This document summarizes a review of experimental and numerical investigations into friction stir welds of AA6063-T6 aluminum alloy. It begins with an abstract and introduction discussing friction stir welding as a solid-state joining process without melting. The amount of heat conducted into the workpiece determines weld quality and tool life. The document then reviews various research using simulation to determine temperature distribution and develop relationships between input parameters and peak temperature. Experimental results for tensile strength and hardness of welded specimens are also reported and compared to simulation results.
Investigation on effect of welding current on welding speed and hardness of h...eSAT Journals
1) The document investigates the effect of welding current on welding speed and hardness of the heat affected zone (HAZ) and weld metal of mild steel.
2) Testing was conducted on mild steel specimens welded with varying current from 80-100 amps using MMAW. Hardness was measured in the parent metal, HAZ and weld metal.
3) Results showed that as welding current increased, welding time decreased and welding speed increased due to a higher electrode melting rate. Hardness of the HAZ and weld metal decreased with increasing current due to higher heat input.
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…
Optimization of friction stir welding parameters for joining aluminum alloy 6...eSAT Journals
Abstract This investigation represents the effects of parameters of friction stir welding on tensile strength and hardness during welding of Aluminium Alloy 6105. A fabricated FSWM set up was used for welding. A high carbon steel tool having 18 mm shoulder diameter and 5.5 mm pin diameter has been used. It was noted that for the friction stir welding of aluminium alloy 6105, maximum tensile strength is 0.0912 KN/mm2, which is obtain at 1250 rpm tool rotation speed, 25 mm/min welding speed and 00 tilt angle. It was also noted that the maximum vicker hardness is 65.7 which is obtain at 1550 rpm rotational speed, 35 mm/min welding speed and 0.50 tilt angle. Keywords: Friction stir welding, Aluminium alloy 6105, tensile strength, hardness, Taguchi L9 orthogonal array
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 is a solid state joining process that uses a rotating cylindrical tool to join two facing workpieces without melting them. As the non-consumable tool made of highly wear resistant material is rotated and slowly plunged into the material to be joined, friction generated between the shoulder and pin of the tool and the workpieces produces sufficient heat to cause the material to soften without reaching its melting point. This allows it to be joined by mechanical mixing/forging of the material in the plastic state. Three main zones are affected - the shoulder affected zone, pin affected zone, and thermo-mechanically affected zone. Heat is generated primarily through friction at the tool shoulder and plastic deformation. Material flow occurs as material is
Explosion welding is a solid-state process that bonds dissimilar metals through high-velocity impact using a controlled detonation. It involves removing oxides from the metal surfaces, distributing an explosive over one metal surface (the prime component), and detonating the explosive to propel the prime component into intimate contact with the other metal surface (the base component). Finite element modeling was used to simulate the explosion welding process and study factors like flyer plate velocity, contact pressure, shear stress, and normal stress and how they influence bond formation. The simulations matched experimental test results and provided insight into the relationships between operating conditions and the physical parameters that determine welding success.
Friction stir welding enhancing or improving strategies Jayesh Gupta
The document discusses strategies to enhance friction stir welding of aluminum alloys. It describes how tool rotation direction, welding medium, and reinforcement with nanomaterials can improve joint quality and properties. Specifically, it notes that counterclockwise tool rotation and submerged welding in water reduce weld defects compared to clockwise rotation and air welding. It also explains how reinforcing with silicon carbide nanoparticles increases strength, hardness, and wear resistance by restricting grain growth and reducing size through the pinning effect.
Investigation on effect of welding current on welding speed and hardness of h...eSAT Journals
1) The document investigates the effect of welding current on welding speed and hardness of the heat affected zone (HAZ) and weld metal of mild steel.
2) Testing was conducted on mild steel specimens welded with varying current from 80-100 amps using MMAW. Hardness was measured in the parent metal, HAZ and weld metal.
3) Results showed that as welding current increased, welding time decreased and welding speed increased due to a higher electrode melting rate. Hardness of the HAZ and weld metal decreased with increasing current due to higher heat input.
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…
Optimization of friction stir welding parameters for joining aluminum alloy 6...eSAT Journals
Abstract This investigation represents the effects of parameters of friction stir welding on tensile strength and hardness during welding of Aluminium Alloy 6105. A fabricated FSWM set up was used for welding. A high carbon steel tool having 18 mm shoulder diameter and 5.5 mm pin diameter has been used. It was noted that for the friction stir welding of aluminium alloy 6105, maximum tensile strength is 0.0912 KN/mm2, which is obtain at 1250 rpm tool rotation speed, 25 mm/min welding speed and 00 tilt angle. It was also noted that the maximum vicker hardness is 65.7 which is obtain at 1550 rpm rotational speed, 35 mm/min welding speed and 0.50 tilt angle. Keywords: Friction stir welding, Aluminium alloy 6105, tensile strength, hardness, Taguchi L9 orthogonal array
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 is a solid state joining process that uses a rotating cylindrical tool to join two facing workpieces without melting them. As the non-consumable tool made of highly wear resistant material is rotated and slowly plunged into the material to be joined, friction generated between the shoulder and pin of the tool and the workpieces produces sufficient heat to cause the material to soften without reaching its melting point. This allows it to be joined by mechanical mixing/forging of the material in the plastic state. Three main zones are affected - the shoulder affected zone, pin affected zone, and thermo-mechanically affected zone. Heat is generated primarily through friction at the tool shoulder and plastic deformation. Material flow occurs as material is
Explosion welding is a solid-state process that bonds dissimilar metals through high-velocity impact using a controlled detonation. It involves removing oxides from the metal surfaces, distributing an explosive over one metal surface (the prime component), and detonating the explosive to propel the prime component into intimate contact with the other metal surface (the base component). Finite element modeling was used to simulate the explosion welding process and study factors like flyer plate velocity, contact pressure, shear stress, and normal stress and how they influence bond formation. The simulations matched experimental test results and provided insight into the relationships between operating conditions and the physical parameters that determine welding success.
Friction stir welding enhancing or improving strategies Jayesh Gupta
The document discusses strategies to enhance friction stir welding of aluminum alloys. It describes how tool rotation direction, welding medium, and reinforcement with nanomaterials can improve joint quality and properties. Specifically, it notes that counterclockwise tool rotation and submerged welding in water reduce weld defects compared to clockwise rotation and air welding. It also explains how reinforcing with silicon carbide nanoparticles increases strength, hardness, and wear resistance by restricting grain growth and reducing size through the pinning effect.
INVESTIGATION ON FRICTION STIR WELDING OF SIMILAR ALUMINIUM ALLOYS (AA6061) ...RenukaReddyVudumula
Friction Stir Welding (FSW) is the latest innovative and most complex process that is widely applied to the welding of lightweight alloys, such as aluminum alloys. this process provides the frictional heating and plastic deformation realized at the interaction between a non-consumable welding tool that rotates on the contact surfaces of the work-pieces. The welding tool is positioned vertically on the material and then moved at welding speed along the joint line.
The plasticized material is transferred behind the tool, forming a welded joint.
In this research, a new approach for friction-stir welding of similar alloys of aluminum alloy 6061 and using cerium particles. The weld mechanical properties of the welds were investigated in this research. The effects of friction-stir welding process parameters such as tool rotational and traverse speeds were also examined. Mechanical properties of the welded parts will be examined by using tensile test, Impact test, and Hardness test.
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
This document summarizes research on friction stir welding of copper. It discusses how copper, aluminum, and stainless steel plates were welded using friction stir welding with varying tool profiles, rotational speeds, and welding speeds. Microstructure analysis found intermixing of the metals in the welded regions. Copper to copper and aluminum to aluminum welds were of the highest quality, while stainless steel could not be welded to copper or aluminum due to differences in hardness. The best welding results occurred with a tapered tool, rotational speed of 1120 RPM, and welding speed of 20 mm/min.
A Review on Effect of Process Parameters on Tensile Strength of Friction Stir...ijsrd.com
This document summarizes research on the effect of process parameters on the tensile strength of friction stir welded aluminum alloys. It discusses how friction stir welding is a solid-state joining technique used in aerospace, automotive, and other industries. Process parameters like tool rotation speed, traverse speed, and axial force influence weld quality and tensile strength. Several studies investigated how adjusting these parameters affected strength of the welded joints. The optimum parameters were found to produce joints with tensile strengths close to the base metal. Overall, it was concluded that process parameters have a significant impact on weld strength and need to be optimized to achieve the highest possible strength.
EXPERIMENTAL EVALUTION OF FRICTION STIR WELDED JOINTS OFsindhu rathod
This document summarizes an experimental evaluation of friction stir welded joints between dissimilar aluminum alloy plates. Key points:
- Friction stir welding was used to join AA6063 and AA6082 aluminum alloy plates using tools with and without TiAlN coating.
- Hardness tests and tensile tests were conducted on the welded joints. The welded joints produced using the coated tools showed higher ultimate tensile strength and hardness values compared to the uncoated tools.
- An optimal tool rotation speed of 1400 rpm and welding speed of 28 mm/min produced the highest weld strength. 2000 rpm and 28 mm/min produced the highest hardness values.
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.
Investigation on Mechanical Properties of TIG Welded Joint and its Efficiencyijtsrd
This work mainly pertains to improvement in the mechanical properties of IS 2062 steel plates welds through gas tungsten arc welding GTAW process. TIG Tungsten inert gas welding are well known welding techniques, that are being used in industries in the current age. Mild steel was the only commonly used material in TIG welding. Mild steel is the first material consumption. The comparison is done on the basis of the mechanical properties of the welded joint of TIG welding. This study is done on mechanical testing and non destructive tests DPT and radiography tests of TIG welding on IS 2062 Mild steel plates. Mr. I. S. N. V. R. Prashanth | K. Lavanya | Meherkeziah | P. Navya ""Investigation on Mechanical Properties of TIG Welded Joint and its Efficiency"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23244.pdf
Paper URL: https://www.ijtsrd.com/engineering/manufacturing-engineering/23244/investigation-on-mechanical-properties-of-tig-welded-joint-and-its-efficiency/mr-i-s-n-v-r-prashanth
Investigation of Effect of Process Parameters on Maximum Temperature during F...IJSRD
In case of friction stir welding, the maximum temperature along the weld line within appropriate range at tool workpiece interface is responsible for quality of welded joint. Through this paper, an attempt is made to establish a relationship between the input process parameters and the maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075. The design of pre-experimental simulation has been performed in accordance with full factorial technique. The simulation of friction stir welding has been performed by varying input parameters, tool rotational speed and welding speed. The analysis of variance (ANOVA) is used to investigate the effect of input parameters on maximum temperature during friction stir welding. A correlation was established between input parameters and maximum temperature by multiple regression lines. This study indicates that the tool rotational speed is the main input parameter that has high statistical influence on maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075.
Research Inventy : International Journal of Engineering and Scienceinventy
esearch Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
REVIEW ON EFFECT OF HEAT INPUT ON TENSILE STRENGTH OF BUTT WELD JOINT USING M...ijiert bestjournal
This document summarizes a research paper that investigated the effect of heat input on the tensile strength of butt weld joints using MIG welding. The researchers found that increasing heat input affected the microstructure of the base metal and heat affected zone. Tensile strength decreased with higher heat input. Microhardness was observed to increase in the weld pool but decrease in the heat affected zone with greater heat input. Optical microscopy showed smaller dendrite sizes and spacing at low heat input compared to larger dendrites and spacing at high heat input. The extent of grain coarsening in the heat affected zone also increased with higher heat input. In conclusion, welding heat input significantly influences the properties of welded joints.
At present scenario, INCONEL alloy 625 becomes widely used material in aero industry due to its High
tensile, creep, and rupture strength, outstanding fatigue and thermal-fatigue strength, oxidation resistance, and
excellent weld ability properties. In present work, the plates of 50mm×50mm×3mm are modelled and assembled
for v-butt joint using solid works. This model is imported in the FEA software (ANSYS) to carry out the transient
thermal analysis. The analysis is carried out with different combinations of welding parameters such as voltage,
current, velocity, speed and melting efficiency. From the analysis result, the temperature distribution at various
locations around the weld bead is evaluated. From structural analysis result, the distortion of work piece due to the
thermal effect is analysed.
The document summarizes an experimental analysis of weld strength in friction stir welding of different grades of aluminum alloy using different tool geometries. Specifically, it analyzes welding 6061, 7005, and 8011 aluminum alloys with a cylindrical tool and tapered threaded tool. Tensile testing found that the tapered threaded tool produced stronger welds across all aluminum grades compared to the cylindrical tool, with strengths increasing up to 30%. This is because the threaded tool generates more friction and distributes the metal more evenly in the weld zone. Visual analysis also found the threaded tool produced better surface finish quality than the cylindrical tool.
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.
This document summarizes a study that used finite element analysis to model and analyze welding distortions in T-joints made through seam and skip arc welding processes. The study created a 3D finite element model to simulate the temperature distribution and resulting distortions. The model results were verified through experimental welding of T-joints made of mild steel, with distortions then measured using a coordinate measuring machine. Varying factors like plate width and thickness allowed analyzing their effects on distortions developed through each welding process.
The document analyzes friction stir welding tools with various threaded pin profiles. Three tool pin profiles are modeled in CATIA and analyzed using ANSYS: cylindrical, frustum, and conical pins with threads. The stress distributions and displacement vectors in the pins are obtained for different rotational speeds and temperatures. The results show that the cylindrical pin profile experiences the lowest stress levels and displacement compared to the other profiles. Increasing rotational speed does not significantly affect the stress, while higher temperatures generally increase stress across all pin profiles. The cylindrical pin profile is determined to be preferable for withstanding loads during friction stir welding.
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 along the circumference of Al pipesSubed Satyal
The document summarizes a presentation on friction stir welding of pipes. It discusses the challenges of experimental procedures for friction stir welding pipes including producing good quality welds and eliminating keyhole defects. It describes the methodology used including using a vertical milling machine with a tapered tool profile. It outlines the welding parameters tested and experimental results including visual inspections showing smooth and rough welds. Microhardness tests showed highest values in the stir zone. Microstructures revealed grain changes in the stir, thermomechanically affected, and heat affected zones. Eliminating the exit hole defect is discussed using a sacrificial element. The conclusion is that taper tool profile produced good quality welds and exit holes can be addressed.
IRJET- Advanced Welding Processes for Distortion Reduction: A ReviewIRJET Journal
This document reviews various advanced welding processes for reducing distortion compared to conventional arc welding processes. It summarizes research comparing the effects of cold metal transfer (CMT) welding, autogenous laser welding, hybrid laser-gas metal arc (GMA) welding, and hybrid laser-magnetic welding on distortion. Studies show these advanced processes generate less heat input and result in lower distortion compared to submerged arc welding and pulsed GMA welding. Specifically, laser welding and laser hybrid welding produce the least amount of angular distortion and transverse displacement. The document concludes advanced welding techniques offer benefits over conventional arc welding in terms of improved weld quality and reduced distortion.
La Web 2.0 se refiere a una nueva generación de páginas web que facilitan el compartir y producir contenido entre los usuarios a través de comunidades en línea, blogs, wikis y otras herramientas. Esto ha llevado a una democratización de los medios donde cualquiera puede publicar información, y ha reducido los costos de difusión de noticias e información. Un ejemplo clave es Wikipedia, la enciclopedia en línea creada y editada colectivamente por los usuarios.
El documento describe las diferentes formas jurídicas de empresa en España, incluyendo el número mínimo de socios, el capital social requerido, la responsabilidad de los socios, el régimen fiscal y los órganos de administración de cada forma. Se mencionan las formalidades de constitución y la normativa legal aplicable, así como las opciones de seguridad social para los socios.
Este documento analiza el comportamiento organizacional de Mega Monserrate, una papelería con 17 años de experiencia en Colombia y Ecuador. Describe las características generales del comportamiento organizacional como competencias, personalidad, percepciones, atribuciones, comunicación, liderazgo, equipos, conflicto, negociación y toma de decisiones. Identifica problemas relacionados con reforzamientos y efectividad, y propone soluciones como reforzamientos positivos basados en estimados de ventas y temporadas altas, así como castigos como avisos previos.
INVESTIGATION ON FRICTION STIR WELDING OF SIMILAR ALUMINIUM ALLOYS (AA6061) ...RenukaReddyVudumula
Friction Stir Welding (FSW) is the latest innovative and most complex process that is widely applied to the welding of lightweight alloys, such as aluminum alloys. this process provides the frictional heating and plastic deformation realized at the interaction between a non-consumable welding tool that rotates on the contact surfaces of the work-pieces. The welding tool is positioned vertically on the material and then moved at welding speed along the joint line.
The plasticized material is transferred behind the tool, forming a welded joint.
In this research, a new approach for friction-stir welding of similar alloys of aluminum alloy 6061 and using cerium particles. The weld mechanical properties of the welds were investigated in this research. The effects of friction-stir welding process parameters such as tool rotational and traverse speeds were also examined. Mechanical properties of the welded parts will be examined by using tensile test, Impact test, and Hardness test.
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
This document summarizes research on friction stir welding of copper. It discusses how copper, aluminum, and stainless steel plates were welded using friction stir welding with varying tool profiles, rotational speeds, and welding speeds. Microstructure analysis found intermixing of the metals in the welded regions. Copper to copper and aluminum to aluminum welds were of the highest quality, while stainless steel could not be welded to copper or aluminum due to differences in hardness. The best welding results occurred with a tapered tool, rotational speed of 1120 RPM, and welding speed of 20 mm/min.
A Review on Effect of Process Parameters on Tensile Strength of Friction Stir...ijsrd.com
This document summarizes research on the effect of process parameters on the tensile strength of friction stir welded aluminum alloys. It discusses how friction stir welding is a solid-state joining technique used in aerospace, automotive, and other industries. Process parameters like tool rotation speed, traverse speed, and axial force influence weld quality and tensile strength. Several studies investigated how adjusting these parameters affected strength of the welded joints. The optimum parameters were found to produce joints with tensile strengths close to the base metal. Overall, it was concluded that process parameters have a significant impact on weld strength and need to be optimized to achieve the highest possible strength.
EXPERIMENTAL EVALUTION OF FRICTION STIR WELDED JOINTS OFsindhu rathod
This document summarizes an experimental evaluation of friction stir welded joints between dissimilar aluminum alloy plates. Key points:
- Friction stir welding was used to join AA6063 and AA6082 aluminum alloy plates using tools with and without TiAlN coating.
- Hardness tests and tensile tests were conducted on the welded joints. The welded joints produced using the coated tools showed higher ultimate tensile strength and hardness values compared to the uncoated tools.
- An optimal tool rotation speed of 1400 rpm and welding speed of 28 mm/min produced the highest weld strength. 2000 rpm and 28 mm/min produced the highest hardness values.
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.
Investigation on Mechanical Properties of TIG Welded Joint and its Efficiencyijtsrd
This work mainly pertains to improvement in the mechanical properties of IS 2062 steel plates welds through gas tungsten arc welding GTAW process. TIG Tungsten inert gas welding are well known welding techniques, that are being used in industries in the current age. Mild steel was the only commonly used material in TIG welding. Mild steel is the first material consumption. The comparison is done on the basis of the mechanical properties of the welded joint of TIG welding. This study is done on mechanical testing and non destructive tests DPT and radiography tests of TIG welding on IS 2062 Mild steel plates. Mr. I. S. N. V. R. Prashanth | K. Lavanya | Meherkeziah | P. Navya ""Investigation on Mechanical Properties of TIG Welded Joint and its Efficiency"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23244.pdf
Paper URL: https://www.ijtsrd.com/engineering/manufacturing-engineering/23244/investigation-on-mechanical-properties-of-tig-welded-joint-and-its-efficiency/mr-i-s-n-v-r-prashanth
Investigation of Effect of Process Parameters on Maximum Temperature during F...IJSRD
In case of friction stir welding, the maximum temperature along the weld line within appropriate range at tool workpiece interface is responsible for quality of welded joint. Through this paper, an attempt is made to establish a relationship between the input process parameters and the maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075. The design of pre-experimental simulation has been performed in accordance with full factorial technique. The simulation of friction stir welding has been performed by varying input parameters, tool rotational speed and welding speed. The analysis of variance (ANOVA) is used to investigate the effect of input parameters on maximum temperature during friction stir welding. A correlation was established between input parameters and maximum temperature by multiple regression lines. This study indicates that the tool rotational speed is the main input parameter that has high statistical influence on maximum temperature along the weld line during friction stir welding of aluminium alloy AA-7075.
Research Inventy : International Journal of Engineering and Scienceinventy
esearch Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
REVIEW ON EFFECT OF HEAT INPUT ON TENSILE STRENGTH OF BUTT WELD JOINT USING M...ijiert bestjournal
This document summarizes a research paper that investigated the effect of heat input on the tensile strength of butt weld joints using MIG welding. The researchers found that increasing heat input affected the microstructure of the base metal and heat affected zone. Tensile strength decreased with higher heat input. Microhardness was observed to increase in the weld pool but decrease in the heat affected zone with greater heat input. Optical microscopy showed smaller dendrite sizes and spacing at low heat input compared to larger dendrites and spacing at high heat input. The extent of grain coarsening in the heat affected zone also increased with higher heat input. In conclusion, welding heat input significantly influences the properties of welded joints.
At present scenario, INCONEL alloy 625 becomes widely used material in aero industry due to its High
tensile, creep, and rupture strength, outstanding fatigue and thermal-fatigue strength, oxidation resistance, and
excellent weld ability properties. In present work, the plates of 50mm×50mm×3mm are modelled and assembled
for v-butt joint using solid works. This model is imported in the FEA software (ANSYS) to carry out the transient
thermal analysis. The analysis is carried out with different combinations of welding parameters such as voltage,
current, velocity, speed and melting efficiency. From the analysis result, the temperature distribution at various
locations around the weld bead is evaluated. From structural analysis result, the distortion of work piece due to the
thermal effect is analysed.
The document summarizes an experimental analysis of weld strength in friction stir welding of different grades of aluminum alloy using different tool geometries. Specifically, it analyzes welding 6061, 7005, and 8011 aluminum alloys with a cylindrical tool and tapered threaded tool. Tensile testing found that the tapered threaded tool produced stronger welds across all aluminum grades compared to the cylindrical tool, with strengths increasing up to 30%. This is because the threaded tool generates more friction and distributes the metal more evenly in the weld zone. Visual analysis also found the threaded tool produced better surface finish quality than the cylindrical tool.
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.
This document summarizes a study that used finite element analysis to model and analyze welding distortions in T-joints made through seam and skip arc welding processes. The study created a 3D finite element model to simulate the temperature distribution and resulting distortions. The model results were verified through experimental welding of T-joints made of mild steel, with distortions then measured using a coordinate measuring machine. Varying factors like plate width and thickness allowed analyzing their effects on distortions developed through each welding process.
The document analyzes friction stir welding tools with various threaded pin profiles. Three tool pin profiles are modeled in CATIA and analyzed using ANSYS: cylindrical, frustum, and conical pins with threads. The stress distributions and displacement vectors in the pins are obtained for different rotational speeds and temperatures. The results show that the cylindrical pin profile experiences the lowest stress levels and displacement compared to the other profiles. Increasing rotational speed does not significantly affect the stress, while higher temperatures generally increase stress across all pin profiles. The cylindrical pin profile is determined to be preferable for withstanding loads during friction stir welding.
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 along the circumference of Al pipesSubed Satyal
The document summarizes a presentation on friction stir welding of pipes. It discusses the challenges of experimental procedures for friction stir welding pipes including producing good quality welds and eliminating keyhole defects. It describes the methodology used including using a vertical milling machine with a tapered tool profile. It outlines the welding parameters tested and experimental results including visual inspections showing smooth and rough welds. Microhardness tests showed highest values in the stir zone. Microstructures revealed grain changes in the stir, thermomechanically affected, and heat affected zones. Eliminating the exit hole defect is discussed using a sacrificial element. The conclusion is that taper tool profile produced good quality welds and exit holes can be addressed.
IRJET- Advanced Welding Processes for Distortion Reduction: A ReviewIRJET Journal
This document reviews various advanced welding processes for reducing distortion compared to conventional arc welding processes. It summarizes research comparing the effects of cold metal transfer (CMT) welding, autogenous laser welding, hybrid laser-gas metal arc (GMA) welding, and hybrid laser-magnetic welding on distortion. Studies show these advanced processes generate less heat input and result in lower distortion compared to submerged arc welding and pulsed GMA welding. Specifically, laser welding and laser hybrid welding produce the least amount of angular distortion and transverse displacement. The document concludes advanced welding techniques offer benefits over conventional arc welding in terms of improved weld quality and reduced distortion.
La Web 2.0 se refiere a una nueva generación de páginas web que facilitan el compartir y producir contenido entre los usuarios a través de comunidades en línea, blogs, wikis y otras herramientas. Esto ha llevado a una democratización de los medios donde cualquiera puede publicar información, y ha reducido los costos de difusión de noticias e información. Un ejemplo clave es Wikipedia, la enciclopedia en línea creada y editada colectivamente por los usuarios.
El documento describe las diferentes formas jurídicas de empresa en España, incluyendo el número mínimo de socios, el capital social requerido, la responsabilidad de los socios, el régimen fiscal y los órganos de administración de cada forma. Se mencionan las formalidades de constitución y la normativa legal aplicable, así como las opciones de seguridad social para los socios.
Este documento analiza el comportamiento organizacional de Mega Monserrate, una papelería con 17 años de experiencia en Colombia y Ecuador. Describe las características generales del comportamiento organizacional como competencias, personalidad, percepciones, atribuciones, comunicación, liderazgo, equipos, conflicto, negociación y toma de decisiones. Identifica problemas relacionados con reforzamientos y efectividad, y propone soluciones como reforzamientos positivos basados en estimados de ventas y temporadas altas, así como castigos como avisos previos.
Producciones Chubaka presenta una presentación de PowerPoint sobre Computines y proporciona enlaces para enviar la presentación a un amigo, acceder a más presentaciones gratuitas en su sitio web, y suscribirse para recibir presentaciones por correo electrónico.
O documento apresenta instruções sobre uma prova de agronomia do SINAES, informando sobre a distribuição das questões, pesos, tempo de duração e regras de aplicação.
El documento resume aspectos clave de la arquitectura, pintura y escultura del Renacimiento en Italia, España y Francia. En Italia, destaca la cúpula de Santa María de las Flores en Florencia diseñada por Brunelleschi. En España, se describe la Casa de las Conchas en Salamanca como ejemplo del estilo plateresco y su singular fachada decorada con conchas. En Francia, se resalta el Castillo Real de Chambord como muestra de la arquitectura renacentista francesa que mezcla formas medievales e italianas.
Friction Stir Welding, a type of welding which was
discovered in the year of 1991 with a few countable methods
and processes. But today it is one of the necessary and
important type of welding techniques. To develop it, several
researchers showed their interests in this technique. Today,
it acts as the heart of welding of automobiles. Thousands of
inventions has been made in field of Friction Stir Welding
and also successfully being implemented. If a researcher
tries to make some research in this field, he has to go
through thousands of journals where hours of time is being
consumed. To solve that problem several Re-view journals
are being published and also successfully solved this issue
of time consumption. In this paper, similarly a re-view of
several important and different types of papers are discussed
with their results, outcomes, the parameters being performed
for analysis.
This paper also discusses about various methods and various
metals as tools and job materials. It will be much easier and
lenient to understand from this paper to research. The
authors of the papers also clearly explained about the usages
and applications of their methods and provided several
statistical data for clear observation of their methods
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Effect of various process parameters on friction stir welded jointeSAT Journals
Abstract Pure and ZnS added ADP (ammonium dihydrogen phosphate) single crystals have been grown at room temperature by the free evaporation method. A total of six crystals have been grown and characterized structurally, chemically, thermally, optically, mechanically and electrically by using the suitable standard methods. Results obtained indicate that the impurity molecules have entered into the ADP crystal matrix. ZnS addition is found to increase the SHG efficiency significantly. All the grown crystals exhibit good optical transmission in the entire visible region. Results of AC and DC electrical measurements indicate a normal dielectric behaviour for all the six crystals grown. The electrical parameters, viz., DC electrical conductivity, dielectric constant, dielectric loss factor and AC electrical conductivity are found to increase with the increase in temperature. The optical, mechanical and electrical parameters are found to vary nonlinearly with the impurity (ZnS) concentration. Keywords: ADP crystal, Crystal growth, Doped crystals, Physical properties, X-ray diffraction.
This document summarizes research on optimizing friction stir welding (FSW) parameters using different tool profiles. It reviews several studies that investigated how tool geometry, rotational speed, feed rate, and depth of cut influence joint strength in FSW. The document also examines the effects of different tool profiles and heat treatments on the mechanical properties and microstructure of aluminum alloy welds. Overall, the research aims to weld two aluminum alloy plates using various tool profiles and optimize joint strength through parametric optimization of the FSW process.
FRICTION STIR WELDING is a very latest tchnology of welding process .Its a green method of solid state joining, and also a defect free method .
To know more about this you can also watch this animation https://youtu.be/kEEST5cgOao
Review Paper on Friction Stir Welding and its Impact on EnvironmentIRJET Journal
This document reviews friction stir welding (FSW), a solid-state welding technique invented in 1991. FSW involves plunging a rotating tool with a shoulder and pin into aluminum or other metal workpieces to generate frictional heat and plasticize the metals, joining them below their melting points. Key benefits of FSW include high weld quality, low distortion, no shielding gas or filler wire needed, and it is more environmentally friendly than arc welding. Process parameters like tool geometry, rotation speed, and pressure influence the weld microstructure and properties. FSW has applications in industries like aerospace, automotive, and shipbuilding.
Experimental Analysis to Optimize parameters of Friction Stir Welding of Alum...IJSRD
This document summarizes research on optimizing parameters for friction stir welding (FSW) of aluminum alloys. It first provides background on FSW and discusses how parameters like tool rotation speed, tilt angle, and travel speed affect weld strength. The document then reviews several other studies investigating these parameters. One study found that a tool rotation speed of 900 rpm, travel speed of 75 mm/min, and axial force of 3 kN produced the highest tensile strength for an aluminum alloy. Another identified tilt angle as the most influential parameter for weld strength. Finally, the document describes using the Taguchi method to optimize FSW parameters for aluminum alloy, identifying tilt angle as most significant. It concludes that tool rotation speed, travel
Review paper on friction stir welding of various materialIRJET Journal
The document reviews friction stir welding (FSW), a solid-state welding technique invented in 1991. It discusses how FSW works, common materials welded, key process parameters like rotational speed and welding speed, and their effects on weld strength and microstructure. Several case studies are presented that examined how varying process parameters impacted tensile strength when welding materials like aluminum alloys, steel, and polymers. The conclusion states that FSW is well-suited for welding aluminum alloys and efforts are ongoing to weld higher-temperature materials and dissimilar metals using this technique.
Characterization And Study of Friction Stir Welding of AA6101 Aluminum Alloy IJERA Editor
Friction stir welding (FSW) combines two plates by frictional heating at the interface with the localized plastic
deformation within the material. In friction stir welding heat is generated by the friction between rotating tool
shoulder and the plates to be welded. The heat thus generated results in thermal softening of the material. The
softened material is then forced to flow by the translation of the tool from the front to the back of the pin. There
it cools, consolidates and results in joint formation. In the process, strength of the joint and percentage
elongation varies from the parent material. AA6101 is equivalent to AA 6061 and AA6063. At present AA6101
is used by the electrical industries only. A detailed experimental study has been done on AA 6101 to its utility as
an Aluminum alloy for structural fabrication.
Experimental Analysis to Optimize the Process Parameter of Friction Stir Weld...IRJET Journal
This document presents an experimental analysis to optimize the process parameters of friction stir welding (FSW) for aluminum alloy AA6082. The researchers conducted FSW experiments using different combinations of tool rotation speed, tilt angle, and welding speed. Tensile strength results of the welded joints were analyzed using Taguchi methods and particle swarm optimization to determine the optimal parameter settings. Specifically, a central composite design was used with three factors at three levels each to evaluate the effects of the FSW parameters on tensile strength. The goal of the research was to develop relationships between FSW variables and tensile/yield strength and identify the best settings for maximizing strength in single and multi-pass welds of AA6082 aluminum alloy.
EFFECT OF TiO2 NANOPARTICLES ON FRICTION STIR WELDED JOINTS OF AA8011 ALUMINI...IRJET Journal
This document discusses a study investigating the effect of TiO2 nanoparticles on friction stir welded joints of AA8011 aluminum alloy. AA8011 aluminum alloy plates were friction stir welded with TiO2 nanoparticles added to the weld groove before welding. Various welding parameters were varied to evaluate their effect on the mechanical properties and microstructure of the welded joints. Tensile tests, impact tests, and microhardness tests were performed on the welded joints and results were compared to published data. The maximum tensile strength and impact value obtained were 52.98 MPa and 5.0 joules, respectively, at a rotational speed of 1400 RPM and welding speed of 25mm/min.
Optimization of Process Parameters of Tungsten Inert Gas Welding by Taguchi M...ijsrd.com
Tungsten Inert Gas welding (TIG) is one of the most important joining technologies in welding-related fabrication. High quality weld joints without spattering and slags qualify this welding technology for the major part of metals. As the filler-metal supply is separated from the arc, the molten pool can be controlled in the best way possible an advantage which ensures the quality of the execution of the weld but entails a relatively low deposition rate and welding speed. When manufacturing consumer products where appearance is of importance; then the choice has to be TIG welding. Jobs that call for code requirements such as nuclear work, piping, and high profile consumer goods often require at least the first weld in the pipe joint to be TIG welding for an effective bond. In some cases all the passes on a multi-pass pipe weld may have to be TIG welding, if demand has high quality and code requirements.
ANALYSIS OF TOOL USED FOR FRICTION STIR SPOT WELDING BY EXPLICIT MESHING SCH...vivatechijri
The document analyzes friction stir spot welding (FSSW) of titanium alloy Ti 6Al 4V plates using explicit finite element modeling. A 3D coupled thermal-stress model is used to simulate the FSSW process. Different tool profiles including circular, square, and triangular tips are analyzed. Results show that a circular tapered tip generates a temperature of 1032°C within the plastic range for successful welding, while square and triangular tips exceed the melting point of 1632°C. A conical tip produces a temperature of 894°C, also within the plastic range. It is concluded that FSSW with a circular tapered tool tip is most effective for welding 3mm thick Ti 6Al 4V plates.
Optimization of Process Parameters in MIG Welding of Two Dissimilar Materialsijtsrd
The joining of dissimilar Aluminum Alloy and Copper aluminum plates of 5mm thickness was carried out by technique. Optimum process parameters were obtained for joints using statistical approach. Five different tool designs have been employed to an alyse the influence of rotation speed and traverse speed over the micro structural and tensile properties. In FSW technique, the process of welding of the base material, well below its melting temperature, has opened up new trends in producing efficient dissimilar joints. Effect of welding speed on microstructures, hardness distribution and tensile properties of the welded joints were investigated. By varying the process parameters, defect free and high efficiency welded joints were produced. The ratio between tool shoulder diameter and pin diameter is the most dominant factor. From micro structural analysis it is evident that the material placed on the advancing side dominates the nugget region. The hardness in the HAZ of 6061 was found to be minimum, where the welded joints failed during the tensile studies. M. S. Amarnath Reddy | Mr. J. Sree Hari | Mr. K. Sai Kiran "Optimization of Process Parameters in MIG Welding of Two Dissimilar Materials" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-6 , October 2018, URL: http://www.ijtsrd.com/papers/ijtsrd18749.pdf
A STUDY ON FRICTION STIR WELDING OF VARIOUS ALUMINIUM ALLOYSIJARIIT
The comprehensive body of knowledge that has built up with respect to the friction stir welding (FSW) of aluminum alloys since the technique was invented in 1991 is reviewed on this paper. The basic principles of FSW are described, including metal flow and thermal history, before discussing how process parameters affect the weld microstructure and the likelihood of defects. Finally, the range of mechanical properties that can be achieved is discussed. It is demonstrated that FSW of aluminum is becoming an increasingly mature technology with numerous commercial applications. Keywords - Friction stir welding, metal flow, process parameters, mechanical properties
Weightage Allocation to influential parameters in FSW for Yield Strength Eval...IJERA Editor
The document discusses weightage allocation to influential parameters in friction stir welding (FSW) for evaluating yield strength. It identifies rotational speed, welding speed, axial force, and tool pin radius as the most influential parameters. An analytical study is conducted to determine the optimal range of parameters based on the maximum temperature generated. Empirical relationships are developed to represent the effect of each parameter on yield strength. Based on the sensitivity of each parameter, weightages of 0.0375, 0.155, 0.307, and 0.5 are allocated to rotational speed, welding speed, axial force, and pin radius respectively, in a single relationship to calculate yield strength.
FSW PROCESS DISSIMILAR (Al) AT 3G POSITIONMin Dzulkiflee
This document summarizes a research project on friction stir welding (FSW) of dissimilar aluminum alloys. The objectives were to design an FSW weld for joining different aluminum series in a 3G position, evaluate the best welding parameters such as rotational and transverse speed, and analyze tensile strength properties. FSW was performed using different transverse speeds and a fixed rotational speed. Tensile testing showed the highest strength was achieved with a transverse speed of 86mm/min, meeting the project's objectives.
This document provides an overview of friction stir welding (FSW). It describes FSW as a solid-state welding process that uses friction and mechanical stirring to join materials without melting. Key points include: FSW uses a rotating tool to generate frictional heat and plastically deform the materials, leaving a solid phase bond; important parameters are tool rotation/travel speeds and geometry; FSW eliminates issues like porosity and shrinkage seen in fusion welding. Applications include aerospace, transportation, industrial structures, and shipbuilding.
This document summarizes key aspects of friction stir welding (FSW), including:
1) FSW is a solid-state welding process that uses a rotating tool to soften and join two facing workpieces without melting.
2) The document describes tool designs, important welding parameters like rotation speed and travel speed, and the effects on weld quality.
3) It also discusses FSW advantages over fusion welding, including improved mechanical properties and lack of defects like porosity.
Reduction of Splatters in Intercell Welding of a Lead Acid BatteryIRJET Journal
This document discusses reducing splatters in intercell welding of lead acid batteries. Splatters are unwanted metal particles expelled during resistance welding that reduce quality. The researcher analyzed the problem using tools like fishbone diagrams and identified key causes as insufficient electrode contact area, tip gap variation, and flag misalignment. Their proposed solutions were increasing the electrode diameter to improve contact area, using a lock nut to control tip gap, and adding ribs to properly align flags. Testing showed these solutions reduced monthly splatter rates from over 4% to under 0.3%, improving productivity, quality, and savings.
Reduction of Splatters in Intercell Welding of a Lead Acid Battery
Cq31612617
1. ranjitsinh D. Jadeja, tausif M. Shaikh / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 1, January -February 2013, pp.612-617
A Review On Experimental And Numerical Investigation Of
Friction Stir Welds Of Aa6063-T6 Aluminium Alloy
1 2
ranjitsinh D. Jadeja, tausif M. Shaikh
1, 2,
Pg Student, Assistance Professor
S.P.B.Patel Engineering College, Mehsana, Gujarat
ABSTRACT
Welding is a manufacturing process, Keywords: Friction stir welding, Peak temperature,
which is carried out for joining of metals. Trend line equation, Temperature distribution,
Friction-stir welding (FSW) is a solid-state Hardness.
joining process (the metal is not melted) and is
used when the original metal characteristics must 1. INTRODUCTION
remain unchanged as much as possible. It Friction stir welding is a relatively new
mechanically intermixes the two pieces of metal joining process, which involves the joining of metals
at the place of the join, then softens them so the without fusion or filler materials. The amount of the
metal can be fused using mechanical pressure, heat conducted into the work piece dictates a
much like joining clay, dough, or plasticine. It is successful process which is defined by the quality,
primarily used on aluminium, and most often on shape and microstructure of the processed zone, as
large pieces that cannot be easily heat-treated well as the residual stress and the distortion of the
after welding to recover temper characteristics. work piece. The amount of the heat gone to the tool
Friction stir welding is a relatively new dictates the life of the tool and the capability of the
joining process, which involves the joining of tool to produce a good processed zone. Hence,
metals without fusion or filler materials. The understanding the heat transfer aspect of the friction
amount of the heat conducted into the work piece stir welding is extremely important for improving
dictates a successful process which is defined by the process.
the quality, shape and microstructure of the Friction stir welding was invented by The
processed zone, as well as the residual stress and Welding Institute (TWI) in December 1991. TWI
the distortion of the work piece. The amount of filed successfully for patents in Europe, the U.S.,
the heat gone to the tool dictates the life of the Japan, and Australia. TWI then established TWI
tool and the capability of the tool to produce a Group-Sponsored Project 5651,"Development of the
good processed zone. Hence, understanding the New Friction Stir Technique for Welding
heat transfer aspect of the friction stir welding is Aluminum," in 1992 to further study this technique.
extremely important for improving the process.
Many research works were carried out to Why welding is used- Because it is,
simulate the friction stir welding using various Suitable for thicknesses ranging from
soft wares to determine the temperature fractions of a millimeter to a third of a meter.
distribution for a given set of welding conditions. Versatile, being applicable to a wide range
Very few attempted to determine the maximum of component shapes and sizes.
temperature by varying the input parameters
using ANSYS. The objective of this research is to As per American Welding Society (AWS)
develop a finite element simulation of friction stir It is defines weld as a localized coalescence
welding of AA6063-T6 Aluminium alloy. Trend of metals or non-metals produced either by heating
line equations will develope for thermal the materials to suitable temperatures with or
conductivity, specific heat and density to know without the application of pressure alone and with or
the relationship of these factors with peak without the use of filler material.
temperature. Tensile and hardness values for the
welded specimens are found for different CLASSIFICATION OF WELDING
rotational speed and feed. Variation of PROCESSES
temperature with input parameters is also Arc welding
observe. The simulation model will be test with Gas welding
experimental results. The results of the Resistance welding
simulation are in good agreement with that of Solid state welding
experimental results. . Thermo chemical welding
Radiant energy welding
WORKING PRINCIPLE OF FSW
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2. ranjitsinh D. Jadeja, tausif M. Shaikh / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 1, January -February 2013, pp.612-617
A constantly rotated cylindrical-shouldered tool with edge of the tool to the trailing edge of the tool probe
a profiled nib is transversely fed at a constant rate and is forged together by the intimate contact of the
into a butt joint between two clamped pieces of tool shoulder and the pin profile. This leaves a solid-
butted material. The nib is slightly shorter than the phase bond between the two pieces. The process can
weld depth required, with the tool shoulder riding be regarded as a solid-phase keyhole welding
atop the work surface. technique since a hole to accommodate the probe is
generated, then moved along the weld during the
welding sequence.
Important Welding Parameter
Tool rotation and traverse speeds
There are two tool speeds to be considered
in friction-stir welding; how fast the tool rotates and
how quickly it traverses the interface. These two
parameters have considerable importance and must
be chosen with care to ensure a successful and
efficient welding cycle. The relationship between the
welding speeds and the heat input during welding is
complex but, in general, it can be said that
increasing the rotation speed or decreasing the
FIG: 1 FRICTION STIR WELDING traverse speed will result in a hotter weld. In order to
produce a successful weld it is necessary that the
Frictional heat is generated between the material surrounding the tool is hot enough to enable
wear-resistant welding components and the work the extensive plastic flow required and minimise the
pieces. This heat, along with that generated by the forces acting on the tool. If the material is too cold
mechanical mixing process and the adiabatic heat then voids or other flaws may be present in the stir
within the material, cause the stirred materials to zone and in extreme cases the tool may break.
soften without melting. As the pin is moved forward,
a special profile on its leading face forces plasticized Tool tilt and plunge depth
material to the rear where clamping force assists in a The plunge depth is defined as the depth of
forged consolidation of the weld. This process of the the lowest point of the shoulder below the surface of
tool traversing along the weld line in a plasticized the welded plate and has been found to be a critical
tubular shaft of metal results in severe solid parameter for ensuring weld quality. Plunging the
state deformation involving dynamic shoulder below the plate surface increases the
recrystallization of the base material. pressure below the tool and helps ensure adequate
forging of the material at the rear of the tool. Tilting
How Does FSW Work? the tool by 2–4 degrees, such that the rear of the tool
In FSW, a cylindrical, shouldered tool with is lower than the front, has been found to assist this
a profiled probe is rotated and slowly plunged into forging process. The plunge depth needs to be
the weld joint between two pieces of sheet or plate correctly set, both to ensure the necessary downward
material that are to be welded together (Figure). The pressure is achieved and to ensure that the tool fully
parts must be clamped onto a backing bar in a penetrates the weld. Given the high loads required,
manner that prevents the abutting joint faces from the welding machine may deflect and so reduce the
being forced apart or in any other way moved out of plunge depth compared to the nominal setting, which
position. may result in flaws in the weld. On the other hand,
an excessive plunge depth may result in the pin
rubbing on the backing plate surface or a significant
undermatch of the weld thickness compared to the
base material. Variable load welders have been
developed to automatically compensate for changes
in the tool displacement while TWI have
demonstrated a roller system that maintains the tool
FIG: 2 WORKING OF FSW position above the weld plate.
Frictional heat is generated between the
wear-resistant welding tool and the material of the
workpieces. This heat causes the workpieces to
soften without reaching the melting point and allows
the tool to traverse along the weld line. The resultant
plasticized material is transferred from the leading
613 | P a g e
3. ranjitsinh D. Jadeja, tausif M. Shaikh / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 1, January -February 2013, pp.612-617
After the material has passed the pin the
side pressure exerted by the "die" forces the material
back together and consolidation of the join occurs as
the rear of the tool shoulder passes overhead and the
large down force forges the material. More recently,
an alternative theory has been advanced that
advocates considerable material movement in certain
locations. This theory holds that some material does
rotate around the pin, for at least one rotation, and it
is this material movement that produces the "onion-
ring" structure in the stir zone.
The researchers used a combination of thin
copper strip inserts and a "frozen pin" technique,
where the tool is rapidly stopped in place. They
suggested that material motion occurs by two
processes:
1. Material on the advancing front side of a
FIG: 3 WORKING OF FSW TOOL weld enters into a zone that rotates and advances
with the pin. This material was very highly
Tool Design deformed and sloughs off behind the pin to form arc-
The design of the tool is a critical factor as shaped features when viewed from above (i.e. down
a good tool can improve both the quality of the weld the tool axis). It was noted that the copper entered
and the maximum possible welding speed. It is the rotational zone around the pin, where it was
desirable that the tool material is sufficiently strong, broken up into fragments. These fragments were
tough, and hard wearing at the welding temperature. only found in the arc shaped features of material
Further it should have a good oxidation resistance behind the tool.
and a low thermal conductivity to minimise heat loss 2. The lighter material came from the
and thermal damage to the machinery further up the retreating front side of the pin and was dragged
drive train. Hot-worked tool steel such as AISI H13 around to the rear of the tool and filled in the gaps
has proven perfectly acceptable for welding between the arcs of advancing side material. This
aluminium alloys within thickness ranges of 0.5 – material did not rotate around the pin and the lower
50 mm [8] but more advanced tool materials are level of deformation resulted in a larger grain size.
necessary for more demanding applications such as
highly abrasive metal or higher melting point ADVENTAGES OF FSW
materials such as steel or titanium. Widespread Good mechanical properties in the as-welded
commercial applications of friction stir welding condition.
process for steels and other hard alloys such Improved safety due to the absence of toxic
as titanium alloys will require the development of fumes or the spatter of molten material.
cost-effective and durable tools. Material selection, No consumables — A threaded pin made of
design and cost are important considerations in the conventional tool steel, e.g., hardened H13, can
search for commercially useful tools for the welding weld over 1 km (1 mi) of aluminium, and no
of hard materials. Work is continuing to better filler or gas shield is required for aluminium.
understand the effects of tool material's composition, Easily automated on simple milling machines —
structure, properties and geometry on their lower setup costs and less training.
performance, durability and cost. Can operate in all positions (horizontal, vertical,
etc.), as there is no weld pool.
Flow of Material Generally good weld appearance and minimal
Early work on the mode of material flow thickness under/over-matching, thus reducing the
around the tool used inserts of a different alloy, need for expensive machining after welding.
which had a different contrast to the normal material Low environmental impact.
when viewed through a microscope, in an effort to
determine where material was moved as the tool DISADVENTAGES OF FSW
passed. The data was interpreted as representing a Exit hole left when tool is withdrawn.
form of in-situ extrusion where the tool, backing Large down forces required with heavy-duty
plate and cold base material form the "extrusion clamping necessary to hold the plates together.
chamber" through which the hot, plasticized material
Less flexible than manual and arc processes
is forced. In this model the rotation of the tool draws
(difficulties with thickness variations and non-
little or no material around the front of the pin
linear welds).
instead the material parts in front of the pin and
passes down either side.
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Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 1, January -February 2013, pp.612-617
Often slower traverse rate than some fusion to model the three-dimensional heat transfer process
welding techniques, although this may be offset because it reduces the difficulty of modeling the
if fewer welding passes are required. moving tool. In this model the main parameter
considered is the heat input from the tool shoulder
and tool pin. The temperature distributions of the
2. LITERATURE SURVEY weld at various welding speeds are obtained. The
Many investigators have suggested various friction stir welding experiments are carried out at a
methods to explain the experimental and numerical transverse speed of 0.75 mm/sec of tool. Brinell’s
investigation of friction stir welding. Hardness test, tensile test and micro structure
analysis are performed on the welded material.
A. Scialpi et al[1],was carried out FSW process
shows several advantages, in particular the Yuh J. Chao et al[4] was formulate the heat transfer
possibility to weld dissimilar aluminium alloys. In of the FSW process into two boundary value
this paper, thin aluminium alloy 2024-T3 and 6082- problems (BVP)—a steady state BVP for the tool
T6 sheets, 0.8 mm thick, have been welded in the and a transient BVP for the workpiece. To quantify
rolling direction by lFSW (FSW for ultra-thin the physical values of the process the temperatures
sheets). Both similar and dissimilar joints have been in the workpiece and the tool are measured during
successfully produced and analysed. Mechanical FSW. Using the measured transient temperature
characterization has been executed through static fields finite element numerical analyses were
and uniaxial fatigue tests with a constant load performed to determine the heat flux generated from
amplitude. Finally, microhardness and residual stress the friction to the workpiece and the tool. Detailed
measurements have been executed on welded sheets temperature distributions in the workpiece and the
for each joint typology. tool are presented. Discussions relative to the FSW
process are then given. In particular, the results show
Dr. Muhsin Jaber Jweeg et al[2] was investigated that (1) the majority of the heat generated from the
Finite element modeling of transient temperature friction, i.e., about 95%, is transferred into the
distribution is used to understand physical workpiece and only 5% flows into the tool and (2)
phenomena occurring during the dwell (penetration) the fraction of the rate of plastic work dissipated as
phase and moving of welding tool in friction stir heat is about 80%.
welding (FSW) of 5mm plate made of 7020-T53
aluminum alloy at 1400rpm and 40mm/min. Basil M. Darras[5] was worked commercial 5052
Thermocouples are used in locations near to the pin Aluminum alloy sheets are friction stir processed at
and under shoulder surface to study the welding tool different rotational and translational speeds. The
penetration in the workpiece in advance and retreate effects of process parameters on the resulting
sides along welding line in three positions (penetrate microstructure and mechanical properties are
(start welding) , mid, pullout (end welding)). investigated. The results show that FSP produces
Numerical results of ANSYS 12.0 package are very fine and homogenous grain structure, and it is
compared to experimental data including axial load observed that smaller grain size structure is obtained
measurements at different tool rotational speeds at lower rotational speeds. It is also observed that the
(710rpm.900rpm.1120rpm and 1400rpm) Based on hardness of the processed sheet depends strongly on
the experimental records of transient temperature at the rotational and translational speeds and varies
several specific locations of thermocouples during widely within the processed region. The results
the friction stir welding process the temperatures are suggest that the temperature achieved during
higher on the advancing side (629.2 oK) than the processing plays an important role in determining
retreating side (605 oK) along welding line and the microstructure and properties of the processed
temperature in the top of workpiece under tool sheet. In addition, a new modeling approach based
shoulder is higher(645 oK) than bottom (635.79oK). on experiments and theory is proposed to predict the
The results of the simulation are in good agreement grain size of the friction stir processed material as a
with that of experimental results. The peak function of process parameters. The proposed
temperature obtained was 70% of the melting point approach involves determination of the strain rate
of parent metal. distribution in the processed (deformation) zone
based on the velocity fields of the material and
Selvamani S.T et al[3] was carried out A three correlating the strain rate distribution with the
dimensional finite element model is developed to average grain size of the resulting microstructure
study the thermal history in the butt welding of 6061 using Zener-Holloman parameter.
aluminum alloy using ANSYS package. Solid 70
elements are used to develop the model. The heat M Song and R Kovacevic[6] was formulate A
source incorporated in the model involves the mathematical model to describe the detailed three-
friction among the material, probe and shoulder. In dimensional transient heat transfer process in friction
this work, a moving co-ordinate has been introduced stir welding (FSW) is presented. This work is both
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5. ranjitsinh D. Jadeja, tausif M. Shaikh / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 1, January -February 2013, pp.612-617
theoretical and experimental. An explicit central Tran Hung Tra et al[9] was investigated Behavior
diVerential scheme is used in solving the control of fatigue crack which was propagated at some
equations, the heat transfer phenomena during the representative areas in the friction stir welded
tool penetrating, the welding and the tool-removing (FSWed) joint of aluminum alloy 6063 T5 was
periods that are studied dynamically. The heat input studied. By extracting the T–L orientation specimens
from the tool shoulder is modelled as a frictional so that the loading axis on the fatigue test and the
heat and the heat from the tool pin is modelled as a crack propagation direction were transverse and
uniform volumetric heat generated by the plastic longitudinal to the welding direction, respectively,
deformation near the pin. The temperature variation the crack propagation tests were carried out for both
during the welding is also measured to validate the the as-welded and post-weld heat treated (PWHTed)
calculated results. The calculated results are in good FSWs at room temperature and 200 _C. The
agreement with the experimental data. experiments showed that the fatigue crack
propagation (FCP) rates were sensitive to the
G. Buffa, L. Fratini, S. Pasta[7] was worked on the propagating location, the test temperature, and the
effects of the thermal and mechanical actions on the PWHT condition as well. It was also found that the
residual stress field occurring in friction stir welding different FCP rates were driven by the
(FSW) of AA7075-T6 were investigated. Both microstructural influences in and around the welded
numerical and experimental analyses were carried zone. While the residual stress was remarkable in the
out to highlight the metallurgical phenomena and shoulder limit areas, it had a minor effect on the FCP
induced residual stresses in FS welded blanks. The behavior.
welding process was simulated using a continuous
rigid-viscoplastic finite element model (FEM) in a 3. CONCLUSION
single block approach through the software From the above literature survey we find
DEFORM-3DTM, Lagrangian implicit code that there are many researches done on experimental
designed for metal forming processes. Then, the and numerical investigation of friction stir welding.
temperature histories at each node of the FE model But I found that there are very few researches done
were extracted and transferred to a further FE model on AA6063-T6 Aluminium alloy so we want to do
of the joint considering an elasto-plastic behavior of research on this material. We like to use Finite
the AA7075-T6 material. The map of the residual Element analysis for optimization.
stress were extrapolated from the numerical model
along several directions. Thus the cut-compliance REFERENCES
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6. ranjitsinh D. Jadeja, tausif M. Shaikh / International Journal of Engineering Research and
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