. Joint strength was evaluated by a tensile shear test. During the welding process, the surface layer of the titanium plate was cut off by the pin, and intensively mixed with aluminum situated on the titanium plate. The microstructures analysis showed that a visible swirl-like mixed region existed at the interface. In this region, the Al metal, Ti metal and the mixed layer of them were all presented. The ultimate tensile shear strength of joint reached 100% of 1060Al that underwent thermal cycle provided by the shoulder. - Highlights: ► FSW with cutting pin was successfully employed to form Al/Ti lap joint. ► Swirl-like structures formed due to mechanical mixing were found at the interface. ► High-strength joints fractured at Al suffered thermal cycle were produced.

  17. Effect of friction stir welding on microstructure and corrosion behavior of LF6 aluminum alloy

    Science.gov (United States)

    Ghauri, Faizan Ali; Farooq, A.; Ahmad, A.; Deen, K. M.

    2017-03-01

    The LF6 aluminum alloy plates were joined by friction stir welding method. The tool rotational (1180 rpm) and transverse speed (0.56 mm s-1) were kept constant during welding of 4 mm thick plates. The microstructural features, hardness and tensile properties of the welded samples were determined to evaluate the structural integrity in comparison with the base metal. The electrochemical behavior of base metal (BM), thermo-mechanically affected zone (TMAZ) and weld nugget zone (WNZ) was also investigated by potentiodynamic polarization and electrochemical impedance spectroscopy in 3.5% NaCl solution. The microstructural study revealed significant grain refinement and agglomeration of β (Mg2Al3) intermetallic precipitates in the WNZ. The relatively higher hardness and a decrease in the ductility (3%) also assured the formation of precipitates β precipitates in the WNZ welded samples. The fracture surface of welded sample also revealed the existence of β precipitates within the elongated dimples which may be considered as the crack initiation sites. The relatively lower corrosion rate (23.68 mpy) and higher charge transfer resistance (403 Ω cm2) of BM compared to WNZ could be associated with the galvanic dissolution of Al-matrix through competitive charge transfer and relaxation (adsorption/desorption of intermediate species) processes specifically at the vicinity of the β precipitates.

  18. Formability of fiber-reinforced thermoplastics in hot press forming process based on friction properties

    NARCIS (Netherlands)

    Sachs, Ulrich; Haanappel, Sebastiaan; Rietman, Bert; ten Thije, R.H.W.; Akkerman, Remko

    2013-01-01

    In this paper an advanced solid state cladding process, based on Friction Stir Welding, is presented. The Friction Surface Cladding (FSC) technology enables the deposition of a solid-state coating using filler material on a substrate with good metallurgical bonding. A relatively soft AA1050 filler

  19. Mechanical properties and fracture behaviour of ODS steel friction stir welds at variable temperatures

    Energy Technology Data Exchange (ETDEWEB)

    Dawson, H., E-mail: huwdawson@gmail.com [School of Materials, University of Manchester, Manchester M13 9PL (United Kingdom); Serrano, M.; Hernandez, R. [Structural Materials Division, Technology Department, CIEMAT, Avda de la Complutense 40, 28040 Madrid (Spain); Cater, S. [Friction and Forge Processes Department, Joining Technologies Group, TWI Technology Centre (Yorkshire), Advanced Manufacturing Park, Wallis Way, Catcliffe, Rotherham S60 5TZ (United Kingdom); Jimenez-Melero, E. [School of Materials, University of Manchester, Manchester M13 9PL (United Kingdom)

    2017-05-02

    We have assessed the microstructure and the temperature-dependent mechanical behaviour of five bead-on-plate friction stir welds of Oxide Dispersion Strengthened (ODS) steel, produced using systematic changes to the tool rotation and traverse speed. Friction stir welding can potentially retain the fine dispersion of nanoparticles, and therefore also the high-temperature strength and radiation damage resistance of these materials. Tensile testing was carried out on the MA956 base material at a range of temperatures, from room temperature up to 750 °C. The mechanical properties of the welds were investigated via tensile testing at room temperature and at 500 °C, together with micro-hardness testing. The welds exhibited similar strength and ductility to the base material at both testing temperatures as welding caused a partial loss of particle strengthening, alongside an increase in grain boundary strengthening due to a greatly refined grain size in the stir zones. The micro-hardness data revealed a trend of increasing hardness with increasing tool traverse speed or decreasing rotation speed. This was attributed to the smaller grain size and lower nanoparticle number density in the welds created with these parameters. At 500 °C, the yield stress and ultimate tensile stress of the base material and the welds decreased, due to a progressive reduction in both the Orowan-type particle strengthening and the grain boundary strengthening.

  20. Effect of Heat Exposure on the Fatigue Properties of AA7050 Friction Stir Welds

    Science.gov (United States)

    White, B. C.; Rodriguez, R. I.; Cisko, A.; Jordon, J. B.; Allison, P. G.; Rushing, T.; Garcia, L.

    2018-05-01

    This work examines the effect of heat exposure on the subsequent monotonic and fatigue properties of friction stir-welded AA7050. Mechanical characterization tests were conducted on friction stir-welded specimens as-welded (AW) and specimens heated to 315 °C in air for 20 min. Monotonic testing revealed high joint efficiencies of 98% (UTS) in the AW specimens and 60% in the heat-damaged (HD) specimens. Experimental results of strain-controlled fatigue testing revealed shorter fatigue lives for the HD coupons by nearly a factor of four, except for the highest strain amplitude tested. Postmortem fractography analysis found similar crack initiation or propagation behavior between the AW and HD specimens; however, the failure locations for the AW were predominantly in the heat-affected zone, while the HD specimens also failed in the stir zone. Microhardness measurements revealed a relatively uniform strength profile in the HD group, accounting for the variety of failure locations observed. The differences in both monotonic and cyclic properties observed between the AW and HD specimens support the conclusion that the heat damage (315 °C at 20 min) acts as an over-aging and a quasi-annealing treatment.

  1. Effect of friction stir welding and post-weld heat treatment on a nanostructured ferritic alloy

    International Nuclear Information System (INIS)

    Mazumder, B.; Yu, X.; Edmondson, P.D.; Parish, C.M.; Miller, M.K.; Meyer, H.M.; Feng, Z.

    2016-01-01

    Nanostructured ferritic alloys (NFAs) are new generation materials for use in high temperature energy systems, such as nuclear fission or fusion reactors. However, joining these materials is a concern, as their unique microstructure is destroyed by traditional liquid-state welding methods. The microstructural evolution of a friction stir welded 14YWT NFA was investigated by atom probe tomography, before and after a post-weld heat treatment (PWHT) at 1123K. The particle size, number density, elemental composition, and morphology of the titanium-yttrium-oxygen-enriched nanoclusters (NCs) in the stir and thermally-affected zones were studied and compared with the base metal. No statistical difference in the size of the NCs was observed in any of these conditions. After the PWHT, increases in the number density and the oxygen enrichment in the NCs were observed. Therefore, these new results provide additional supporting evidence that friction stir welding appears to be a viable joining technique for NFAs, as the microstructural parameters of the NCs are not strongly affected, in contrast to traditional welding techniques.

  2. Development of liquid-nitrogen-cooling friction stir spot welding for AZ31 magnesium alloy joints

    Science.gov (United States)

    Wu, Dong; Shen, Jun; Zhou, Meng-bing; Cheng, Liang; Sang, Jia-xing

    2017-10-01

    A liquid-nitrogen-cooling friction stir spot welding (C-FSSW) technology was developed for welding AZ31 magnesium alloy sheets. The liquid-nitrogen cooling degraded the deformability of the welded materials such that the width of interfacial cracks increased with increasing cooling time. The grain size of the stirred zone (SZ) and the heat-affected zone (HAZ) of the C-FSSW-welded joints decreased, whereas that of the thermomechanically affected zone (TMAZ) increased with increasing cooling time. The maximum tensile shear load of the C-FSSW-welded joints welded with a cooling time of 5 or 7 s was larger than that of the friction stir spot welding (FSSW)-welded joint, and the tensile shear load decreased with increasing cooling time. The microhardness of the C-FSSW-welded joints was greater than that of the FSSW-welded joint. Moreover, the microhardness of the SZ and the HAZ of the C-FSSW-welded joints increased, whereas that of the TMAZ decreased, with increasing cooling time.

  3. Effect of friction stir welding and post-weld heat treatment on a nanostructured ferritic alloy

    Energy Technology Data Exchange (ETDEWEB)

    Mazumder, B., E-mail: mazumderb@ornl.gov [Center for Nanophase Materials Sciences, Oak Ridge National Laboratory, Oak Ridge, TN 37831 (United States); Yu, X.; Edmondson, P.D.; Parish, C.M. [Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831 (United States); Miller, M.K. [Center for Nanophase Materials Sciences, Oak Ridge National Laboratory, Oak Ridge, TN 37831 (United States); Meyer, H.M.; Feng, Z. [Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831 (United States)

    2016-02-15

    Nanostructured ferritic alloys (NFAs) are new generation materials for use in high temperature energy systems, such as nuclear fission or fusion reactors. However, joining these materials is a concern, as their unique microstructure is destroyed by traditional liquid-state welding methods. The microstructural evolution of a friction stir welded 14YWT NFA was investigated by atom probe tomography, before and after a post-weld heat treatment (PWHT) at 1123K. The particle size, number density, elemental composition, and morphology of the titanium-yttrium-oxygen-enriched nanoclusters (NCs) in the stir and thermally-affected zones were studied and compared with the base metal. No statistical difference in the size of the NCs was observed in any of these conditions. After the PWHT, increases in the number density and the oxygen enrichment in the NCs were observed. Therefore, these new results provide additional supporting evidence that friction stir welding appears to be a viable joining technique for NFAs, as the microstructural parameters of the NCs are not strongly affected, in contrast to traditional welding techniques.

  4. Characterization and Strain-Hardening Behavior of Friction Stir-Welded Ferritic Stainless Steel

    Science.gov (United States)

    Sharma, Gaurav; Dwivedi, Dheerendra Kumar; Jain, Pramod Kumar

    2017-12-01

    In this study, friction stir-welded joint of 3-mm-thick plates of 409 ferritic stainless steel (FSS) was characterized in light of microstructure, x-ray diffraction analysis, hardness, tensile strength, ductility, corrosion and work hardening properties. The FSW joint made of ferritic stainless steel comprises of three distinct regions including the base metal. In stir zone highly refined ferrite grains with martensite and some carbide precipitates at the grain boundaries were observed. X-ray diffraction analysis also revealed precipitation of Cr23C6 and martensite formation in heat-affected zone and stir zone. In tensile testing of the transverse weld samples, the failure eventuated within the gauge length of the specimen from the base metal region having tensile properties overmatched to the as-received base metal. The tensile strength and elongation of the longitudinal (all weld) sample were found to be 1014 MPa and 9.47%, respectively. However, in potentiodynamic polarization test, the corrosion current density of the stir zone was highest among all the three zones. The strain-hardening exponent for base metal, transverse and longitudinal (all weld) weld samples was calculated using various equations. Both the transverse and longitudinal weld samples exhibited higher strain-hardening exponents as compared to the as-received base metal. In Kocks-Mecking plots for the base metal and weld samples at least two stages of strain hardening were observed.

  5. Corrosion Performance of Friction Stir Linear Lap Welded AM60B Joints

    Science.gov (United States)

    Kish, J. R.; Birbilis, N.; McNally, E. M.; Glover, C. F.; Zhang, X.; McDermid, J. R.; Williams, G.

    2017-11-01

    A corrosion investigation of friction stir linear lap welded AM60B joints used to fabricate an Mg alloy-intensive automotive front end sub-assembly was performed. The stir zone exhibited a slightly refined grain size and significant break-up and re-distribution of the divorced Mg17Al12 (β-phase) relative to the base material. Exposures in NaCl (aq) environments revealed that the stir zone was more susceptible to localized corrosion than the base material. Scanning vibrating electrode technique measurements revealed differential galvanic activity across the joint. Anodic activity was confined to the stir zone surface and involved initiation and lateral propagation of localized filaments. Cathodic activity was initially confined to the base material surface, but was rapidly modified to include the cathodically-activated corrosion products in the filament wake. Site-specific surface analyses revealed that the corrosion observed across the welded joint was likely linked to variations in Al distribution across the surface film/metal interface.

  6. In temperature forming of friction stir lap welds in aluminium alloys

    Science.gov (United States)

    Bruni, Carlo; Cabibbo, Marcello; Greco, Luciano; Pieralisi, Massimiliano

    2018-05-01

    The objective of such investigation is the study in depth of the forming phase of welds realized on three sheet metal blanks in aluminium alloys by friction stir lap welding. Such forming phase was performed by upsetting at different constant forming temperatures varying from 200°C to 350°C with constant ram velocities of 0.01 and 0.1 mm/s. The temperature values were obtained by the use of heating strips applied on the upper tool and on the lower tool. It was observed an increase in the friction factor, acting at the upsetting tool-workpiece interface, with increasing temperature that is very useful in producing the required localized deformation with which to improve the weld. It was also confirmed that the forming phase allows to realize a required thickness in the weld area allowing to neglect the surficial perturbation produced by the friction stir welding tool shoulder. The obtained thickness could be subjected to springback when too low temperatures are considered.

  7. Tensile Properties of Friction Stir Welded Joints of AA 2024-T6 Alloy at Different Welding Speeds

    Science.gov (United States)

    Avula, Dhananjayulu; Devuri, Venkateswarlu; Cheepu, Muralimohan; Dwivedi, Dheerendra Kumar

    2018-03-01

    The influence of welding speed on the friction stir welded joint properties of hardness, tensile properties, defects and microstructure characterization are studied in the present study. The friction stir welding was conducted on AA2014-T6 heat treated alloy with 5 mm thickness plate in butt joint configuration. The welding speed was varied from 8 mm/min to 120 mm/min at the fixed travel speed and load conditions. It is observed that the welding speeds at higher rate with wide range can be possible to weld this alloy at higher rates of tool revolution suggesting that the inherent capability of friction stir welding technique for aluminum 2014 alloys. The strength of the joints gradually increases with enhancing of welding speed. The micro structural observations exhibited the formation of equiaxed grains in the stir zone and slightly in the thermo-mechanically affected zone. In addition, the size of the grains decreases with increase in welding speed owing to the presence of low heat input. Hence the hardness of the joints slightly increased in the stir zones over the other zones of the weld nugget. The joint strength initially increases with the welding speed and starts to decreases after reaching to the maximum value. The relationship between the welding conditions and friction stir welded joint properties has been discussed.

  8. Friction stir welding of dissimilar AA2024 and AA7075 aluminum alloys

    International Nuclear Information System (INIS)

    Khodir, Saad Ahmed; Shibayanagi, Toshiya

    2008-01-01

    The present study focuses on the microstructure and mechanical properties of dissimilar joints of 2024-T3 Al alloy to 7075-T6 Al alloy produced by friction stir welding. Effects of welding speed and fixed location of base metals on microstructures, hardness distributions, and tensile properties of the welded joints were investigated. SEM-EDS analysis revealed that the stir zone contains a mixed structure and onion ring pattern with a periodic change of grain size as well as a heterogeneous distribution of alloying elements. The maximum tensile strength of 423.0 MPa was achieved for the joint produced at welding speed of 1.67 mm/s when 2024 Al alloy was located on the advancing side

  9. Interfacial microstructure and properties of copper clad steel produced using friction stir welding versus gas metal arc welding

    Energy Technology Data Exchange (ETDEWEB)

    Shen, Z.; Chen, Y. [Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo (Canada); Haghshenas, M., E-mail: mhaghshe@uwaterloo.ca [Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo (Canada); Nguyen, T. [Mechanical Systems Engineering, Conestoga College, Kitchener (Canada); Galloway, J. [Welding Engineering Technology, Conestoga College, Kitchener (Canada); Gerlich, A.P. [Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo (Canada)

    2015-06-15

    A preliminary study compares the feasibility and microstructures of pure copper claddings produced on a pressure vessel A516 Gr. 70 steel plate, using friction stir welding versus gas metal arc welding. A combination of optical and scanning electron microscopy is used to characterize the grain structures in both the copper cladding and heat affected zone in the steel near the fusion line. The friction stir welding technique produces copper cladding with a grain size of around 25 μm, and no evidence of liquid copper penetration into the steel. The gas metal arc welding of copper cladding exhibits grain sizes over 1 mm, and with surface microcracks as well as penetration of liquid copper up to 50 μm into the steel substrate. Transmission electron microscopy reveals that metallurgical bonding is produced in both processes. Increased diffusion of Mn and Si into the copper cladding occurs when using gas metal arc welding, although some nano-pores were detected in the FSW joint interface. - Highlights: • Cladding of steel with pure copper is possible using either FSW or GMAW. • The FSW yielded a finer grain structure in the copper, with no evidence of cracking. • The FSW joint contains some evidence of nano-pores at the interface of the steel/copper. • Copper cladding by GMAW contained surface cracks attributed to high thermal stresses. • The steel adjacent to the fusion line maintained a hardness value below 248 HV.

  10. Nugget Structure Evolution with Rotation Speed for High-Rotation-Speed Friction-Stir-Welded 6061 Aluminum Alloy

    Science.gov (United States)

    Zhang, H. J.; Wang, M.; Zhu, Z.; Zhang, X.; Yu, T.; Wu, Z. Q.

    2018-03-01

    High-rotation-speed friction stir welding (HRS-FSW) is a promising technique to reduce the welding loads during FSW and thus facilitates the application of FSW for in situ fabrication and repair. In this study, 6061 aluminum alloy was friction stir welded at high-rotation speeds ranging from 3000 to 7000 rpm at a fixed welding speed of 50 mm/min, and the effects of rotation speed on the nugget zone macro- and microstructures were investigated in detail in order to illuminate the process features. Temperature measurements during HRS-FSW indicated that the peak temperature did not increase consistently with rotation speed; instead, it dropped remarkably at 5000 rpm because of the lowering of material shear stress. The nugget size first increased with rotation speed until 5000 rpm and then decreased due to the change of the dominant tool/workpiece contact condition from sticking to sliding. At the rotation speed of 5000 rpm, where the weld material experienced weaker thermal effect and higher-strain-rate plastic deformation, the nugget exhibited relatively small grain size, large textural intensity, and high dislocation density. Consequently, the joint showed superior nugget hardness and simultaneously a slightly low tensile ductility.

  11. Microstructural characterisation of friction stir welding joints of mild steel to Ni-based alloy 625

    Energy Technology Data Exchange (ETDEWEB)

    Rodriguez, J. [Brazilian Nanotechnology National Laboratory (LNNano), P.O. Box 6192, Campinas, SP (Brazil); University of Campinas (UNICAMP), Campinas, SP (Brazil); Ramirez, A.J., E-mail: ramirezlondono.1@osu.edu [Brazilian Nanotechnology National Laboratory (LNNano), P.O. Box 6192, Campinas, SP (Brazil); University of Campinas (UNICAMP), Campinas, SP (Brazil); Department of Materials Science and Engineering, The Ohio State University — OSU, Columbus, OH 43221 (United States)

    2015-12-15

    In this study, 6-mm-thick mild steel and Ni-based alloy 625 plates were friction stir welded using a tool rotational speed of 300 rpm and a travel speed of 100 mm·min{sup −1}. A microstructural characterisation of the dissimilar butt joint was performed using optical microscopy, scanning and transmission electron microscopy, and energy dispersive X-ray spectroscopy (XEDS). Six different weld zones were found. In the steel, the heat-affected zone (HAZ) was divided into three zones and was composed of ferrite, pearlite colonies with different morphologies, degenerated regions of pearlite and allotriomorphic and Widmanstätten ferrite. The stir zone (SZ) of the steel showed a coarse microstructure consisting of allotriomorphic and Widmanstätten ferrite, degenerate pearlite and MA constituents. In the Ni-based alloy 625, the thermo-mechanically affected zone (TMAZ) showed deformed grains and redistribution of precipitates. In the SZ, the high deformation and temperature produced a recrystallised microstructure, as well as fracture and redistribution of MC precipitates. The M{sub 23}C{sub 6} precipitates, present in the base material, were also redistributed in the stir zone of the Ni-based alloy. TMAZ in the steel and HAZ in the Ni-based alloy could not be identified. The main restorative mechanisms were discontinuous dynamic recrystallisation in the steel, and discontinuous and continuous dynamic recrystallisation in the Ni-based alloy. The interface region between the steel and the Ni-based alloy showed a fcc microstructure with NbC carbides and an average length of 2.0 μm. - Highlights: • Comprehensive microstructural characterisation of dissimilar joints of mild steel to Ni-based alloy • Friction stir welding of joints of mild steel to Ni-based alloy 625 produces sound welds. • The interface region showed deformed and recrystallised fcc grains with NbC carbides and a length of 2.0 μm.

  12. Optimisation of hardness and tensile strength of friction stir welded ...

    African Journals Online (AJOL)

    DR OKE

    adopted to develop mathematical model between the response and process parameters. .... Table 3 Normalised values and Deviational Sequence ... If the expectancy is the smaller the better, then the original sequence should be normalised ...

  13. Origin of unusual fracture in stirred zone for friction stir welded 2198-T8 Al-Li alloy joints

    Energy Technology Data Exchange (ETDEWEB)

    Tao, Y. [Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China); University of Chinese Academy of Sciences, Beijing 100049 (China); Ni, D.R., E-mail: drni@imr.ac.cn [Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China); Xiao, B.L.; Ma, Z.Y. [Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016 (China); Wu, W.; Zhang, R.X. [AVIC Beijing Aeronautical Manufacturing Technology Research Institute, Beijing 100024 (China); Zeng, Y.S., E-mail: yszeng@hotmail.com [AVIC Beijing Aeronautical Manufacturing Technology Research Institute, Beijing 100024 (China)

    2017-05-02

    Friction stir welded (FSW) joints of conventional precipitation-hardened aluminum alloys usually fracture in the lowest hardness zone (LHZ) during tension testing. However, all of the FSW joints of a 2198-T8 Al-Li alloy fractured in the stirred zone (SZ) instead of the LHZ with the welding parameters of 800 rpm-200 mm/min and 1600 rpm-200 mm/min under the condition that no welding defects existed in the SZ. The experiment results revealed that lazy S was not the dominant factor resulting in the unusual fracture. The SZ consisted of three subzones, i.e., the shoulder-affected zone, the pin-affected zone, and the transition zone between them. While the former two zones were characterized by fine and equiaxed recrystallized grains, incompletely dynamically recrystallized microstructure containing coarse elongated non-recrystallized grains was observed in the transition zone. The transition zone exhibited the lowest average Taylor factor in the SZ, resulting in a region that was crystallographically weak. Furthermore, obvious lithium segregation at grain boundaries was observed in the transition zone via time-of-flight secondary ion mass spectroscopy analysis, but not in the shoulder-affected zone or the pin-affected zone. The combined actions of both the two factors resulted in the appearance of preferential intergranular fracture in the transition zone and eventually caused the failure in the SZ. The lithium segregation at grain boundaries in the transition zone was closely associated with both the segregation in the base material and the partially dynamically recrystallized microstructure resulting from the inhomogeneous plastic deformation in the SZ.

  14. Origin of unusual fracture in stirred zone for friction stir welded 2198-T8 Al-Li alloy joints

    International Nuclear Information System (INIS)

    Tao, Y.; Ni, D.R.; Xiao, B.L.; Ma, Z.Y.; Wu, W.; Zhang, R.X.; Zeng, Y.S.

    2017-01-01

    Friction stir welded (FSW) joints of conventional precipitation-hardened aluminum alloys usually fracture in the lowest hardness zone (LHZ) during tension testing. However, all of the FSW joints of a 2198-T8 Al-Li alloy fractured in the stirred zone (SZ) instead of the LHZ with the welding parameters of 800 rpm-200 mm/min and 1600 rpm-200 mm/min under the condition that no welding defects existed in the SZ. The experiment results revealed that lazy S was not the dominant factor resulting in the unusual fracture. The SZ consisted of three subzones, i.e., the shoulder-affected zone, the pin-affected zone, and the transition zone between them. While the former two zones were characterized by fine and equiaxed recrystallized grains, incompletely dynamically recrystallized microstructure containing coarse elongated non-recrystallized grains was observed in the transition zone. The transition zone exhibited the lowest average Taylor factor in the SZ, resulting in a region that was crystallographically weak. Furthermore, obvious lithium segregation at grain boundaries was observed in the transition zone via time-of-flight secondary ion mass spectroscopy analysis, but not in the shoulder-affected zone or the pin-affected zone. The combined actions of both the two factors resulted in the appearance of preferential intergranular fracture in the transition zone and eventually caused the failure in the SZ. The lithium segregation at grain boundaries in the transition zone was closely associated with both the segregation in the base material and the partially dynamically recrystallized microstructure resulting from the inhomogeneous plastic deformation in the SZ.

  15. Prediction of mechanical properties in friction stir welds of pure copper

    International Nuclear Information System (INIS)

    Heidarzadeh, A.; Saeid, T.

    2013-01-01

    Highlights: • Range of parameters for defect-free friction stir welded pure copper was reached. • Models were developed for predicting UTS, TE and hardness of pure copper joints. • Analysis of variance was used to validate the developed models. • Effect of welding parameters on mechanical behavior of welded joints was explored. • The microstructure and fracture surface of welded joints were investigated. - Abstract: This research was carried out to predict the mechanical properties of friction stir welded pure copper joints. Response surface methodology based on a central composite rotatable design with three parameters, five levels, and 20 runs, was used to conduct the experiments and to develop the mathematical regression model by using of Design-Expert software. The three welding parameters considered were rotational speed, welding speed, and axial force. Analysis of variance was applied to validate the predicted models. Microstructural characterization and fractography of joints were examined using optical and scanning electron microscopes. Also, the effects of the welding parameters on mechanical properties of friction stir welded joints were analyzed in detail. The results showed that the developed models were reasonably accurate. The increase in welding parameters resulted in increasing of tensile strength of the joints up to a maximum value. Elongation percent of the joints increased with increase of rotational speed and axial force, but decreased by increasing of welding speed, continuously. In addition, hardness of the joints decreased with increase of rotational speed and axial force, but increased by increasing of welding speed. The joints welded at higher heat input conditions revealed more ductility fracture mode

  16. Optimization of Thermo-mechanical Conditions in Friction Stir Welding

    DEFF Research Database (Denmark)

    Tutum, Cem Celal

    with the Seqquential Quadratic Programming (SQP) gradient-based optimization algorithm in order to find the welding speed and the heat input that would yield a prescribed average temperature close to the solidus temperature under the tool, thereby expressing a condition which is favourable for the process.......Several models for the FSW process have been applied. Initially, the thermal models were addressed since they in essence constitute the basis of all other models of FSW, be it microstructural, flow or residual stress models. Both analytical and numerical models were used and combined...

  17. Surface integrity analysis of abrasive water jet-cut surfaces of friction stir welded joints

    Czech Academy of Sciences Publication Activity Database

    Kumar, R.; Chattopadhyaya, S.; Dixit, A. R.; Bora, B.; Zeleňák, Michal; Foldyna, Josef; Hloch, Sergej; Hlaváček, Petr; Ščučka, Jiří; Klich, Jiří; Sitek, Libor; Vilaca, P.

    2017-01-01

    Roč. 88, č. 5 (2017), s. 1687-1701 ISSN 0268-3768 R&D Projects: GA MŠk(CZ) LO1406; GA MŠk ED2.1.00/03.0082 Institutional support: RVO:68145535 Keywords : friction stir welding (FSW) * abrasive water jet (AWJ) * optical profilometer * topography * surface roughness Subject RIV: JQ - Machines ; Tools OBOR OECD: Mechanical engineering Impact factor: 2.209, year: 2016 http://link.springer.com/article/10.1007/s00170-016-8776-0

  18. Initial Development in Joining of ODS Alloys Using Friction Stir Welding

    Energy Technology Data Exchange (ETDEWEB)

    Ren, Weiju [ORNL; Feng, Zhili [ORNL

    2007-08-01

    Solid-state welding of oxide-dispersion-strengthened (ODS) alloy MA956 sheets using friction stir welding (FSW) was investigated. Butt weld was successfully produced. The weld and base metals were characterized using optical microscopy, scanning electronic microscopy, transmission electronic microscopy, and energy dispersion x-ray spectrum. Microhardness mapping was also conducted over the weld region. Analyses indicate that the distribution of the strengthening oxides was preserved in the weld. Decrease in microhardness of the weld was observed but was insignificant. The preliminary results seem to confirm the envisioned feasibility of FSW application to ODS alloy joining. For application to Gen IV nuclear reactor heat exchanger, further investigation is suggested.

  19. Microstructure and pitting corrosion of friction stir welded joints in 2219-O aluminum alloy thick plate

    International Nuclear Information System (INIS)

    Xu Weifeng; Liu Jinhe

    2009-01-01

    Effect of welding parameters on the microstructure and pitting corrosion of different positions along the thickness of weld nu