This document discusses advances in tooling materials for friction stir welding (FSW). FSW has become a major joining process since its invention in 1991. New tool designs like the Whorl, MX-Triflute, and Flared-Triflute probes have improved weld quality. Variations in tooling like Skew-Stir and Re-Stir have increased the weld region. Stronger materials like molybdenum alloys and ODS alloys allow welding more difficult alloys but are more expensive. New tool designs and materials are improving FSW for applications like aerospace and shipbuilding.
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
Five Steps to Optimize Casting and Eliminate DefectsDesign World
Traditionally, engineers had a hard time predicting defects with their cast designs. With simulation, engineers can now predict defects from porosity and cold shots to air pockets.
Watch the webinar: http://www.designworldonline.com/optimize-casting-and-eliminate-defects/#_
Introduction to Manufacturing Processes and their Applications (Casting, Forging, Sheet metal working and Metal joining processes), Description of Casting process: Sand casting(Cope&Drag). Sheet metal Forming,(shearing, bending, drawing), Forging (Hot working and cold working comparison) ,Electric Arc welding, Comparison of Welding, Soldering, Brazing
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
Five Steps to Optimize Casting and Eliminate DefectsDesign World
Traditionally, engineers had a hard time predicting defects with their cast designs. With simulation, engineers can now predict defects from porosity and cold shots to air pockets.
Watch the webinar: http://www.designworldonline.com/optimize-casting-and-eliminate-defects/#_
Introduction to Manufacturing Processes and their Applications (Casting, Forging, Sheet metal working and Metal joining processes), Description of Casting process: Sand casting(Cope&Drag). Sheet metal Forming,(shearing, bending, drawing), Forging (Hot working and cold working comparison) ,Electric Arc welding, Comparison of Welding, Soldering, Brazing
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Journals
Abstract Friction Stir Welding (FSW) is a solid state welding process. In particular, it can be used to join high-strength aerospace magnesium and other metallic alloys that are hard to weld by conventional fusion welding. It was performed on 4 mm thickness AZ91 Magnesium alloy. Magnesium alloy have more advantage than aluminum such as light weight, softer, tendency to bend easily, cost effective in terms of energy requirements so magnesium alloy has selected in this FSW technique. In friction stir welding (FSW), a momentous residual stress is present in weld due to complex nature of fixturing system compared to fusion welding. These residual stresses can affect properties of welded components during service. Therefore, for estimating magnitude of welding residual stresses and their nature of distribution along with thermal history, a three dimensional non- linear thermo-mechanical finite element (NLTMFE) model using ABAQUS/ CAE package was developed for butt welded magnesium alloy AZ91. The objective of this work is to predict the temperature distribution in both materials and evaluate the mechanical properties during the friction stir welding on magnesium alloy. Keywords: Fsw, Nltmfe, Abaqus, Cae, Az91.
Numerical simulation of friction stir butt welding processes for az91 magnesi...eSAT Publishing House
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 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.
Friction Stir.Welding is an advance metal joining process: A ReviewIJERA Editor
The friction stir welding is recently developed solid state welding process which overcome the problem
associated with fusion welding technology. The properties achieved by friction stir welding is better than that
achieve by fusion welding technique It has been invented as a solid-state joining technique and initially applied
to aluminum alloys. FSW is used to replace rivets joints in the aeronautical industry. Recently the aircraft and
military industries widely have been using aluminum alloys particularly because of their fine strength to weight
ratio. However in compare with steels they represent welding difficulties and also lower ductility. In last years it
has been observed that Friction Stir Welding (FSW) method represents better microstructure and mechanical
properties than conventional methods in welding aluminum alloys. It has been widely investigated for mostly
low melting materials, such as Al, Mg and Cu alloys. Aluminum is the most usable material in engineering
application and a lot of improvement is needed in the area of its welding. The latest works on friction stir
welding of aluminum have been directed towards improving the quality of weld, reducing defects and applying
the process of FSW to aluminum for specific applications. This joining technique is energy efficient,
environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys
and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the
most significant development in metal joining in a last decade. The FSW of Aluminums and its alloys has been
commercialized; and recent interest is focused on joining dissimilar materials. However, in order to
commercialize the process, research studies are required to characterize and establish proper process parameters
for FSW. This paper summarizes the trends and advances of this welding processes in the field of welding.
Future aspects of the study are also discussed.
Casting with Al 7075 alloys is considered to have good mechanical properties. The
quality of casting products is also influenced by gating systems, riser use and
mechanical properties. The purpose of this study was to determine the mechanical
properties of propeller cast products using a riser, applying the use of risers to produce
flawless products. The research method is propeller casting using two gating systems
and using a riser. The results of this study indicate that from the two propeller casting
using a riser in the TIP section but the hardness value is different, namely directly gated
with the riser in the TIP section 73.24 HB, section HUB 72.24 HB. While on the upper
channel with risers at TIP 67.5 HB, HUB 75.44 HB. For the micro structure there is a
porosity defect on the channel directly with the riser caused by the freezing process
during the pouring process of metal liquid in the mold, the direct channel with the riser
is defect that occurs on the propeller leaves, while the upper duct with the riser is not
defective and the results are perfect.
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.