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FATIGUE BEHAVIOUR OF
FRICTION STIR WELDED
JOINTS
O Project Guide: Dr. A. RAZAL ROSE
O Team
Members:
O 1.AKSHANSH MISHRA
(1021310334)
O 2.SARAVANAN M (1021310333)
O 3.ANAND SINGH (1021310338)
O
CONTENTS
O OBJECTIVE
O INTRODUCTION
O METHODOLOGY
O REFERENCES
OBJECTIVE
O Evaluating the Weldability and Fatigue behaviour of
Magnesium Alloy Friction Stir Welded Joints.
INTRODUCTION
O Friction stir welding is the combine action of frictional
heating and mechanical deformation due to rotating tool.
In comparison to fusion welding process high quality
weld can be achieved, it requires low apparent energy in
inputs, and it leads to less distortion and less residual
stress.
O Friction Stir welding can be divided into three sub
phases:-
O 1) Plunge and dwell
O 2) Traverse
O 3) Dwell
Plunge and Dwell Phase
O At the start of plunge and dwell phase both tool and
work piece are at ambient temperature.
O When the rotating tool is inserted into the work piece,
the material is too cold to flow and the rubbing action
creates chipping as in any machining process.
O The rate of insertion determines the rate of temperature
rise and plasticity.
O For metals with higher melting point, the rotating tool is
sometimes intentionally retained at this position for short
time so as to reach desired temperature required for
plastic flow. This is known as Dwell Phase.
Traverse and Retract Phase
O Traverse Phase: Once the work piece interface is
sufficiently heated up, the tool is traversed along the
desired direction to accomplish joining. This is actual
welding phase.
O Retract Phase: On completion of joining process, the
tool is finally retracted from the work piece.
Methodology
O Analyse the bar material properties
O Prepare the weld specimen
O Conduct the experiment
O Characterize the welded joints
O Analyse the fatigue behaviour of FSW
joint
O Result and Conclusion
Material Composition
O Magnesium (Mg) is strong, stiff, and lightweight, making it the
most widely used element in engineered structures after iron
and Aluminium. Its strength and stiffness can be further
improved when alloyed with Aluminium.
O Nevertheless, bulk mechanical properties rely greatly on
chemical composition and thermo mechanical history, as these
factors influence microstructure..
O AZ 61 contains Aluminium (nominally 6%), zinc (nominally 1%),
and other trace elements. Table 1 summarizes the chemical
composition for AZ 61. The presence of zinc and other trace
elements has little impact on the microstructure, and the phase
diagram is used to deduce the composition of slowly cooled AZ
61.
Element % by mass
Aluminium 5-7
Zinc 0.8-1
Copper <0.03
Silicon <0.01
Iron <0.01
Nickel <0.005
Magnesium Balance
Mechanical Properties
Properties
Proof Stress 75-200 MPa
Tensile Strength 135-285MPa
Elongation 2-10%
Typical Density 1.8gm/c𝑚3
Young’s Modulus 42GPa
Applications
O Friction stir welding and its variants friction stir spot
welding and friction stir processing are used for the
following industrial applications :-
 Shipbuilding Industries
 Aerospace
 Robotics
 General Fabrication,
References
O A.RAZAL ROSE, K. MANISEKAR - Effect of axial force
on microstructure and tensile properties of friction stir
welded AZ61A magnesium alloy.
O D.R.NI, D.L.CHEN – Low cycle fatigue properties of
friction stir welded joints of semi-solid processed AZ91D
Magnesium alloy.

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FRICTION STIR WELDING PROJECT

  • 1. FATIGUE BEHAVIOUR OF FRICTION STIR WELDED JOINTS O Project Guide: Dr. A. RAZAL ROSE O Team Members: O 1.AKSHANSH MISHRA (1021310334) O 2.SARAVANAN M (1021310333) O 3.ANAND SINGH (1021310338) O
  • 2. CONTENTS O OBJECTIVE O INTRODUCTION O METHODOLOGY O REFERENCES
  • 3. OBJECTIVE O Evaluating the Weldability and Fatigue behaviour of Magnesium Alloy Friction Stir Welded Joints.
  • 4. INTRODUCTION O Friction stir welding is the combine action of frictional heating and mechanical deformation due to rotating tool. In comparison to fusion welding process high quality weld can be achieved, it requires low apparent energy in inputs, and it leads to less distortion and less residual stress. O Friction Stir welding can be divided into three sub phases:- O 1) Plunge and dwell O 2) Traverse O 3) Dwell
  • 5.
  • 6. Plunge and Dwell Phase O At the start of plunge and dwell phase both tool and work piece are at ambient temperature. O When the rotating tool is inserted into the work piece, the material is too cold to flow and the rubbing action creates chipping as in any machining process. O The rate of insertion determines the rate of temperature rise and plasticity. O For metals with higher melting point, the rotating tool is sometimes intentionally retained at this position for short time so as to reach desired temperature required for plastic flow. This is known as Dwell Phase.
  • 7. Traverse and Retract Phase O Traverse Phase: Once the work piece interface is sufficiently heated up, the tool is traversed along the desired direction to accomplish joining. This is actual welding phase. O Retract Phase: On completion of joining process, the tool is finally retracted from the work piece.
  • 8. Methodology O Analyse the bar material properties O Prepare the weld specimen O Conduct the experiment O Characterize the welded joints O Analyse the fatigue behaviour of FSW joint O Result and Conclusion
  • 9. Material Composition O Magnesium (Mg) is strong, stiff, and lightweight, making it the most widely used element in engineered structures after iron and Aluminium. Its strength and stiffness can be further improved when alloyed with Aluminium. O Nevertheless, bulk mechanical properties rely greatly on chemical composition and thermo mechanical history, as these factors influence microstructure.. O AZ 61 contains Aluminium (nominally 6%), zinc (nominally 1%), and other trace elements. Table 1 summarizes the chemical composition for AZ 61. The presence of zinc and other trace elements has little impact on the microstructure, and the phase diagram is used to deduce the composition of slowly cooled AZ 61.
  • 10. Element % by mass Aluminium 5-7 Zinc 0.8-1 Copper <0.03 Silicon <0.01 Iron <0.01 Nickel <0.005 Magnesium Balance
  • 11. Mechanical Properties Properties Proof Stress 75-200 MPa Tensile Strength 135-285MPa Elongation 2-10% Typical Density 1.8gm/c𝑚3 Young’s Modulus 42GPa
  • 12. Applications O Friction stir welding and its variants friction stir spot welding and friction stir processing are used for the following industrial applications :-  Shipbuilding Industries  Aerospace  Robotics  General Fabrication,
  • 13. References O A.RAZAL ROSE, K. MANISEKAR - Effect of axial force on microstructure and tensile properties of friction stir welded AZ61A magnesium alloy. O D.R.NI, D.L.CHEN – Low cycle fatigue properties of friction stir welded joints of semi-solid processed AZ91D Magnesium alloy.