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friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
friction stir welding of aluminium alloy
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friction stir welding of aluminium alloy

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  • 1. A Presentation onEffect of Friction Stir Welding on mechanical properties and formability of thin commercial Al blanks Submitted by Manish Singh (2011MEP3270) Under the guidance of Dr. S. Aravindan and Dr. D. Ravi Kumar Department of Mechanical Engineering Indian Institute of Technology, Delhi
  • 2. Contents1. Introduction2. Experimental setup3. Experimental procedure4. Results and discussion5. Conclusion6. Gantt chart7. References
  • 3. Friction stir welding : FSW is a solid–state, hot–shearjoining process in which a rotating tool with a shoulder movesalong the butting surfaces of two rigidly clamped plates placed ona backing plate as shown in Fig. Schematic illustration of the Friction Stir Welding process[1].
  • 4. Friction Stir Welding Set up:1. Vertical Milling machine2. Fixture3. Backing Plate4. Tool5. Specimen
  • 5. Fixture:
  • 6. Backing PlateBacking plate (200X100X8 mm) used in FSW process.
  • 7. FSW ToolsTable 1- Tools Used for Welding Tool Tool 1 Tool 2 Tool 3 Tool Figure Tool pin 8 mm 12 mm 16 mm Diameter Tool dimensions Values Shoulder length (mm) 10 Shank diameter (mm) 19.95 Shank length (mm) 57
  • 8. Specimen: Specimen (170X50X1.7 mm).
  • 9. Experimental procedure No Yes
  • 10. Process parameterThe welding was carried out by using the selected variations of parameters as shownin Table1 which is obtained by Taguchi’s orthogonal array method for minimizingthe number of experiments. Welding Run Rotational Welding speed Tool diameter Depth of No. speed (rpm) (mm/min) (mm) plunging (mm) 1 450 80 8 0.2 2 450 160 12 0.2 3 450 250 16 0.2 4 560 160 8 0.2 5 560 250 12 0.2 6 560 80 16 0.2 7 710 250 8 0.2 8 710 80 12 0.2 9 710 160 16 0.2
  • 11. Table 4- Vickers Hardness values of all samples with respect to weld region Distance from Centre Line Welding Run 1 Welding Run 4 Welding Run 7 Sample no. -7 44.9 44.4 45.6 -6 43.4 44.6 43.6 -5 43.32 42.4 42.6 -4 40.7 41.7 41.5 -3 42.5 40.1 40.6 -2 39.8 40.8 37.6 -1 37.9 39.3 37.5 0 41.8 38.1 36.3 1 38.6 36.9 38.3 2 41.2 36.8 40.0 3 42.4 39.5 41.3 4 42.6 41.5 41.6 5 42.8 41.1 41.9 6 43.8 40.6 42.1 7 44.2 44.6 43.8
  • 12. Microhardness profile of welded samples
  • 13. Limiting Dome Height Test of FS Welded Samples Welding Weld Run No. LDH Test Samples LDH (mm) Remarks parameters Rotational Failure Speed = 450 occurs from 11.04 rpm weld centre Welding line Run No. 1 Speed = 80 mm/min Failure Shoulder occurs from 13.76 Diameter = 8 TMAZ/HA mm Z
  • 14. WeldingWeld Run No. LDH Test Samples LDH (mm) Remarks parameters Rotational Speed = 560 Failure occurs rpm 12.72 from Welding TMAZ/HAZ Speed = 160 Run No. 4 mm/min Shoulder Failure occurs Diameter = 11.32 from Weld 8 mm centre line Welding parameters
  • 15. Welding LDHWeld Run No. LDH Test Samples Remarks parameters (mm) Failure Rotational occurs in Speed = 710 12.04 Weld centre rpm line Welding Run No. 7 Speed = 250 mm/min Failure Shoulder occurs from Diameter = 8 14.28 Weld centre mm line
  • 16. Tensile test Weld Nugget Tensile Sample along the Weld Weld Centre Line Tensile Sample Transverse to the Weld Hardness Sample Transverse to the Weld
  • 17. Conclusion:1. Hardness in advancing side is more than the retreating side in HAZ and TMAZ because the grain refinment is more in advancing side than retreating side.2. From the LDH tests, it is observed that LDH in run 7(710 rpm, 250 mm/min, 8mm) is higher than the LDH in run 1(450 rpm, 160 mm/min, 8mm) and run 4(560 rpm, 160 mm/min, 8mm). As formability strongly depends on mechanical properties of the welded blank, further tests (tensile tests and LDH tests) have to be carried out to draw the conclusions.3. In LDH tests the failure occurred in the weld region in some samples and in HAZ/TMAZ in other samples.
  • 18. Work done till now Time1. To study the literature and see the various aspect of project 25thJuly - 15th February2. Weld specimen preparation by friction stir welding process. 10th January- 25th January3. To study the micro-structure of weld specimen 25th January- 5th February4. Performance of micro hardness test and LDH test. 5th February - 18th February5. Report writing. 15th February -20th FebruaryWork to be done1. Weld specimen for remaining runs is going to be prepared.2. LDH tests and microhardness tests will be performed after that.
  • 19. Gantt chart Time June Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar. Apr. May ActivityLiteraturereviewSetuppreparationTWBspreparation byFSWSamplepreparation &MechanicaltestingForming testReportwriting
  • 20. References1. R. Nandan ,T. DebRoy ,H.K.D.H. Bhadeshia, Recent advances in friction-stir welding – Process, weldment structure and properties, Progress in Materials Science 53 (2008) 980–1023.2. J. Jeswiet, M. Geiger, U. Engel, M. Kleiner, M. Schikorra, J. Duflou, R. Neugebauer, P. Bariani, S. Bruschi, Metal forming progress since 2000, CIRP Journal of Manufacturing Science and Technology 1 (2008) 2–17.3. Amir Abbas Zadpoor, Jos Sinke, Rinze Benedictus, Raph Pieters, Mechanical properties and microstructure of friction stir welded tailor-made blanks, Materials Science and Engineering A 494 (2008) 281290.4. Sushanta Kumar Panda, D. Ravi Kumar, Improvement in formability of tailor welded blanks by application of counter pressure in biaxial stretch forming, journal of materials processing technology 2 0 4 ( 2 0 0 8 ) 70–79.5. R Ganesh Narayanan1 and K Narasimhan, Predicting the forming limit strains of tailor-welded blanks, The manuscript was received on 17 April 2008 and was accepted after revision for publication on 20 June 2008.6. M.Sivashanmugam, S.Ravikumar, T.Kumar, V.Seshagiri Rao, D.MuruganandamA Review on Friction Stir Welding for Aluminium Alloys, 978-1-4244-9082-0/10/$26.00 ©2010 IEEE7. D.M. Rodrigues, A. Loureiro, C. Leitao, R.M. Leal, B.M. Chaparro, P. Vilaça, Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds, Materials and Design 30 (2009) 1913–1921.8. Wonoh Lee, Kyung-Hwan Chung, Daeyong Ki, Junehyung Kim, Chongmin Kim, Kazutaka Okamoto, R.H. Wagoner, Kwansoo Chung, Experimental and numerical study on formability of friction stir welded TWB sheets based on hemispherical dome stretch tests, International Journal of Plasticity 25 (2009) 1626–1654.9. Daeyong Kim, WonohLee, JunehyungKim, ChongminKim, KwansooChung, Formability evaluation of friction stir welded 6111-T4 sheet with respect to joining material direction, International Journal of Mechanical Sciences 52 (2010) 612–625.10. Kwansoo Chung, Wonoh Lee, Daeyong Kim, Junehyung Kim, Kyung-Hwan Chung, Chongmin Kim, Kazutaka Okamoto, R.H. Wagoner, Macro-performance evaluation of friction stir welded automotive tailor- welded blank sheets: Part I – Material properties, International Journal of Solids and Structures 47 (2010) 1048–1062.

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