Ahmed ibrahim razooqi -- study the microstructure and mechanical properties of dissimilar friction stir spot welding of carbon steel 1006 to aluminum alloy aa2024-t3
Ahmed Ibrahim Razooqi ---
Study the microstructure and mechanical properties of dissimilar friction stir spot welding of carbon steel 1006 to aluminum alloy aa2024-t3.
Friction stir spot welding-FSSW has been suggested as effectual process to welding difficult materials such as dissimilar materials and
thin sheet of metal alloys. In this study, using dissimilar materials were welded carbon steel-1006 on upper plate and aluminum alloy
AA2024-T3 on lower plate. Macrostructure, micro-structural analysis and mechanical properties of the joints are done. The effect of
penetration depth, dwell time and spindle speed on tensile shear load are investigated with invariable of other parameter during welding
process. The maximum tensile shear load (3.31KN) was occurred when using 0.4mm of penetration depth, 10 sec of dwell time and 1400
rpm of spindle speed. Also, two type of failure shape was observed interfacial fracture of carbon steel sheet and pull -out fracture of
AA2024-T3 sheet.
Experimental Investigation of Tensile Strength and Deflection Characteristics...IOSR Journals
Aluminum alloys are used in many applications in which the combination of high strength and low
weight is attractive; ship building, air frame, transportation industry etc. are some areas in which the low
weight can be significant value. Friction stir welding (FSW) is a new welding technique particularly well suited
to aluminum alloys though this technique is also used for other materials. Friction stir welding promises joints
with low porosity, fine microstructures, minimum phase transformation and low oxidation compared to
conventional welding techniques. It is capable of joining combinations of alloys not amenable to conventional
welding.Experiments for tensile and deflection tests were carried out and reported in this research paper. The
base material used for friction stir welding was AA 6351–T4 Aluminum alloy. Tensile strength and breaking
loads were increased with increase of rotational speed of the tool but it drops after attaining marginal speed.
Deflections of friction stir welded specimens and base materials were compared and they exhibited almost
similar trends at different load conditions and deflections of all the specimens were increased with increment of
load
Effect of welding parameters and tool shape on properties of friction stir we...IJERA Editor
Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. It has many benefits when applied to welding of aluminum alloys. FSW process parameters such as welding speed, rotational speed and tool geometry play vital roles in the weld quality. The aim of this research is to investigate the effects of different welding speeds, rotational speeds and tool pin profile on the weld quality of a AA6061 aluminum alloy. A friction stir welding tool consists of rotating shoulder and pin that heats the working piece by friction and moves a softened alloy around it to form a joint. In this research work the effect of the tool shape and welding parameters (rotating speed and welding speed) on the mechanical properties of an aluminium plates will be investigated experimentally. The induced heat during the welding process played the main role in the mechanical and appearance of the joints, which is related to the welding parameters.
Effect Of Process Parameters On Mechanical Properties Of Friction Stir.Welded...IJERA Editor
Friction Stir Welding (FSW) is an advance joining process for different similar and dissimilar materials. It is
commonly used for joining of Aluminum alloys. However it is necessary to overcome some challenges for its
wide-spread uses. Tool design and the selection of process parameters are critical issues in the usage of this
process. This study focuses on the process parameters that is required for producing effective friction stir
welding of two similar aluminum alloys (AA6101T6 to AA6101T6) and dissimilar Aluminum alloys
(AA6101T6 alloy to AA6351T6) . Three different tool diameters such as 20 mm, 25 mm and 30 mm with three
different tool rotational speeds such as 600 rpm, 800 rpm and 1200 rpm have been used to weld the joints. The
welded samples were tested for mechanical properties as well as microstructure. It was observed that 30 mm
tool gives better weld quality for friction stir welding of similar aluminum alloy but 25 mm tool with 1200 rpm
rotational speed gave satisfactory weld quality for friction stir welding of dissimilar aluminum alloys. It is one
of the important welding process that can adopted for welding of aluminum alloys with excellent mechanical
properties. The results were confirmed by further experiments.
Experimental Investigation of Friction Stir Welding Of Aluminum Aa6061 Alloy ...iosrjce
The combination of wrought aluminum-magnesium-silicon alloy confirming to aluminum AA6061
alloy widely accepted because of light weight fabrication structures, high strength to weight ratio and good
corrosion resistance. 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 when compared to fusion welding process that are
routinely used for joining structural aluminum alloys. In this FSW process a non consumable tool is used to
generate frictional heat in the abutting surfaces. Experiments for surface roughness, Rockwell hardness and
tensile tests are carried out and reported in this paper. The base material used for friction stir welding is
aluminum AA 6061 alloy. Surface roughness values decreases with the increase in speed of the tool and also
there exists an optimum speed to have the good surface finish. Hardness increases with decrease in speed of the
tool but increases after reaching a certain value. Tensile strength increases with the increase in speed of the
tool and also there exists an optimum values for particular feed of the tool.
Through this paper an attempt is made to study and review a special welding technology of friction stir welding (FSW) which is a solid-state joining process. Friction Stir Welding (FSW) is a recent advanced technique, invented by The Welding Institute (TWI) in 1991, that utilizes a nonconsumable rotating welding tool to generate frictional heat and plastic deformation at the welding location; thereby, affecting the formation of a joint while the material is in the solid state. In particular, FSW can be used to join high-strength aerospace aluminum alloys and other high temperature metallic alloys that are difficult to weld by conventional fusion welding method. FSW is considered to be the most significant development in metal joining process in a decade The comprehensive body of knowledge that has built up with respect to the friction stir welding (FSW) of aluminum alloys. This study addresses the current state of understanding and development of the FSW process. The principles of weld formation, welding parameters, design principles, including metal flow and thermal history, before discussing how process parameters affect the weld properties Danail Abdullah"A Review of Friction Stirs Welding" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-1 | Issue-4 , June 2017, URL: http://www.ijtsrd.com/papers/ijtsrd124.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/124/a-review-of-friction-stirs-welding/danail-abdullah
Friction stir welding of aluminium 5086 alloyseSAT Journals
Abstract Friction Stir welding (FSW) is a solid state attachment method used for welding of metals of same and different metals. This process of friction stir welding (FSW) is widely using for the reason it can produces sound welds and doesn't have common issues like solidification and liquefaction cracking connected to the fusion techniques. The Friction stir welding of Al 5086 alloys had been commercialized and up to date interest is targeted on change of integrity with different metals. Thus on commercialize this method, analysis studies are required to characterize. particularly, FSW has impressed researchers to aim modification of integrity different metals like aluminum 5086 that differ in properties and sound welds with none or restricted inter metallic bonding of components has been done. In this paper we have to make a research on the current analysis state of FSW between aluminum 5086 with attention on the resulting welding and tensile strength, microstructure, elongation and the tools are used to produce the welds and also an insight into future analysis during this process of study the project of friction welding. By this process in our project we got an idea of going to maintain the rotational speed (rpm) 450 to 1400 and also by changing welding rpm (speed). This friction stir welding is used in nasa for joining of two totally different or same types of materials. Keywords: Friction stir welding, Tool, Welding parameters, and Mechanical properties etc…
Modeling and Simulation of Base Plate of Friction Stir Welding-Advanced Weldi...ijsrd.com
Friction stir processing is an emerging technique based on the principles of friction stir welding (FSW). It is a solid-state joining method that is energy efficient, environmentally friendly, and versatile. It is considered by many to be the most significant development in metal joining in a decade. The basic concept of friction stir processing is remarkably simple. A rotating tool with pin and shoulder is inserted in the material to be joined, and traversed along the line of interest. The heating is localized, and is generated by friction between the tool and the work piece, with additional adiabatic heating from metal deformation. A processed zone is produced by movement of material from the front of the pin to the back of the pin.
Experimental Investigation of Tensile Strength and Deflection Characteristics...IOSR Journals
Aluminum alloys are used in many applications in which the combination of high strength and low
weight is attractive; ship building, air frame, transportation industry etc. are some areas in which the low
weight can be significant value. Friction stir welding (FSW) is a new welding technique particularly well suited
to aluminum alloys though this technique is also used for other materials. Friction stir welding promises joints
with low porosity, fine microstructures, minimum phase transformation and low oxidation compared to
conventional welding techniques. It is capable of joining combinations of alloys not amenable to conventional
welding.Experiments for tensile and deflection tests were carried out and reported in this research paper. The
base material used for friction stir welding was AA 6351–T4 Aluminum alloy. Tensile strength and breaking
loads were increased with increase of rotational speed of the tool but it drops after attaining marginal speed.
Deflections of friction stir welded specimens and base materials were compared and they exhibited almost
similar trends at different load conditions and deflections of all the specimens were increased with increment of
load
Effect of welding parameters and tool shape on properties of friction stir we...IJERA Editor
Friction stir welding (FSW) is a widely used solid state joining process for soft materials such as aluminium alloys because it avoids many of the common problems of fusion welding. It has many benefits when applied to welding of aluminum alloys. FSW process parameters such as welding speed, rotational speed and tool geometry play vital roles in the weld quality. The aim of this research is to investigate the effects of different welding speeds, rotational speeds and tool pin profile on the weld quality of a AA6061 aluminum alloy. A friction stir welding tool consists of rotating shoulder and pin that heats the working piece by friction and moves a softened alloy around it to form a joint. In this research work the effect of the tool shape and welding parameters (rotating speed and welding speed) on the mechanical properties of an aluminium plates will be investigated experimentally. The induced heat during the welding process played the main role in the mechanical and appearance of the joints, which is related to the welding parameters.
Effect Of Process Parameters On Mechanical Properties Of Friction Stir.Welded...IJERA Editor
Friction Stir Welding (FSW) is an advance joining process for different similar and dissimilar materials. It is
commonly used for joining of Aluminum alloys. However it is necessary to overcome some challenges for its
wide-spread uses. Tool design and the selection of process parameters are critical issues in the usage of this
process. This study focuses on the process parameters that is required for producing effective friction stir
welding of two similar aluminum alloys (AA6101T6 to AA6101T6) and dissimilar Aluminum alloys
(AA6101T6 alloy to AA6351T6) . Three different tool diameters such as 20 mm, 25 mm and 30 mm with three
different tool rotational speeds such as 600 rpm, 800 rpm and 1200 rpm have been used to weld the joints. The
welded samples were tested for mechanical properties as well as microstructure. It was observed that 30 mm
tool gives better weld quality for friction stir welding of similar aluminum alloy but 25 mm tool with 1200 rpm
rotational speed gave satisfactory weld quality for friction stir welding of dissimilar aluminum alloys. It is one
of the important welding process that can adopted for welding of aluminum alloys with excellent mechanical
properties. The results were confirmed by further experiments.
Experimental Investigation of Friction Stir Welding Of Aluminum Aa6061 Alloy ...iosrjce
The combination of wrought aluminum-magnesium-silicon alloy confirming to aluminum AA6061
alloy widely accepted because of light weight fabrication structures, high strength to weight ratio and good
corrosion resistance. 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 when compared to fusion welding process that are
routinely used for joining structural aluminum alloys. In this FSW process a non consumable tool is used to
generate frictional heat in the abutting surfaces. Experiments for surface roughness, Rockwell hardness and
tensile tests are carried out and reported in this paper. The base material used for friction stir welding is
aluminum AA 6061 alloy. Surface roughness values decreases with the increase in speed of the tool and also
there exists an optimum speed to have the good surface finish. Hardness increases with decrease in speed of the
tool but increases after reaching a certain value. Tensile strength increases with the increase in speed of the
tool and also there exists an optimum values for particular feed of the tool.
Through this paper an attempt is made to study and review a special welding technology of friction stir welding (FSW) which is a solid-state joining process. Friction Stir Welding (FSW) is a recent advanced technique, invented by The Welding Institute (TWI) in 1991, that utilizes a nonconsumable rotating welding tool to generate frictional heat and plastic deformation at the welding location; thereby, affecting the formation of a joint while the material is in the solid state. In particular, FSW can be used to join high-strength aerospace aluminum alloys and other high temperature metallic alloys that are difficult to weld by conventional fusion welding method. FSW is considered to be the most significant development in metal joining process in a decade The comprehensive body of knowledge that has built up with respect to the friction stir welding (FSW) of aluminum alloys. This study addresses the current state of understanding and development of the FSW process. The principles of weld formation, welding parameters, design principles, including metal flow and thermal history, before discussing how process parameters affect the weld properties Danail Abdullah"A Review of Friction Stirs Welding" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-1 | Issue-4 , June 2017, URL: http://www.ijtsrd.com/papers/ijtsrd124.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/124/a-review-of-friction-stirs-welding/danail-abdullah
Friction stir welding of aluminium 5086 alloyseSAT Journals
Abstract Friction Stir welding (FSW) is a solid state attachment method used for welding of metals of same and different metals. This process of friction stir welding (FSW) is widely using for the reason it can produces sound welds and doesn't have common issues like solidification and liquefaction cracking connected to the fusion techniques. The Friction stir welding of Al 5086 alloys had been commercialized and up to date interest is targeted on change of integrity with different metals. Thus on commercialize this method, analysis studies are required to characterize. particularly, FSW has impressed researchers to aim modification of integrity different metals like aluminum 5086 that differ in properties and sound welds with none or restricted inter metallic bonding of components has been done. In this paper we have to make a research on the current analysis state of FSW between aluminum 5086 with attention on the resulting welding and tensile strength, microstructure, elongation and the tools are used to produce the welds and also an insight into future analysis during this process of study the project of friction welding. By this process in our project we got an idea of going to maintain the rotational speed (rpm) 450 to 1400 and also by changing welding rpm (speed). This friction stir welding is used in nasa for joining of two totally different or same types of materials. Keywords: Friction stir welding, Tool, Welding parameters, and Mechanical properties etc…
Modeling and Simulation of Base Plate of Friction Stir Welding-Advanced Weldi...ijsrd.com
Friction stir processing is an emerging technique based on the principles of friction stir welding (FSW). It is a solid-state joining method that is energy efficient, environmentally friendly, and versatile. It is considered by many to be the most significant development in metal joining in a decade. The basic concept of friction stir processing is remarkably simple. A rotating tool with pin and shoulder is inserted in the material to be joined, and traversed along the line of interest. The heating is localized, and is generated by friction between the tool and the work piece, with additional adiabatic heating from metal deformation. A processed zone is produced by movement of material from the front of the pin to the back of the pin.
TENSILE BEHAVIOUR OF ALUMINIUM PLATES (5083) WELDED BY FRICTION STIR WELDING IAEME Publication
Using arc welding, gas welding and other welding process, it is very difficult to weld the aluminum alloys. Friction stir welding, on the other hand, can be used to join most Al alloys and
better surface finishing is achieved. Although the work piece does heat up during friction stir weld, the temperature does not reach the melting point.
1 ijcmes dec-2015-17-optimization of friction stir welding parameters for joi...INFOGAIN PUBLICATION
Friction stir welding was a promising welding technology from the same moment of its existence because of its easy use, being ecologically friendly processed and with no need for filler metal. The present paper discusses the investigate the mechanical properties in order to demonstrate the feasibility of friction stir welding for joining Al 6061 aluminum alloy welding was performed on pipe. The pipe sections, 30mm, and relatively thin walled 2, 3 and 4 mm. Wire welded as similar alloy joints using (FSW) process In order to investigate the effect of rotation speed 485,710, 910, 1120,1400 and 1800 RPM and travel speeds 4, 8 and 10 mm/min. On mechanical propertie.
This work also focuses on mathematic models such as regression analysis (RA) to predict the tensile strength, the percentage of elongation and hardness of friction stir welded 6061 aluminum alloy. The Tensile strength, the percentage of elongation and hardness of weld joints were predicted by taking the parameters Tool rotation speed, material thickness and travel speed as a function. The results obtained through regresion analysis The models have been proved to be successful in terms of agreement with experimental results ratio 94.6%.
A Review on Optimization of the Process Parameters in Friction Stir Welding o...IJAEMSJORNAL
This study is describing a simple and systematic methodology for optimizing the Process parameters of friction stir welding (FSW) of (AA6105 and AA6082) aluminium alloy using Taguchi technique. The main focus of this review paper is to discuss FSW principle, process parameter and mechanical properties. The current study focuses on the friction stir welding of wrought aluminium alloys 6082 and aluminium alloy 6105 that are commonly used in the structural and automotive industries. Apart from this paper FSW process has been done on various aluminium alloys but dissimilar friction stir welding of these two materials are not reported in their research. A systematic study has been performed on the joint properties on the dissimilar welding of the selected materials and their relationships between various parameters.
Optimization of friction stir welding process parameter using taguchi method ...eSAT Journals
Abstract Friction stir welding (FSW) is relatively new solid state joining process. This joining technique is energy efficient, environment friendly and versatile. Welding is a multiinput-output process in which quality of welded joint is depends upon a input parameter. Therefore optimization of input process parameter is required to achieve good quality of welding. There are so many methods of optimization in which Taguchi method and Response surface methodology are selected for optimization of process parameter. In this review the effect of process parameter on welded joint studied and optimizes the parameter by using Taguchi method and Response surface methodology. The study of Friction stir welding of Aluminium alloy and High density polyethylene sheets shows the improvement in welded joint quality by optimization of process parameter. The main process parameters which affect the strength of welded joint is tool rotational speed, welding speed, axial force and tool pin profile. Keywords: Friction stir welding (FSW), Optimization, Taguchi Method Response surface Methodology Prediction models
Characterization and processing of friction stir welding on copper weldseSAT Journals
Abstract FSW(Friction Stir Welding) is a welding technology will be a part of different metals with sensible properties. During this paper, fsw attachment b/n steel, aluminum and copper plates with thicknesses of 3 millimeter was welded. Here we tend to had considered completely different completely different} materials with different combinations i.e copper and copper, copper and aluminum, aluminum & stainless steel, stainless steel & copper. Friction Stir Welding experiments were employed to get the good wieldable properties by maintaining the rpm speeds to 1120 revolutions per minute and attachment speed within the limit of 14-112 mm/min and here we can adjust the pin profile of the location respect to the line butt. Micro struc analysis can be done for examine the parent and the welded material. Cutting and sectioning of the welded pieces for metallographic analysis of the planes which are perpendicular for the attachment and the travelling direction & which is parallel to the friction welding was done. Here the mechanical properties of welding which was were determined by employing the same standard micro hardness and also tensile hardness testing and finding the maximum elongation of the metals to the properties of fsw. From experimental fsw process it can be found the pin profile and also the rotational speed, feed is an important in manufacturing of free welds in fsw of aluminum, copper and steel. Key Words: FSW, Aluminum, copper, stainless steel.
Fatigue Performance in Grinding and Turning: An OverviewIJMER
This paper analysis the influence of Abrasive Flow Machining (AFM), Turning and Grinding on
fatigue performance of Fe250. Surface condition has a strong effect on fatigue life, and that most surfaces
produced by conventional manufacturing operations such as machining and forging have poor fatigue
behavior than polished surfaces commonly used for laboratory specimens. It is found that the surfaces
produced with different machining process and having the same surface roughness having different fatigue
performances. High –cycle fatigue data was obtained for Fe 250 using three types of machining process
viz, AFM, Turning and Grinding .S-N curve is plotted for the samples obtained with all the three process. It
was found that the samples produced with AFM having the highest fatigue life.
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
FRICTION STIR WELDING OF ALUMINIUM ALLOYS - A REVIEWIAEME Publication
This welding is a novel process used to join metallic alloys. Friction stir welding is in vogue in aerospace, automotive and other industrial establishments for connecting alloys like aluminum, magnesium and copper. Rotational speed, welding speed and the angle of attack are important in the process of FSW. They analyze the weld quality. FSW produces stronger weld joint then the original material in selected parameters. FSW is a solid-state process, where metal is not melted uses a cylindrical shouldered tool with a profiled pin rotated and gradually plunged into the weld joint between two metal parts of plate or sheet that are to be welded together.
EFFECT OF FORGE FORCE ON MECHANICAL PROPERTIES OF DISSIMILAR METAL FRICTION W...IAEME Publication
Several structural applications demand use of steels like low carbon steels and stainless steels because their sound weldability and ductility. Fusion welding of these steels especially in dissimilar metal combination attracts many problems such as cracking, porosity, low ductility etc. To overcome these problems, solid-state welding processes such as friction welding has to be employed as it can provide a solution to the recurrent problems arising in fusion welding. An attempt is made in this work to study the effect of forge force on mechanical properties such as tensile strength and impact toughness of the similar and dissimilar metal friction welds of stainless steel and low carbon steel. It is observed that tensile strength of dissimilar metal welds increased with increase in the forge force while the impact toughness decreased with increase in the forge force.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Experimental Analysis to Optimize parameters of Friction Stir Welding of Alum...IJSRD
This paper is a review of research work in the last decade on friction stir welding. In many industrial applications steel is readily replaced by non-ferrous alloys like aluminum alloys. Aluminum alloys having good mechanical properties as equated structural steel and low weight that allows a significant reduction in weight. But the welding of aluminum alloys by regular processes can causes serious problems. The difficulties are like loss of alloying elements and presence of separation and porosities in the weld joint. Friction stir welding (FSW) is a solid state welding process, which removes all these problems of solidification related with the conventional fusion welding processes. In this research work an attempt has been made to develop an the relationship between FSW variables (tool rotation and tilt angle) and tensile strength and yield strength of number of pass friction stir welded aluminium alloy AA 6082 butt joints. Taguchi method is used for analysing the problem in which several independent variables influence the response. A three-parameter -three-level central composite design was used to determine the optimal factors of friction stir welding process for aluminium alloy.
TENSILE BEHAVIOUR OF ALUMINIUM PLATES (5083) WELDED BY FRICTION STIR WELDING IAEME Publication
Using arc welding, gas welding and other welding process, it is very difficult to weld the aluminum alloys. Friction stir welding, on the other hand, can be used to join most Al alloys and
better surface finishing is achieved. Although the work piece does heat up during friction stir weld, the temperature does not reach the melting point.
1 ijcmes dec-2015-17-optimization of friction stir welding parameters for joi...INFOGAIN PUBLICATION
Friction stir welding was a promising welding technology from the same moment of its existence because of its easy use, being ecologically friendly processed and with no need for filler metal. The present paper discusses the investigate the mechanical properties in order to demonstrate the feasibility of friction stir welding for joining Al 6061 aluminum alloy welding was performed on pipe. The pipe sections, 30mm, and relatively thin walled 2, 3 and 4 mm. Wire welded as similar alloy joints using (FSW) process In order to investigate the effect of rotation speed 485,710, 910, 1120,1400 and 1800 RPM and travel speeds 4, 8 and 10 mm/min. On mechanical propertie.
This work also focuses on mathematic models such as regression analysis (RA) to predict the tensile strength, the percentage of elongation and hardness of friction stir welded 6061 aluminum alloy. The Tensile strength, the percentage of elongation and hardness of weld joints were predicted by taking the parameters Tool rotation speed, material thickness and travel speed as a function. The results obtained through regresion analysis The models have been proved to be successful in terms of agreement with experimental results ratio 94.6%.
A Review on Optimization of the Process Parameters in Friction Stir Welding o...IJAEMSJORNAL
This study is describing a simple and systematic methodology for optimizing the Process parameters of friction stir welding (FSW) of (AA6105 and AA6082) aluminium alloy using Taguchi technique. The main focus of this review paper is to discuss FSW principle, process parameter and mechanical properties. The current study focuses on the friction stir welding of wrought aluminium alloys 6082 and aluminium alloy 6105 that are commonly used in the structural and automotive industries. Apart from this paper FSW process has been done on various aluminium alloys but dissimilar friction stir welding of these two materials are not reported in their research. A systematic study has been performed on the joint properties on the dissimilar welding of the selected materials and their relationships between various parameters.
Optimization of friction stir welding process parameter using taguchi method ...eSAT Journals
Abstract Friction stir welding (FSW) is relatively new solid state joining process. This joining technique is energy efficient, environment friendly and versatile. Welding is a multiinput-output process in which quality of welded joint is depends upon a input parameter. Therefore optimization of input process parameter is required to achieve good quality of welding. There are so many methods of optimization in which Taguchi method and Response surface methodology are selected for optimization of process parameter. In this review the effect of process parameter on welded joint studied and optimizes the parameter by using Taguchi method and Response surface methodology. The study of Friction stir welding of Aluminium alloy and High density polyethylene sheets shows the improvement in welded joint quality by optimization of process parameter. The main process parameters which affect the strength of welded joint is tool rotational speed, welding speed, axial force and tool pin profile. Keywords: Friction stir welding (FSW), Optimization, Taguchi Method Response surface Methodology Prediction models
Characterization and processing of friction stir welding on copper weldseSAT Journals
Abstract FSW(Friction Stir Welding) is a welding technology will be a part of different metals with sensible properties. During this paper, fsw attachment b/n steel, aluminum and copper plates with thicknesses of 3 millimeter was welded. Here we tend to had considered completely different completely different} materials with different combinations i.e copper and copper, copper and aluminum, aluminum & stainless steel, stainless steel & copper. Friction Stir Welding experiments were employed to get the good wieldable properties by maintaining the rpm speeds to 1120 revolutions per minute and attachment speed within the limit of 14-112 mm/min and here we can adjust the pin profile of the location respect to the line butt. Micro struc analysis can be done for examine the parent and the welded material. Cutting and sectioning of the welded pieces for metallographic analysis of the planes which are perpendicular for the attachment and the travelling direction & which is parallel to the friction welding was done. Here the mechanical properties of welding which was were determined by employing the same standard micro hardness and also tensile hardness testing and finding the maximum elongation of the metals to the properties of fsw. From experimental fsw process it can be found the pin profile and also the rotational speed, feed is an important in manufacturing of free welds in fsw of aluminum, copper and steel. Key Words: FSW, Aluminum, copper, stainless steel.
Fatigue Performance in Grinding and Turning: An OverviewIJMER
This paper analysis the influence of Abrasive Flow Machining (AFM), Turning and Grinding on
fatigue performance of Fe250. Surface condition has a strong effect on fatigue life, and that most surfaces
produced by conventional manufacturing operations such as machining and forging have poor fatigue
behavior than polished surfaces commonly used for laboratory specimens. It is found that the surfaces
produced with different machining process and having the same surface roughness having different fatigue
performances. High –cycle fatigue data was obtained for Fe 250 using three types of machining process
viz, AFM, Turning and Grinding .S-N curve is plotted for the samples obtained with all the three process. It
was found that the samples produced with AFM having the highest fatigue life.
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
FRICTION STIR WELDING OF ALUMINIUM ALLOYS - A REVIEWIAEME Publication
This welding is a novel process used to join metallic alloys. Friction stir welding is in vogue in aerospace, automotive and other industrial establishments for connecting alloys like aluminum, magnesium and copper. Rotational speed, welding speed and the angle of attack are important in the process of FSW. They analyze the weld quality. FSW produces stronger weld joint then the original material in selected parameters. FSW is a solid-state process, where metal is not melted uses a cylindrical shouldered tool with a profiled pin rotated and gradually plunged into the weld joint between two metal parts of plate or sheet that are to be welded together.
FRICTION STIR WELDING OF ALUMINIUM ALLOYS - A REVIEW
Similar to Ahmed ibrahim razooqi -- study the microstructure and mechanical properties of dissimilar friction stir spot welding of carbon steel 1006 to aluminum alloy aa2024-t3
EFFECT OF FORGE FORCE ON MECHANICAL PROPERTIES OF DISSIMILAR METAL FRICTION W...IAEME Publication
Several structural applications demand use of steels like low carbon steels and stainless steels because their sound weldability and ductility. Fusion welding of these steels especially in dissimilar metal combination attracts many problems such as cracking, porosity, low ductility etc. To overcome these problems, solid-state welding processes such as friction welding has to be employed as it can provide a solution to the recurrent problems arising in fusion welding. An attempt is made in this work to study the effect of forge force on mechanical properties such as tensile strength and impact toughness of the similar and dissimilar metal friction welds of stainless steel and low carbon steel. It is observed that tensile strength of dissimilar metal welds increased with increase in the forge force while the impact toughness decreased with increase in the forge force.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Experimental Analysis to Optimize parameters of Friction Stir Welding of Alum...IJSRD
This paper is a review of research work in the last decade on friction stir welding. In many industrial applications steel is readily replaced by non-ferrous alloys like aluminum alloys. Aluminum alloys having good mechanical properties as equated structural steel and low weight that allows a significant reduction in weight. But the welding of aluminum alloys by regular processes can causes serious problems. The difficulties are like loss of alloying elements and presence of separation and porosities in the weld joint. Friction stir welding (FSW) is a solid state welding process, which removes all these problems of solidification related with the conventional fusion welding processes. In this research work an attempt has been made to develop an the relationship between FSW variables (tool rotation and tilt angle) and tensile strength and yield strength of number of pass friction stir welded aluminium alloy AA 6082 butt joints. Taguchi method is used for analysing the problem in which several independent variables influence the response. A three-parameter -three-level central composite design was used to determine the optimal factors of friction stir welding process for aluminium alloy.
A Review on Effect of Process Parameters on Tensile Strength of Friction Stir...ijsrd.com
Friction stir welding (FSW) is an innovative solid state joining process. This paper discuss about the friction stir welding of joining heat treated aluminum alloys for Aerospace and Automobile industries. These welded joints have higher tensile strength to weight ratio and finer micro structure. FSW of aluminum alloys have the potential to hold good mechanical and metallurgical properties. An attempt is made to determine and evaluate the influence of the process parameters of FSW on the weldments. The aim of this study was to investigate the effect of process parameters on the tensile strength of the welded joints.
FRICTION STIR WELDING OF AA6063- EXPERIMENTATION AND TESTINGijiert bestjournal
Generally,for joining process for soft materials s uch as aluminum alloys and also for hard materials like steels friction stir welding is usedas it avoids ma ny of the common problems obtained in fusion weldin g. Also if we gone through joining of aluminum alloys could be usually faced problems in many cases available in various fields like automotive,aerosp ace,ship building industries,electronics etc. whe re fusion welding is not possible due to large differe nce in physical and chemical properties of the components to be joined. Mainly the problems occurr ed in the welding processes like porosity formation,solidification cracking,and chemical reaction may arise during fusion welding of dissimilar materials . Even if good welded joints may be obtained in some limited cases with special attentions to the joint design and preparation,process parameters and fill er metals. For avoiding the drawbacks of fusion welding friction stir welding (FSW) seems to be a v ery reliable technique as it permits welding of aluminum alloys.To avoid the majorly obtained healt h defects observed during traditional welding methods or fusion welding it can be used. The produ ctions of ultraviolet rays and the gases produced i n the process which are harmful to human beings are minim ized to large extent. The parts produces in FSW of aluminum alloys have been becoming increasingly sig nificant in industrial applications because of thei r technical and economicbenefits.
Study of Pitting Corrosion Behavior of FSW weldments of AA6101- T6 Aluminium ...IJERA Editor
Friction Stir Welding (FSW) is a promising solid state joining process widely used generally for Al alloys,
especially in aerospace, marine and automobile applications. In present work, the microstructure and corrosion
behavior of friction stir welded AA6101 T6 Al alloy is studied. The friction stir welding was carried using
vertical milling machine with different tool rotational speeds and welding speeds. The microstructure at weld
nugget or stir zone (SN), thermo-mechanically affected zone (TMAZ), heat affected zone (HAZ) and base metal
were observed using optical microscopy. The corrosion tests of base alloy and welded joints were carried out in
3.5% NaCl solution at temperature of 30º C. Corrosion rate and emf were determined using cyclic polarization
measurement.
EVALUATION OF PROCESSES PARAMETER AND MECHANICAL PROPERTIES IN FRICTION STIR ...IAEME Publication
The present study focuses on Friction Stir Welding of steel being very popular due to the vast application in the fields of automotive and ship building industries. The main constrained of welding steel has considered due to severe loads and temperatures at the interface of FSW tool and parent materials. Ti and pcBN based alloys are suitable for joining steel alloys up to 15 mm thick was found during study. Many researchers carried out study on FSW of steel and found on weld process parameters, mechanical properties, microstructure and the tool employed to produce the weld. It was found that carbon content, welding speed as well as the rotational speed affects between the mechanical properties and the microstructure of the weld.
A STUDY OF EFFECT PROCESS PARAMETERS ON TENSILE STRENGTH IAEME Publication
Friction stir welding (FSW) is a comparatively innovative solids-state joining
process. This joining mechanism is very energy efficient, environment friendly and
multitalented. The aim of this paper is improvement an affiliation between in the welding
parameters and mechanical properties of the AA6061T-6 type of aluminum alloy using
the friction stir welding mechanism .The effects of the various processing parameters
they are, tool rotational speed, traverse speed, axial force and geometry play tool they
are play an important role on the quality of welded joining. The FSW joints mechanism
have advanced tensile strength to the heaviness ratio. The present work of this paper is
done to think about the impact of the contribution parameters on the tensile strength.
The tensile welding parameters mainly influenced by the following variables they are
weld speed, feed, and tilt angle. The parameters are take these of the examiner attributes
they are the attributes are rotational speed, weld speed, axial force, shoulder diameter
and tilt angle. From this examination it is found that the square tool pin profile
producers are mechanically sound defect free welds compare to the tool to pin effects
Similar to Ahmed ibrahim razooqi -- study the microstructure and mechanical properties of dissimilar friction stir spot welding of carbon steel 1006 to aluminum alloy aa2024-t3 (20)
Experimental and numerical analysis of expanded pipe using rigid conical shap...ahmed Ibrahim
The experimental and numerical analysis was performed on pipes suffering large plastic deformation through expanding them using rigid conical shaped mandrels, with three different
cone angles (15◦, 25◦, 35◦) and diameters (15, 17, 20) mm. The experimental test for the strain results investigated the expanded areas. A numerical solution of the pipes expansion process was
also investigated using the commercial finite element software ANSYS. The strains were
measured for each case experimentally by stamping the mesh on the pipe after expanding, then compared with Ansys results. No cracks were generated during the process with the selected
angles. It can be concluded that the strain decreased with greater angles of conical shape and an increase in expansion ratio results in an increase of expansion force and a decrease in the pipe thickness and length resulting in pipe thinning and shortening. Good agreement is evident between experimental and ANSYS results within discrepancy (16.90017%) in the X direction and (27.68698%) in the Y direction. Also, the stress distribution is investigated and it can be concluded that the case of Diameter (Do cone) = 35mm and (A) = α = 15° is the optimum.K
Ahmed ibrahim razooqi...corrosion conduct of austenitic stainless steel 316 l...ahmed Ibrahim
Corrosion conduct of Austenitic stainless steel 316L subjected
to surface treatment.
Abstract. The influence of low temperature liquid nitriding as a surface heat treatment analogy
with laser peening treatment at the various of throbs on pitting corrosion of the “AISI 316L
Austenitic stainless steel” is investigated in this paper. According to typical ASTM (G71-31) a
number of corrosion examination samples are equipped with the measurements of (15 * 15 * 3)
mm which distributed into the many groups. Three sets were exposed to liquid nit riding
process at temperatures of (500, 400, 300) Co for one hour. The specimens (without coating)
were exposed to a number of the throbs (1,2,3) by laser peening. Microstructure varia tions,
compression residual stress, hardness, were inspected in this work. The corrosion and its
variables (potential cell, current density) were also evaluated using the potential stat
examination and applying the Tafel method using saltwater solution (3.5% NaCl). Tafle
equation was used to compute the corrosion degree. The results revealed that the liquid
nitriding participated to raise the corrosion rate at (500) Co, compared to the original metal
because of chromium nitride and also leaser peening participated to the increase in the
corrosion rate due to plastic deformation which led to the heterogeneity in the microstructure
but liquid nitriding at temperature (400) oC gave the best result where it was closer to the parent
metal’s, also laser peening at one throb showed the lower corrosion rate.
Patented + براءة اختراع (Ahmed.I.Razooqi)ahmed Ibrahim
Helical and slotted cylinder springs are indispensable elements in mechanical engineering. This Patented investigates helical and slotted cylinder springs subjected to axial loads under static and dynamic conditions. The objective is to determine the stiffness of a circular cross-section helical coil compression spring and slotted cylinder springs with five sizes and dynamic characteristics. A theoretical and finite element models are developed and presented in order to describe the various steps undertaken to calculate the spring’s stiffnesses. Five cases of the spring’s geometric are presented. A finite element model was generated using ANSYS software and the stiffness matrix evaluated by applying a load along the spring’s axis, then calculating the corresponding changes in deformation. The stiffness is obtained by solving the changes of load and deformation. The natural frequencies, mode shapes and transient response of springs are also determined. Finally, a comparison of the stiffnesses are obtained using the theoretical methods and those obtained from the finite element analysis were made and good agreement are evident and it can be found that the stiffness of spring for the slotted cylinder spring is much larger than that for helical spring and the stiffness for slotted cylinder spring increases with the number of slots per section. Natural frequencies, mode shape and transient response of helical spring and slotted cylinder spring have been represented in ANSYS software and results have been compared and it found that the natural frequency has also increased in the same proportion of stiffness because the natural frequency is directly proportional to the stiffness for all the cases that have been studied
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Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
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Data file handling has been effectively used in the program.
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Event Management System Vb Net Project Report.pdfKamal Acharya
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Final project report on grocery store management system..pdfKamal Acharya
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Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
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Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Courier management system project report.pdfKamal Acharya
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Ahmed ibrahim razooqi -- study the microstructure and mechanical properties of dissimilar friction stir spot welding of carbon steel 1006 to aluminum alloy aa2024-t3
2. 3038 International Journal of Engineering & Technology
Fig. 2: Picture of Micrograph for the Cross Section of (FSSW) [6].
The friction spot join method takes up between 2 to 5 sec, this
short time enough to generate of heat and formation of stir zone
lead to create a weld between the 2 contacting sheets. Notice high
peak temperatures gave a good contact interface between the adja-
cent material and rotating pin within the stir zone [9]
The basic difference between a conventional welding process and
the solid-state welding is that there is no melt of the work-sheet in
solid state welding method. It has many benefits of this method
such as weight reduction, cost savings, low maintenance, better
work environment ,recyclability and high consistence compared to
other Al spot welding processes such as riveting and
(RSW)resistance spot welding. Friction stir spot welding of high-
er-melt metals and alloys, including aluminum, stainless steel,
steels ,titanium and nickel are quite a few successful applications
of friction stir welding [2].
The welding of steel and aluminum is become a prime research
subject for automobile industry because of modern demands for
light weight hybrid designs, high strength, corrosion resistance
and improved crash properties. The welding technologies of these
two materials are perfectly limited by their different chemical and
physical properties. So that the avoid brittle intermetallic phases
between (Fe+Al), the problem of formation of thick and to avoid
the different melting points of materials ,adhesive joining is the
main used welding technology for these types of joints in manu-
facturing process. Friction stir spot welding process provides by
best durability and results [10].
K. O. Sanusi et al. in (2017 )evaluated the material characteriza-
tion of dissimilar (FSSW) process between Al and Cu alloy. The
condition of this process (800 rpm) of rotational speed (50, 150,
250) mm/min of transverse speeds and the total number of speci-
mens used was 9 altogether. The spot welds were characterized by
using (SEM)scanning electron microscopy and (OEM)optical
microscope. In addition of microstructure cross-section of the
weld, the shear test of the spot welding was done. Show from
results the welding between metals and alloys was successful by
used FSSW and can be used in the many application of manufac-
turing [11].
E. Fereiduni et al. in (2015 )studied the effect of the dwell time
and rotational speed on microstructure and mechanical properties
of friction stir spot welded aluminum alloy AA5083 and 12 steel
alloy sheets, it was taken the dwell time (from 5 to 15 sec) for the
both rotation tool speed (900, 1100 r.p.m) and found the optimum
condition when using (900 r.p.m, 12 sec) reached to the max. fail-
ure load of 4020N [12].
T. Liyanage et al. in (2014) investigated spot joining between
AA6111 / low carbon steel sheets by using pin penetration depth
of 0.4 mm, plunge rate of 1 mm /sec and tool rotational speed of
3000 r.p.m. Although AA6111with low carbon steel dissimilar
joints friction spot welding overcame the failure strength proper-
ties needed resistance friction stir spot welding of aluminum alloy
as base material, the intermetallic phases and the finding many of
cracks lead to impact toughness properties and poor ductility [13].
G. Figner et al. in (2013) examined the dissimilar friction stir spot
welding (FSSW) of aluminum alloy AA5754 with 4alvanized
steel HX 340LAD. Specimen were produced for mechanical prop-
erties testing using a spindle Speeds range of 800-3 200 rpm,
dwell times range of 0- 8 sec, but the plunge depth 2.2 mm and
plunge rate (12 mm/min) were constant for all welding. Concluded
the maximum tensile shear strength was 8.3kN at 3 sec and 3200
rpm [10.]
H. Liu et al. in (2013) studied the friction stir spot welding of
(2A12-T4) aluminum alloy and investigated mechanical properties
and micro-structural characteristics of this joint. Found a softened
micro-structural area found in the joint, and it consisted of (SZ)
stir-zone, (TMAZ)thermal mechanically affected -zone and
(HAZ)heat affected-zone, also record minimum value of hardness
in the region of TMAZ and the maximum of hardness in the re-
gion of SZ because increasing welding heat input. The tensile
shear load of the weld increased with increasing rotation of tool
speed, but it decreased with decreasing shoulder plunging depth or
increasing plunge rate [14].
Sun et al. in (2013) welded AA6061-T6 with mild steel sheets at
(1mm) of thickness by using friction spot welding process. They
estimated that the ideal dwell time and rotational speed were and
2second and 700 rpm, respectively, when used 3 different pin
lengths (1, 1.3 and 1.5) mm to join the specimen .The max. tensile
shear strength (3200 N) was achieved for the tool at (1mm) pin
length at the ideal rotational speed and dwell time.
Adding that the results seen no notice intermetallic layer found
along welding between Al alloy and steel. [15].
Y.C. Chen et al. in (2012) welded Aluminum alloy (6111-T4) and
steel alloy (DC04) sheets by friction stir spot process and changed
these parameters weld times from 0.5-18 second, welding speed
from 60 to 2000 mm/min, but some of parameters were fixed in
experiments such as plunge depth of 0.1 mm and a low rotation
speed 800 rpm to reduce the heat input. The maximum fracture
energy of 6.5 kN.mm and maximum failure load of 3.5 kN was
obtained with weld time of only 1.1 second, welding speed of 1
m/min [16].
E .Taban et al. in (2009) joined between Al alloy (6061-T6) and
steel (AISI 1018) by using friction spot welding with many pa-
rameters and this welding evaluated by metallurgical analysis such
as micro-structural and (SEM) scanning electron microscopy, also
mechanical testing such as micro-hardness . Results of these tests
provide the failures were seen on the aluminum side in the plasti-
cized layer of the joint. Further, bond lines were seen by a thin
layer of formed Al–Fe inter-metallic [17].
C. Y. Lee et al. in (2009) used dissimilar welding of low carbon
steel and Al–Mg alloy were happened by (FSSW). These joining
conditions get it possible to weld steel plate by using welding
tools manufacturing from tool steel and increased depth of pene-
tration tool. Maximum value of tensile shear force was 3 kN,
when depth of penetration tool was 0.5 mm, if the depth of pene-
tration tool higher than 0.5mm that lead to deformation of Alumi-
num sheet of top side. In the result of interface observation and
formation strongly interaction layer between steel and aluminum
alloy [18].
The aim of this search checking the ability of join the different
sheet metals such as (carbon steel with Aluminum) by new pro-
cess friction stir spot welding. To make sure this welding finish
successfully we must observe microstructure and inspect the me-
chanical properties for welding specimens. After that estimate the
optimum condition for friction stir spot welding process.
2. Experimental work
2.1. Materials used
Mild carbon steel (1006-AISI) and aluminum alloy (AA2024-T3)
sheets were used for this present work as shown in the figure (3).
The dimension of first material was 100 × 25 ×0.8 mm of mild
carbon steel (1006-AISI) and the dimension of second material
was 100 × 25 ×1.1 mm of aluminum alloy AA2024-T3, the lap
welded with steel sheet on the top.
Fig. 3: Sheets Preparation for Welding.
All the welded specimens were comprised of two 100 mm × 25
mm sheets (parallel to the rolling direction) with an overlap area
3. International Journal of Engineering & Technology 3039
of 25 mm by 25 mm, which were welded in the center of the over-
lap area.
The following tables (1) and (2) shown actual chemical composi-
tions of the materials used. These alloys were analyzed to find
their actual chemical compositions in the Central Organization for
Standardization and Quality Control in Baghdad and compared
with their standard values [19]. The mechanical properties of two
materials are presented in tables (3) and (4).
Table 1: Actual Chemical Composition of Mild Carbon Steel 1006- AISI
Element wt% C Mn P S Cr Ni Mo Cu
Measured 0.062 0.169 0.016 0.006 0.055 0.035 0.002 0.006
Table 2: Actual Chemical Compositions of AA2024-T3 Aluminum Alloy
Element wt% Si Fe Cu Mn Mg Cr Zn Ti Ti+Zr Al
Measured 0.09 0.22 4.7 0.58 1.4 0.04 0.1 0.01 0.01 Balance
Table 3: Actual Mechanical Properties of Mild Carbon Steel
Property σu (MPa) σy (MPa)
Measured 229.12 127.7
Table 4: Actual Mechanical Properties of AA2024-T3 Aluminum Alloy
Property σu (MPa) σy (MPa)
Measured 449.2 329.5
2.2. Specimen preparation
Each sample was prepared by cutting sheets in the dimensions:
Length (L) = 100 mm and Width (W) = 25 mm, according to
American Welding Society (AWS) resistance welding handbook
[20].
The overlap spot joint alignment and dimensions are shown in
table (5) and figure (4). The overlap joint sample has dimensions
of 25mm wide
Fig. 5: Vertical Milling Machine Used to Achieve the Spot Welding.
In addition, 175mm length.
Fig. 4: Overlapping of FSSW Sample All Dimensions in Mm.
Table 5: Dimensions of Welded Samples.
Type of material
Thickness
(t) mm
Width
(W) mm
Length (L)
mm
Contact
overlap
mm
AA2024-T3 1.1 25 mm 100 mm 25 mm
Carbon steel
(1006-AISI)
0.8 25 mm 100 mm 25 mm
Table 6: Parameters of Friction Stir Spot Welding For Carbon Steel and
AA2024-T3
Rotation speed
(rpm)
Feed rate
(mm/min)
Preheat (dwell
time) second
Depth
mm
1800, 1400, 16 10, 15 0.2,
900,710 0.4
2.3. Friction stir spot welding (FSSW) technique
A vertical universal milling machine was used shown in figure (5)
for FSSW experiments of mild carbon steel and AA2024-T3. The
important properties of universal milling machine, as Spindle
rotation speed range from (35.5-1800 rpm), Spindle power is 4.5
kW and Feed rates (16-800 mm/min). The milling machine was
used with variable rotation speeds from (1800-710 rpm). Using
tungsten carbide tool in this study have 10 mm diameter. A key
geometrical feature of the tool is shown in figure (6), the tool was
held by a standard tool holder. The welding parameters used to
make the FSSW joints are presented in below table (6).
Fig. 6: Tool Geometrical Dimension, A) Tool Geometry B) Tool Photo-
graph All Dimensions in Mm.
FSSW process procedure has been done in three stages:
First stage, the pre- heating was achieved for each welded
sample before the plunging step in order to generate the heat
in samples, see figure (7-a).
Second stage, the tool pin was plunged from upper, see fig-
ure (7-b).
Third stage, the tool is removed easily; see Figure (7-c).
Fig. 7: Friction Stir Spot Welding (FSSW) Steps A-First Stage, B- Second
Stage and C- Third Stage.
After that, welded all specimens in the same of condition and di-
mension above, the final shape of specimens as seen in the figure
(8).
4. 3040 International Journal of Engineering & Technology
Fig.8: Samples of Welded Specimens.
3. Results and discussion
3.1. Weld appearance
The macro-photo of the joint is shown in figure (9), it shown the
cross section of the spot and interface region between dissimilar
metals. When, used carbon steel for upper sheet and aluminum
alloy for lower sheet that lead to need high power to joining two
plats, but this joined was too strong because the carbon-steel was
hardly ever deformed because the melting temperature of alumi-
num is lower than that of carbon-steel. erThTrehT,rT lTwd rw er
oese e e rT s Thr oT[21.]
Fig. 9: Macrostructure Photographs of Cross-Section of Dissimilar FSSW
Joints.
3.2. Microstructure analysis
The microstructures analysis was performed to examine the integ-
rity of the welded joints. Figure (10) show the results of micro-
structures analysis for Carbon Steel -1006 to Aluminum Alloy
AA2024-T3 welded by FSSW process.
Fig. 10: Microstructures of the Cross-Section of Friction Stir Spot Welds
for Different Regions at Spindle Speed (1400 Rpm), Feed Rate
(16mm/Min), Depth of Tool (0.4mm) And Dwell Time (10sec): A) Cross
Section of Weld Zone, B) Magnified Views of the Regions Respectively.
They observed that the defects were appeared at the edge of the
welded sample which may come from the wears from the tools [2]
and the microstructures of the joints varied significantly depend-
ing on the tensile shear strength, dwell time and tool rotational
speed [8].
In the weld zone notice that no evidence of melted material and
the other hand the microstructure was not deformed in the Fe plate
side [18]. The interface between Fe and Al sheets at the weld was
investigated as show in the microstructure results.
3.3. Tensile shear strength results
A according the results below, the value of tensile shear load de-
pending on many variables such as penetration depth (mm), spin-
dle speed (rpm) and dwell time (sec). The average tensile shear
loads of the samples welded at different parameters process condi-
tions are shown in table (7).
Table 7: Tensile Shear Strength Values of Carbon Steel -1006 to AA2024-
T3
e sdwT
eeTTdher
eTTd h T
rrmr s
hTrT
(dlTww rT)
eToesd
pxe
oe
hTe r
rr
eTse wT
erT h Te
No
1800 16
e r ehT-
rT( 10)
1 0.2 1.71
2 0.4 2.98
e r ehT-
rT( 15)
3 0.2 0.65
4 0.4 1.16
710 16
e r ehT-
rT( 10)
5 0.2 2.56
6 0.4 3.31
e r ehT-
rT( 15)
7 0.2 2.41
8 0.4 2.77
710 16
e r ehT-
rT( 10)
9 0.2 1.98
10 0.4 2.81
e r ehT-
rT( 15)
11 0.2 0.81
12 0.4 1.12
710 16
e r ehT-
rT( 10)
13 0.2 0.89
14 0.4 2.51
e r ehT-
rT( 15)
15 0.2 0.66
16 0.4 1.78
3.3.1. Effect of tool penetration depth and dwell time
The tools were rotated at constant speed to occurring penetration
and stir the materials to be welded. The work-piece (or specimen)
is kept in a lap-configuration of FSSW. The penetration depth of
tool in the upper plate in charge to decide the general quality of
the welds. Also, the plunge depth in the lower plate and the thick-
ness of upper and lower plates are other parameters can be consid-
ered [4].
The below Figures (11) and (12) seen the impact of tool depth and
pre-heat time on average tensile shear test. The main effect of tool
depth can be show, when used 0.2 and 0.4 mm with different
spindle speed. Increasing the tool depth at constant dwell time
leads to higher strength. This result was observed at different
spindle speeds. This is clearly visible for 10 and 15 second pre-
heat times. These results conform with [6].
Therefore, the using of tool depth 0.4 mm lead to increasing of
failure load than tool depth 0.2 mm at constant dwell time 10 sec
approximately 65% at tool speed 710r.p.m ,30% at tool speed
900r.p.m ,23% at tool speed 1400r.p.m,43% at tool speed
1800r.p.m.
The dwell time is called for the time duration when the tool stays
contact with the work-piece during all stages (plunging, string and
drawing out). From figure (11) and figure (12) can be concluded
the shorter time lead to achieved the higher tensile shear load that
mean to obtained super joint strengths by using short weld times.
The tensile load improved by increasing dwell time to 10 sec, after
that the joint strength decreased with increasing of the dwell time
to 15 sec. The long dwell time caused the excess formation of
inter-metallic layer. Also, some of the welds saw poor strength
depending on some accrual of alloy elements at the interface, be-
cause the i.e Fe/Al [21].
5. International Journal of Engineering & Technology 3041
Dwell time is proved has great influence on failure load followed
by tool depth and tool rotation speed. These results conform with
[4], [12] and [16.]
If compare between failure load when used dwell time(10sec) and
failure load when used dwell time (15sec) at the same depth of
tool (0.4mm), which the failure load with dwell time 10sec in-
creases approximately 29% at tool speed 710r.p.m ,60% at tool
speed 900r.p.m ,16% at tool speed 1400r.p.m,61% at tool speed
1800r.p.m.
Fig. 11: Illustration Effect at Different Depth and Pre-Heat (10) Second on
Tensile Shear Load.
Fig. 12: Illustration Effect at Different Depth and Pre-Heat (15) Second on
Tensile Shear Load.
3.3.2. Effect of tool rotational speed
To studding the effect of spindle speed (tool speed) on tensile
shear strength of welding, all specimens welding were run out at
the travels speed of 16mm/min. The tool rotation speed was
change from 710 rpm to 1800 rpm. Figure (13) and (14) shows the
spindle speed against average tensile shear load at different dwell
time (10, 15 sec). For each parameter used, five specimens were
tested, and the standard-deviation was usually less than 12 % of
the average load value. Increasing the spindle speed at constant
dwell time leads to higher strength reach to 1400rpm spindle
speed, after that the tensile load decrease when used 1800 rpm
spindle speed. Generally, this result was shown clearly visible for
10 and 15second dwell times. These results conform with [10].
The maximum failure load was 3.31KN at spindle speed 1400rpm,
penetration depth 0.4mm and dwell time 10sec.
Fig. 13: Effect of Spindle Speed (Rpm) on the Tensile Shear Load at
0.4mm Depth of Tool with Different Dwell Time.
Fig. 14: Effect of Spindle Speed (Rpm) on the Tensile Shear Load at
0.2mm Depth of Tool with Different Dwell Time.
3.4. Failure mode
Figure (15) shows the fracture mode of surface for the specimen
of tensile shear tests. For all welds, the fracture taken at the
steel/aluminum interface. Aluminum was found at the near of exit-
hole for tool at the steel fracture surface.
The 2 main modes of failure for FSSW process are: interfacial and
pullout fracture.
Pullout failures occurred because the emerging scant higher ener-
gy absorption leads to the larger displacement-prior to separation
of these sheets.
The average fracture load for static-lap tensile shear tests of the
nugget pullout mode is slight higher than the interfacial-fracture
for dissimilar welds [10].
Fig. 15: Failure Mode: A) Interfacial Fracture of Carbon Steel -1006 Sheet
B) Pull-Out Fracture of AA2024-T3 Sheet.
4. Conclusion
In this study, the carbon steel -1006 plate and aluminum alloy
AA2024-T3plate were welded successfully. The friction stir spot
welding process was investigated by macro -structural observa-
tion, microstructure analysis, shear tensile load and failure mode.
As a result:
1) The uniform of macrostructure photographs of cross-section
of dissimilar (steel/aluminum) for FSSW joints.
2) The fine grains size, uniformly distributed and very fine
strengthening-precipitates in the weld zone were observed
from microstructure analysis.
3) Many welding parameters such as, penetration depth (mm),
dwell time (sec) and spindle speed (rpm), selected in the
dissimilar FSSW to studying the effective.
4) The tensile shear load or failure load increasing with in-
crease spindle speed until reach the maximum value
(3.31KN), after that the failure load began to decrease.
5) For both of the applied depth of tool 0.2 and 0.4mm, the
failure load first improved and then decreased with the in-
creased dwell time 15 sec.
6) The best result of shear tensile load obtained when using
high penetration depth of tool 0.4mm for all condition be-
cause the high depth lead to stronger joints.
7) The optimum shear tensile load found with (1400rpm) spin-
dle speed, (0.4mm) depth of tool and (10sec) dwell time,
when kept constant of feed rate 16 mm/min at all condition.
6. 3042 International Journal of Engineering & Technology
8) Two shape observing of failure mode: Interfacial fracture of
Carbon Steel -1006 sheet and pullout fracture of AA2024-
T3 sheet.
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