This document discusses the verification of Johnson-Cook material model constants for aluminum alloy AA2024-T3 to simulate friction stir welding using finite element analysis. It finds that the Johnson-Cook constants have a significant impact on the accuracy of simulation results for temperature, forces, and defect formation. The study tests various constants reported in literature and finds that with constants A=369 MPa, B=684 MPa, n=0.73, C=0.0083, m=1.7, the simulation results most closely match experimental findings. It concludes the selection of accurate material constants is important for finite element modeling of friction stir welding and other severe plastic deformation processes.
Verification of johnson cook material model constants of aa2024-t3 for use in...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
Study on Effect of Manual Metal Arc Welding Process Parameters on Width of He...IJMER
This document summarizes a study on the effect of welding parameters on the width of the heat affected zone (HAZ) during manual metal arc welding (MMAW) of mild steel. The welding parameters investigated included current, voltage, welding speed, and heat input. Samples were welded with varying combinations of these parameters. The microstructure and width of the HAZ was then analyzed for each sample. The goal of the study was to determine the relationship between welding parameters and HAZ width in order to control and minimize the HAZ during MMAW welding of mild steel.
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.
A Review Paper- Influence Of Welding On The Mechanical Properties Of Mild Ste...IJSRED
This paper reviews the influence of welding on the mechanical properties of mild steel and EN31 butt welds at different groove angles. It discusses how the welding process uses heat to join materials and can change the mechanical properties near the heat-affected zone. It explores how factors like welding current, groove angle, and plate thickness can affect properties like hardness, impact strength, tensile strength, and compressive strength. The paper concludes that these mechanical properties may vary with plate thickness and groove angle for mild steel, EN8, and EN31 materials.
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.
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.
Effect of configuration on lateral displacement and cost of the structure for...eSAT Journals
Abstract
The choice of a cost effective lateral-force-resisting system for high-rise structures is challenging. There is no streamlined methodology to quantitatively compare the cost-effectiveness of each system beyond the more qualitative perception based evaluation of advantages or disadvantages. Developers currently base their decisions on architectural layout and structural integrity. Cost considerations are often primarily based on experience.
This decision making process has three primary shortfalls.
1) It may not incorporate factors which greatly affect the economy of a particular framing system.
2) It may not allow engineers to carryout designs at the least cost.
3) Comparison of framing systems may not address the specific building types.
This investigation proposes a prototype cost-effective model for selecting either a skeleton framing system or skeleton frame with bracing system for steel structural frames. A model for selecting cost-effective skeleton framing system or skeleton frame with bracing system will be a valuable tool for all decision makers. Engineers, in particular, will be able to select optimal steel framing faster, thus reducing design time and iterations. Furthermore, selection of economic framing system will also result in direct cost savings for steel structural frames.
The study involves the design and cost estimation of steel frames representing skeleton framing system and skeleton frame with bracingsystem. The cost effectiveness of the framing systems are compared based on lateral displacement requirements and cost.The preferred framing system should meet lateral displacement requirements and is lower in cost. The results of this pilot study showed that the Skelton framing system with bracing is the cost-effective choice for 30storeys steel space frames at wind speeds of 55m/sec, 50m/sec and 47m/sec.
Keywords: Bracings, SFS (Skeleton framing system), SFWB (Skeleton frame with bracing system) etc…
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.
Verification of johnson cook material model constants of aa2024-t3 for use in...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
Study on Effect of Manual Metal Arc Welding Process Parameters on Width of He...IJMER
This document summarizes a study on the effect of welding parameters on the width of the heat affected zone (HAZ) during manual metal arc welding (MMAW) of mild steel. The welding parameters investigated included current, voltage, welding speed, and heat input. Samples were welded with varying combinations of these parameters. The microstructure and width of the HAZ was then analyzed for each sample. The goal of the study was to determine the relationship between welding parameters and HAZ width in order to control and minimize the HAZ during MMAW welding of mild steel.
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.
A Review Paper- Influence Of Welding On The Mechanical Properties Of Mild Ste...IJSRED
This paper reviews the influence of welding on the mechanical properties of mild steel and EN31 butt welds at different groove angles. It discusses how the welding process uses heat to join materials and can change the mechanical properties near the heat-affected zone. It explores how factors like welding current, groove angle, and plate thickness can affect properties like hardness, impact strength, tensile strength, and compressive strength. The paper concludes that these mechanical properties may vary with plate thickness and groove angle for mild steel, EN8, and EN31 materials.
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.
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.
Effect of configuration on lateral displacement and cost of the structure for...eSAT Journals
Abstract
The choice of a cost effective lateral-force-resisting system for high-rise structures is challenging. There is no streamlined methodology to quantitatively compare the cost-effectiveness of each system beyond the more qualitative perception based evaluation of advantages or disadvantages. Developers currently base their decisions on architectural layout and structural integrity. Cost considerations are often primarily based on experience.
This decision making process has three primary shortfalls.
1) It may not incorporate factors which greatly affect the economy of a particular framing system.
2) It may not allow engineers to carryout designs at the least cost.
3) Comparison of framing systems may not address the specific building types.
This investigation proposes a prototype cost-effective model for selecting either a skeleton framing system or skeleton frame with bracing system for steel structural frames. A model for selecting cost-effective skeleton framing system or skeleton frame with bracing system will be a valuable tool for all decision makers. Engineers, in particular, will be able to select optimal steel framing faster, thus reducing design time and iterations. Furthermore, selection of economic framing system will also result in direct cost savings for steel structural frames.
The study involves the design and cost estimation of steel frames representing skeleton framing system and skeleton frame with bracingsystem. The cost effectiveness of the framing systems are compared based on lateral displacement requirements and cost.The preferred framing system should meet lateral displacement requirements and is lower in cost. The results of this pilot study showed that the Skelton framing system with bracing is the cost-effective choice for 30storeys steel space frames at wind speeds of 55m/sec, 50m/sec and 47m/sec.
Keywords: Bracings, SFS (Skeleton framing system), SFWB (Skeleton frame with bracing system) etc…
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.
This document reviews various welding techniques. It begins by introducing welding as a process for joining materials like metals through melting and discusses some common welding techniques like shielded metal arc welding, gas tungsten arc welding, gas metal arc welding, and flux-cored arc welding. The document then reviews literature on optimizing welding parameters and their effects on weld properties. Specifically, it looks at research optimizing parameters for gas metal arc welding, gas tungsten arc welding and submerged arc welding. The document describes the methodology for conducting experiments on gas metal arc welding and gas tungsten arc welding of austenitic stainless steel to analyze properties like hardness, strength and corrosion resistance under varied welding conditions.
Effect of chromium powder mixed dielectric on performance characteristic of a...eSAT Journals
Abstract
In this paper, the effect of chromium powder mixed dielectric fluid on machining characteristics of AISI D2 die steel has been studied. Peak current, pulse on time, pulse off time, concentration of powder are the process parameters. The process performance is measured in terms of material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR). The research outcome will identify the important process parameters that maximize MRR, minimize TWR and SR. The design of experiment has been undertaken using Taguchi method. ANOVA analysis has been used to investigate the percentage contribution of each process parameter for optimizing the performance. The study indicates that all the selected parameters except pulse off time have a significant effect on MRR. Current is found to be the most significant factor for MRR and TWR. With increase in current, TWR increases. Also, surface roughness increases with increase in pulse off time.
Keywords: PMEDM, Material removal rate, Tool wear rate, Surface roughness, Taguchi method
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.
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.
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
Evaluation of the Influence of the Welding Current on the Surface Quality of ...theijes
Welding is a metallurgical process; all aspects of a welding process can be more or less, related to metallurgy of the materials involved in welding,either base metal or electrodes. It is a rapid joining technique extensively used for joining thin assemblies in military and automotive applications. The resistance spot welding process bonds contacting metal surfaces via the heat obtained from resistance to an electrical current flow.Process parameters like welding current, time and pressure are closely controlled to obtain superior weld quality. Welding current is generally considered as a key factor affecting the weld quality. The paper deals with evaluation of welding current as the most important parameter of resistance spot welding on the surface quality of welded steel sheets.Various values of welding current were used in the experiments and consequently the marks of spot welded tips on the welded material surfaces were observed. Hot-dip galvanized steel sheets of H220PD and TRIP RAK 40/70 were used for resistance spot welding.
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.
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
Friction stir welding of aluminium 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…
Influence of process parameters on depth of penetration of welded joint in mi...eSAT Journals
Abstract The effect of various welding process parameters on the weldability of Mild Steel specimens of grade EN-3A having dimensions 150mm× 100mm× 6 mm, welded by metal inert gas welding were investigated. The welding current, arc voltage, welding speed, are chosen as welding parameters. The depth of penetrations were measured for each specimen after the welding operation is done on closed butt joint and the effects of welding speed, current, voltage parameters on depth of penetration were investigated. Index Terms: Mild Steel (EN-3A), metal inert gas welding, welding current, arc voltage and welding speed.
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.
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.
A review paper on friction stir weldingNaga Muruga
This document summarizes 15 journal articles on friction stir welding (FSW). It provides details on the materials studied, parameters analyzed, and key findings for each article. The articles covered new FSW tool designs, mechanical properties of joints, process monitoring techniques, microstructure analysis, and modeling of residual stress and material flow. Studying these articles helped provide an overview of recent developments and improvements in FSW, as well as the most common parameters analyzed to optimize the process.
The document reviews research on thermal, thermo-mechanical, and thermal stress distribution during friction stir welding (FSW). Several studies have used experimental, theoretical, numerical, and analytical methods to analyze temperature distribution, heat generation, residual stresses, and other thermal effects during FSW. Finite element modeling has been widely used to model thermal phenomena and compare results to experimental data. The research shows that temperature, heat input, and process parameters significantly impact weld properties. Understanding thermal effects is important for optimizing FSW parameters and conditions.
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.
The effect of welding heat input and welding speed on microstructure of chrom...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
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
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.
Study of Simulated Temperature of Butt Joint during Friction Stir Welding Of ...IJERA Editor
Friction stir welding (FSW) is one of the latest welding technology that utilizes a special tool for generation of frictional heat in the work piece by its rotation due to which joining occurs without melting of metal. For this reason friction stir welding lies under the category of solid state joining. A part from experimental work, there is large space to work on simulation of FSW by using simulation tools. In the present paper, simulation of friction stir welding of aluminium alloy AA-6061 is done by using HyperWeld module of Altair HyperWorks. The virtual experiment of friction stir welding is conducted for variable tool rotational speeds with constant travelling speed and study of simulation results of variation in temperature distribution along the weld line of butt joint is done. The results of simulation shows that the temperature is symmetrically distributed along the weld line. It is observed that the maximum temperature along the weld line increases with the increase in rotational speed. It is also observed that the temperature at advancing side is greater that retreating side.
The document is a collection of images and short phrases posted on social media. It discusses checking phones instead of having real social interactions, the dangers of distracted driving, finding new friends and opportunities by looking up from phones, and encourages togetherness.
This document provides a quiz to test financial literacy. It contains questions about concepts like compound interest, types of bank accounts, credit cards, long-term savings plans, investments, credit scores, and budgets. After reviewing the concepts, students are assigned to create a comic strip teaching others about one of the financial topics.
This document reviews various welding techniques. It begins by introducing welding as a process for joining materials like metals through melting and discusses some common welding techniques like shielded metal arc welding, gas tungsten arc welding, gas metal arc welding, and flux-cored arc welding. The document then reviews literature on optimizing welding parameters and their effects on weld properties. Specifically, it looks at research optimizing parameters for gas metal arc welding, gas tungsten arc welding and submerged arc welding. The document describes the methodology for conducting experiments on gas metal arc welding and gas tungsten arc welding of austenitic stainless steel to analyze properties like hardness, strength and corrosion resistance under varied welding conditions.
Effect of chromium powder mixed dielectric on performance characteristic of a...eSAT Journals
Abstract
In this paper, the effect of chromium powder mixed dielectric fluid on machining characteristics of AISI D2 die steel has been studied. Peak current, pulse on time, pulse off time, concentration of powder are the process parameters. The process performance is measured in terms of material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR). The research outcome will identify the important process parameters that maximize MRR, minimize TWR and SR. The design of experiment has been undertaken using Taguchi method. ANOVA analysis has been used to investigate the percentage contribution of each process parameter for optimizing the performance. The study indicates that all the selected parameters except pulse off time have a significant effect on MRR. Current is found to be the most significant factor for MRR and TWR. With increase in current, TWR increases. Also, surface roughness increases with increase in pulse off time.
Keywords: PMEDM, Material removal rate, Tool wear rate, Surface roughness, Taguchi method
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.
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.
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
Evaluation of the Influence of the Welding Current on the Surface Quality of ...theijes
Welding is a metallurgical process; all aspects of a welding process can be more or less, related to metallurgy of the materials involved in welding,either base metal or electrodes. It is a rapid joining technique extensively used for joining thin assemblies in military and automotive applications. The resistance spot welding process bonds contacting metal surfaces via the heat obtained from resistance to an electrical current flow.Process parameters like welding current, time and pressure are closely controlled to obtain superior weld quality. Welding current is generally considered as a key factor affecting the weld quality. The paper deals with evaluation of welding current as the most important parameter of resistance spot welding on the surface quality of welded steel sheets.Various values of welding current were used in the experiments and consequently the marks of spot welded tips on the welded material surfaces were observed. Hot-dip galvanized steel sheets of H220PD and TRIP RAK 40/70 were used for resistance spot welding.
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.
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
Friction stir welding of aluminium 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…
Influence of process parameters on depth of penetration of welded joint in mi...eSAT Journals
Abstract The effect of various welding process parameters on the weldability of Mild Steel specimens of grade EN-3A having dimensions 150mm× 100mm× 6 mm, welded by metal inert gas welding were investigated. The welding current, arc voltage, welding speed, are chosen as welding parameters. The depth of penetrations were measured for each specimen after the welding operation is done on closed butt joint and the effects of welding speed, current, voltage parameters on depth of penetration were investigated. Index Terms: Mild Steel (EN-3A), metal inert gas welding, welding current, arc voltage and welding speed.
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.
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.
A review paper on friction stir weldingNaga Muruga
This document summarizes 15 journal articles on friction stir welding (FSW). It provides details on the materials studied, parameters analyzed, and key findings for each article. The articles covered new FSW tool designs, mechanical properties of joints, process monitoring techniques, microstructure analysis, and modeling of residual stress and material flow. Studying these articles helped provide an overview of recent developments and improvements in FSW, as well as the most common parameters analyzed to optimize the process.
The document reviews research on thermal, thermo-mechanical, and thermal stress distribution during friction stir welding (FSW). Several studies have used experimental, theoretical, numerical, and analytical methods to analyze temperature distribution, heat generation, residual stresses, and other thermal effects during FSW. Finite element modeling has been widely used to model thermal phenomena and compare results to experimental data. The research shows that temperature, heat input, and process parameters significantly impact weld properties. Understanding thermal effects is important for optimizing FSW parameters and conditions.
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.
The effect of welding heat input and welding speed on microstructure of chrom...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
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
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.
Study of Simulated Temperature of Butt Joint during Friction Stir Welding Of ...IJERA Editor
Friction stir welding (FSW) is one of the latest welding technology that utilizes a special tool for generation of frictional heat in the work piece by its rotation due to which joining occurs without melting of metal. For this reason friction stir welding lies under the category of solid state joining. A part from experimental work, there is large space to work on simulation of FSW by using simulation tools. In the present paper, simulation of friction stir welding of aluminium alloy AA-6061 is done by using HyperWeld module of Altair HyperWorks. The virtual experiment of friction stir welding is conducted for variable tool rotational speeds with constant travelling speed and study of simulation results of variation in temperature distribution along the weld line of butt joint is done. The results of simulation shows that the temperature is symmetrically distributed along the weld line. It is observed that the maximum temperature along the weld line increases with the increase in rotational speed. It is also observed that the temperature at advancing side is greater that retreating side.
The document is a collection of images and short phrases posted on social media. It discusses checking phones instead of having real social interactions, the dangers of distracted driving, finding new friends and opportunities by looking up from phones, and encourages togetherness.
This document provides a quiz to test financial literacy. It contains questions about concepts like compound interest, types of bank accounts, credit cards, long-term savings plans, investments, credit scores, and budgets. After reviewing the concepts, students are assigned to create a comic strip teaching others about one of the financial topics.
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Este documento proporciona una introducción a varias funciones avanzadas de Excel, incluyendo funciones matemáticas (suma, producto, promedio), lógicas (máximo, mínimo), formato condicional, filtros y tablas/gráficos dinámicos. Explica cómo usar estas funciones para analizar y resumir grandes cantidades de datos, así como dar formato a celdas en base a criterios determinados.
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This document lists the names of various artists and artworks. It includes 18 artist names, some with additional details like the title of the artwork. The majority of names appear to be individual artists, but a few have multiple listings, indicating they may have multiple works included or described. Overall this summary provides an inventory of artists and art pieces, without any additional context about the meaning or purpose of the document.
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What have you learnt about technologies from the process of constructing this...liamouse96
The document discusses the various technologies the student learned during the process of creating a thriller opening called "Payback". They learned how to use a Kodak camcorder to record professional footage, including how to improve sound and add effects. They also learned the importance of using a tripod to keep shots steady and allow panning. For editing, they used iMovie and learned basic and advanced editing tools. Additional media technologies like Prezi, Blogger, and SlideShare were used to present their work, and they learned how to use these platforms to link accounts, import different file formats, and upload content.
What have you learnt about technologies from the process of constructing this...liamouse96
The document discusses the various technologies the students learned during the process of creating a thriller opening called "Payback". They learned how to use a Kodak camcorder to record professional footage, including adding audio and effects. Using a tripod was also important for steady shots and allowed panning. The students learned to edit using iMovie, starting with basic tools and progressing to advanced features like color alteration and effects. Additional media technologies like Prezi, Blogger, and SlideShare were used to present work in an interactive way and link all elements together in one place.
This document provides an introduction to text and images for various artists including Banksy, (Netherlandish), Carl Jung - Red Book, Kurt Schwitters, Jeff Wolin, Jean Michel Basquiat, Squeak Carnwath, Jess Reno, Lesley Dill, Jerzy Ruszczynski, Ed Ruscha, Glenn Ligon, Betty Levy – Letters Home, Jason Rhoades, Mel Bochner, Lorna Simpson, Susan Gaylord, Susan Richardson, Karen Justis, (unknown), and Almudena Blanca. The document also references lettering.
Modeling and Simulation of Base Plate of Friction Stir Welding-Advanced Weldi...ijsrd.com
Friction stir processing is an emerging technique based on the principles of friction stir welding (FSW). It is a solid-state joining method that is energy efficient, environmentally friendly, and versatile. It is considered by many to be the most significant development in metal joining in a decade. The basic concept of friction stir processing is remarkably simple. A rotating tool with pin and shoulder is inserted in the material to be joined, and traversed along the line of interest. The heating is localized, and is generated by friction between the tool and the work piece, with additional adiabatic heating from metal deformation. A processed zone is produced by movement of material from the front of the pin to the back of the pin.
3 dimensional nonlinear finite element analysis of both thermal and mechanica...Alexander Decker
This document discusses a 3D finite element analysis of the thermal and mechanical response during friction stir welding of 2024-T3 aluminum plates. A coupled thermal-mechanical model is used to sequentially analyze the temperature distribution during welding and resulting thermal residual stresses. Both the heat input from the tool shoulder and pin are considered. The model predicts the highest tensile stresses occur in the longitudinal direction within the heat affected zone. Various process parameters are analyzed, including bottom surface heat transfer conditions and thermal contact conductance at interfaces. The results agree well with published experimental data.
This document summarizes a study that investigated the mechanical and metallurgical properties of friction stir welded AA1100 aluminum alloy joints. Different welding parameters were tested, including tool rotation speed (800-1400 rpm) and material positioning (advancing vs. retreating side). Microhardness, tensile, and fracture surface tests were used to evaluate the mechanical properties. Optical and SEM microscopy were used to analyze the microstructural evolution. The goal was to understand how processing parameters affect properties and defect development in similar AA1100 alloy joints.
Investigation and analysis of metallurgical and mechanical properties of aa11...Alexander Decker
1. The document investigates the mechanical and metallurgical properties of friction stir welded joints of AA1100 aluminum alloy fabricated at different tool rotational speeds and material positions.
2. Tensile tests, microhardness tests, and optical/SEM microscopy of the welds were used to evaluate the mechanical properties and microstructure of the joints.
3. The results showed that joints welded at 1200 rpm had the optimum properties, with smooth weld surfaces and good tensile strength, yield strength, and elongation. Microhardness was also highest at this welding condition.
FINITE ELEMENT SIMULATION OF WELDING IN STEEL PIPES AND PLATESIjorat1
Welding is a common joint type in the fabrication of structural members in aerospace, aeronautical and
pressure vessel industries. Welding is highly reliable and efficient metal joining process. The thermal response of
materials to a welding heat source sometimes causes mechanical problems, e.g. residual stresses and distortion and
changes in mechanical properties due to changes in the microstructure. The Finite Element Method (FEM) is the most
commonly used numerical technique, which provides accurate estimates of thermal parameters for this analysis. Finite
Element Analysis (FEA) is a tool used especially in determining the thermal stresses and temperature distribution of
the welded models, which are difficult to analyze by hand calculations. The objective of the current work is to study
transient temperature in both arc welded pipe and welded plate of 304L stainless steel. The object is modeled in 3D and
analyzed using FEA with an element type of SOLID70 and heat density of the moving circular area heat source is used.
Knowledge of temperature distribution patterns is useful in any welding process to predict microstructure and
distortion. In the current work a model has been developed to predict the thermal cycles during welding of 304L
pipeline steel
The document describes an experimental and FE investigation of friction welding aluminum to copper joints. It discusses the background and types of friction welding processes. The objectives are to prepare a friction welding setup, conduct experiments welding aluminum and copper, evaluate the effect of parameters on joint performance, determine optimal parameters using Taguchi methods, conduct FE simulations, and verify optimal conditions. A literature review covers previous studies optimizing friction welding parameters for different material combinations. The methodology discusses materials, equipment, test methods for tensile strength, hardness and resistance, and using Taguchi design to optimize parameters.
Resistance Spot Welding of CRCA Steel sheets using surface modified electrodesAM Publications
Resistance spot welding has established itself across a wide range of industries as a cost-effective method
for welding. One of the problems of Resistance Spot Welding is the lifetime of welding electrode tips which affects the
quality of the welds formed. An innovative way to prevent the electrode wear is to plate the surface of the electrode
with suitable material. The material chosen in this study is Nickel and Chromium. Plating of these materials is
inexpensive and easily available. The increase in resistance due to plating the electrodes is measured. The metals are
plated on the surface with varying thicknesses separately and their effect on ultimate load, shear stress and nugget
diameter is observed by varying welding current and keeping the weld time and welding pressure constant. It is
investigated from the study that Ni plating with 35 microns thickness and Cr plating with 25 microns thickness
requires less current to weld spots of higher strengths compared to non plated electrodes. This is due to increase in
resistance of the weld system due to plating which requires less current as resistance of the weld system is increased.
Optimization of Process Parameters of Friction Stir Welding for Similar He-30...IRJET Journal
This document discusses optimization of process parameters for friction stir welding of similar HE-30 aluminium alloy. It begins with an abstract that describes the friction stir welding process and the objectives of using Taguchi methods to optimize welding parameters to achieve high tensile strength. It then provides background on friction stir welding, describing how it is a solid-state welding process that uses a rotating tool to plasticize materials without melting. The document discusses how process parameters like rotational speed, travel speed, and tool geometry can affect joint quality and properties. It aims to use an experimental design and analysis approach to determine the optimum welding conditions for high tensile strength when joining HE-30 aluminium alloy.
Since so many years a problem occurs in KSB Pump Va mbori for casting process i.e. cracks occurs in the castings & it is repeated one. Therefore the compan y has given opportunity to me to solve this problem . In case of steel casting there are mainly cracks & also blo w holes induced due to the casting procedure. There are many factors for the casting defects .The factor is unev en material feeding in casting & also due to the mo uld material & also the core material. These cracks finally brea k directly the component of the casting i.e. in cas e of pump the casting component is like Impeller,Volute casing & casing cover. At the time of feeding of steel material in to the casting the material is in liquid us form i.e. it i s hot material & this material is feeding into casting at the time o f feeding it develop different region of heat. At o ne side the temp is high &at other side the temp is low this also pr oduce cracks. To simulate that casting we use the M AGMA SOFTWARE for simulation & validate it using NDT.
This document summarizes a study that investigated the effects of different quenching media (brine solution, water, diesel oil, and air) on the impact strength of single-vee butt welded mild steel joints. Samples of mild steel were welded using a coated electrode and then heat treated at temperatures from 2000°C to 6000°C before being quenched in the different media. Impact testing found that quenching in brine solution resulted in the lowest average impact strength, while quenching in air produced the highest average impact strength. Overall, the results indicated that air was the best quenching medium for welded mild steel, followed by diesel oil, water, and brine solution, when considering impact
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
INVESTIGATION OF RESIDUAL STRESSES IN WELDING AND ITS EFFECT ON MECHANICAL BE...Journal For Research
AISI310 is widely used in the manufacture of heat exchangers, radiant tubes, muffles, furnace parts, food processing equipments. Welding is widely used fabrication method in such type of industrial applications; but unfortunately welding induces few problems such as residual stresses and induced distortions. Residual stresses have significant effect on performance of the weld joint subjected to loading. The AISI310 is welded using matched filler material. Thus the weld joint consist of two different materials having different behavior under tensile loading. In this study residual stresses are estimated by using Labeas and Diamantakos formula and values are assigned as an initial stress in FEM of weld joint. The weldment specimen model is subjected to tensile loading and effect of residual stress on local yielding is investigated. The ANSYS is used for this purpose. The response of weld joint to monotonically increasing tensile load is determined experimentally by conducting the transverse and longitudinal tension tests on UTM. The stress-strain behavior of the weld joint is studied vis a vis virgin 310 stainless steel alloy.
a survey on submerged arc welding (saw) reviewNEERAJKUMAR1898
This document provides a review of submerged arc welding (SAW). It begins with an introduction to SAW, describing it as a process where the arc is shielded by a blanket of granular and fusible flux. It then reviews prior literature on SAW, discussing studies on the effects of process parameters on weld geometry and quality, and post-weld heat treatments. The document also outlines the principles of SAW, including the continuously-fed wire electrode and use of flux to shield the arc from atmosphere and increase heat efficiency. It provides diagrams illustrating the SAW process.
The International Journal of Engineering and Science (The IJES)theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Study of Pitting Corrosion Behavior of FSW weldments of AA6101- T6 Aluminium ...IJERA Editor
Friction Stir Welding (FSW) is a promising solid state joining process widely used generally for Al alloys,
especially in aerospace, marine and automobile applications. In present work, the microstructure and corrosion
behavior of friction stir welded AA6101 T6 Al alloy is studied. The friction stir welding was carried using
vertical milling machine with different tool rotational speeds and welding speeds. The microstructure at weld
nugget or stir zone (SN), thermo-mechanically affected zone (TMAZ), heat affected zone (HAZ) and base metal
were observed using optical microscopy. The corrosion tests of base alloy and welded joints were carried out in
3.5% NaCl solution at temperature of 30º C. Corrosion rate and emf were determined using cyclic polarization
measurement.
1 ijcmes dec-2015-17-optimization of friction stir welding parameters for joi...INFOGAIN PUBLICATION
Friction stir welding was a promising welding technology from the same moment of its existence because of its easy use, being ecologically friendly processed and with no need for filler metal. The present paper discusses the investigate the mechanical properties in order to demonstrate the feasibility of friction stir welding for joining Al 6061 aluminum alloy welding was performed on pipe. The pipe sections, 30mm, and relatively thin walled 2, 3 and 4 mm. Wire welded as similar alloy joints using (FSW) process In order to investigate the effect of rotation speed 485,710, 910, 1120,1400 and 1800 RPM and travel speeds 4, 8 and 10 mm/min. On mechanical propertie.
This work also focuses on mathematic models such as regression analysis (RA) to predict the tensile strength, the percentage of elongation and hardness of friction stir welded 6061 aluminum alloy. The Tensile strength, the percentage of elongation and hardness of weld joints were predicted by taking the parameters Tool rotation speed, material thickness and travel speed as a function. The results obtained through regresion analysis The models have been proved to be successful in terms of agreement with experimental results ratio 94.6%.
Study and Analysis of the Fatigue Behaviour of Friction Stir Butt Welded Dis...IRJET Journal
1) The study analyzed the tensile strength and fatigue behavior of friction stir butt welded dissimilar aluminum alloys AA6082 and AA5754.
2) Fatigue tests showed the dissimilar welds had lower tensile strength and fatigue strength than the base materials AA6082 and AA5754, but comparable strength to AA5754.
3) The fatigue performance of the AA6082 and AA5754 friction stir welded joints showed a shallower stress-life (S-N) curve with improved fatigue performance at lower stress ranges.
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.
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
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ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
Electric vehicle and photovoltaic advanced roles in enhancing the financial p...IJECEIAES
Climate change's impact on the planet forced the United Nations and governments to promote green energies and electric transportation. The deployments of photovoltaic (PV) and electric vehicle (EV) systems gained stronger momentum due to their numerous advantages over fossil fuel types. The advantages go beyond sustainability to reach financial support and stability. The work in this paper introduces the hybrid system between PV and EV to support industrial and commercial plants. This paper covers the theoretical framework of the proposed hybrid system including the required equation to complete the cost analysis when PV and EV are present. In addition, the proposed design diagram which sets the priorities and requirements of the system is presented. The proposed approach allows setup to advance their power stability, especially during power outages. The presented information supports researchers and plant owners to complete the necessary analysis while promoting the deployment of clean energy. The result of a case study that represents a dairy milk farmer supports the theoretical works and highlights its advanced benefits to existing plants. The short return on investment of the proposed approach supports the paper's novelty approach for the sustainable electrical system. In addition, the proposed system allows for an isolated power setup without the need for a transmission line which enhances the safety of the electrical network
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Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
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Introduction- e - waste – definition - sources of e-waste– hazardous substances in e-waste - effects of e-waste on environment and human health- need for e-waste management– e-waste handling rules - waste minimization techniques for managing e-waste – recycling of e-waste - disposal treatment methods of e- waste – mechanism of extraction of precious metal from leaching solution-global Scenario of E-waste – E-waste in India- case studies.
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Verification of johnson cook material model by sanjeev n k
1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 06 | June-2014, Available @ http://www.ijret.org 1
VERIFICATION OF JOHNSON-COOK MATERIAL MODEL CONSTANTS OF AA2024-T3 FOR USE IN FINITE ELEMENT SIMULATION OF FRICTION STIR WELDING AND ITS UTILIZATION IN SEVERE PLASTIC DEFORMATION PROCESS MODELLING
Sanjeev N K1, Vinayak Malik2, H. Suresh Hebbar3
1 Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Mangalore, India
2 Department of Mechanical Engineering, Indian Institute of Science, Bangalore, India
3 Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, Mangalore, India
Abstract
Friction Stir Welding (FSW) is a solid state joining process which is gaining significance in many joining applications. The increased use of various commercial Finite Element (FE) packages are also aiding in widening the applicability of FSW by simulating the process for better understanding. However, reliability and accuracy of estimated results depend much on the selected modeling approach and governing equations. The principal equations that govern modeling of FSW are the material model and the friction model. This paper aims in discussing the influence of Johnson–Cook material model constants reported in literature on results obtained from FE simulations of FSW using ABAQUS. The current study also helps in extending the screened and identified constants of Johnson-Cook material model to processes undergoing severe plastic deformation.
Key Words: FE modeling, FSW, Coupled Eulerian Lagrangian, Johnson-Cook Material Model, ABAQUS
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1. INTRODUCTION
Friction stir welding is a modification of the traditional friction welding. It is a process patented by The Welding Institute in Cambridge, England in 1991. It is a mechanical process whereby solid-state welding is performed using heat generated from the friction of a rotating tool and plastic deformation of weld material [1, 2]. Two metals that are to be welded together are held in place against a backing plate using a clamping system. The rotating tool is then slowly plunged with a downward force into the weld joint. It dwells for a few seconds while enough heat is generated due to friction that the welded material would begin to flow around the tool. Once this point is reached, the tool is traversed along the joint forming the weld behind the tool as it moves along. The schematic representation of basic principle of the FSW process illustrated in Fig-1. The main benefit of friction stir welding is that the base materials to be welded would not be reaching their melting points. FSW was initially applied to aluminum alloys. Since then FSW has rapidly evolved and has opened up a variety of research channels. It is being touted as the most significant development in metal joining in the last decade [1, 2]. Many alloys, including most aerospace Al alloys (e.g., Al 7xxx) and those regarded as difficult to weld by fusion processes (e.g., Al 2xxx), can be welded by FSW [3, 4].
Since FSW process is solid state welding, it offers metallurgical advantages over conventional fusion welding processes. Invention of the FSW process made a number of aluminium alloys, especially the copper containing 2000- series and 7000-series, receptive to welding, which were previously considered to be non-weldable primarily because of their sensitivity to cracking due essentially to a wide freezing range during solidification coupled with the formation of partially melted zones in the heat-affected zone near the fusion line. The significant advantage of FSW is that it is an environment friendly process, which does not make use of flux and consumable electrodes thereby minimizing and avoids the generation of fumes, formation of slag and ultra-violet radiation thus minimizing the level of health hazards [5].
Fig- 1: Schematic of friction stir welding process [6]
2. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 06 | June-2014, Available @ http://www.ijret.org 2
In the analysis of FSW using FE simulations, reliability and
accuracy of estimated results depend much on two major
factors. The first is the flow stress characteristics of work
materials to be welded and the second is the contact
condition at the interfaces.
The influence of work material flow stress upon FE
simulations may be less or even none when there is a
constitutive model for work material that is obtained
empirically from high-strain rate and temperature
deformation tests [7]. Johnson–Cook material model [8] is
most commonly used model to represent the thermo-visco-plastic
behavior of workpiece material. However, the
difficulty arises when one needs to implement accurate
material model and their constants for welding simulations
using a particular FE formulation. In this study, a Coupled
Eulerian Lagrangian finite element formulation is used to
simulate FSW of 2024-T3 aluminium alloy. The effects of
using various Johnson-Cook material constants are
discoursed.
Experimentally measured temperature in the work piece,
force on the tool and macro structural findings for defects
are utilized in investigation and evaluation of the results.
The results depict that the use of various values of Johnson-
Cook constants have influence in predicting temperature,
force and mainly defect formation.
2. FLOW STRESS CHARACTERISTICS
Material flow during FSW is quite complex, it depends on
the tool geometry, process parameters, and material to be
welded. It is of practical importance to understand the
material flow characteristics for optimal tool design and to
obtain high structural efficiency welds [1]. Modeling of the
metal flow in FSW is a challenging problem, but this is a
fundamental task to be understood in developing the
process. Flow models should be able to simultaneously
capture the thermal and mechanical aspects of a given
problem in adequate detail to address the following topics
[9].
Flow visualization, including the flow of similar
/dissimilar metals.
Evaluation of the heat flow that governs the
temperature field.
Tool design to optimize tool profiling for different
materials and thicknesses.
Susceptibility to formation of defects.
The material flow around the probe is one of the main
parameters, determinant for the success of FSW [1].
Numerical FSW flow modeling can be based on analyses
and techniques used for other processes, such as friction
welding, extrusion, machining, forging, rolling, and ballistic
impact [1]. As for heat flow analyses, numerical flow
models can use either an Eulerian or Lagrangian formulation
for the mesh, other solution can be the combination of both
(hybrid solution and Lagrangian–Eulerian) [9]. Here in
present simulation a coupled Eulerian Lagrangian
formulation is used, which is a hybrid solution.
FSW modelers have used a variety of material models
(constitutive laws) to characterize material behavior [10].
They are Sellars and Tegart/Sheppard and Wright law,
Johnson–Cook plasticity law, Buffa law, Zhang and Chen
law, Heurtier law, Arbegast law, Saturated Hart model and
Modified Hart model. But Johnson–Cook plasticity law is
the only law which can be fit over a wide range of strain,
strain rate, and temperature. Several materials, each with its
own set of constants, can be characterized by the Johnson–
Cook law. However, accuracy for a particular material may
be sacrificed for this versatility [8].
Hence, the Johnson-Cook model with variation in constants
for aluminium alloy 2024-T3 is analyzed here for accurate
results. Also simulations are performed with the flow stress
data drawn from the hot working guide [11] and with data as
taken by Sonne, et al. [12], to see the effect on FSW
modeling.
Table- 1: Material properties of AA2024-T3
Material properties Value
Young’s modulus of elastic. [GPa] 73.1
Poisson’s ratio 0.33
Initial yield stress [MPa] 345
Ultimate tensile strength [MPa] 483
Thermal conductivity [Wm–1K–1] 121
Coefficient of thermal expansion [°C–1] 24.7 X 10–6
Density [kgm–3] 2770
Specific heat capacity [Jk–1g°C–1] 875
Solidus [°C] 502
Liquidus [°C] 638
2.1 Johnson-Cook material law
The Johnson-Cook model/law [8] was developed by
conducting torsion and dynamic Hopkinson bar tensile tests
over a wide range of strain rates and temperatures for a
variety of engineering materials. The Johnson-Cook equation
(1) describes the flow stress as a product of the equivalent
strain, strain rate, temperature dependent terms and several
parameters to adequate the real behavior of the materials.
m
n p room
y p
o melt room
ε T-T
σ = A+B ε 1+C 1-
ε T -T
( 1 )
where Tmelt is the melting point or solidus temperature, Troom
the ambient temperature, T the effective temperature, A the
yield stress, B the strain factor, n the strain exponent, m the
temperature exponent, εp/ε0 the plastic strain and C the strain
rate factor. A, B, C, n, and m are material/test constants for
the Johnson-Cook strain rate dependent yield stress. The
Material properties of AA2024-T3, considered for
simulations are as per the values taken by Veljic, et al. [13]
and are given in Table- 1.
3. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 06 | June-2014, Available @ http://www.ijret.org 3
3. MODELING DETAILS
FE model is developed in the commercial code ABAQUS/Explicit using the Coupled Eulerian-Lagrangian Formulation, the Johnson-Cook material law, and Coulomb’s Law of friction.
The tool dimensions considered are 25 mm shoulder dia., frustum shaped pin with 6/4 diameter at base and tip, pin length is 4.7 mm. Material of tool is Hot Die Steel (HDS). The workpiece of 200 X 100 mm area and thickness of 5 mm is considered in model. The Fig- 2 shows the geometry of tool and workpiece. The Eulerian domain is meshed with multi-material thermally coupled 8-node EC3D8RT Eulerian elements [14, 15] and the void region thickness is taken as 1 mm. The friction coefficient of one is considered for all simulation conditions from the previous findings.
(All dimensions are in mm)
Fig- 2: Geometry of tool employed [16]
The simulation and experimental welding conditions considered are; Plunge velocity of 10 mm/min, Dwell Time of 10 sec, Welding speed of 60 mm/min, Plunge depth is 0.2 mm, tool tilt angle of 00 and varying the rotational speed.
4. RESULTS AND DISCUSSION
In the literature various values of constants for the Johnson-Cook were considered for an AA2024-T3 [17-22]. The simulations were performed for the values shown in Table- 2 and validation is done using results of temperature and macrographs obtained from experiment conducted on aluminium 2024-T3 alloy.
Here, for all the cases considered the melting temperature of material and room temperature are 502°C and 25°C respectively. From the literature it is found that, working temperatures in FSW should be around 0.8-0.9 Tmelt [23] for obtaining defect free welds with any set of parameters used in welding. The temperature range from literature, macrographs obtained from experiment and temperature readings measured during experiment using thermocouples are considered in studying the effect of Johnson-Cook material constants at different cases.
It can be comprehended from the simulation results (Fig- 3) that, use of incorrect Johnson-Cook material constants have a major effect on material flow, temperature predicted and in capability of model in predicting defect formation. The same effects may be realized in modeling of other manufacturing processes undergoing severe plastic deformation.
Table- 2: Material constants for the Johnson-Cook strain rate dependent yield stress
A
(MPa)
B
(MPa)
n
C
m
Case-1
345
780
0.17
0.0083
1.7
Case-2
265
426
0.34
0.015
1
Case-3
245
414
0.8
0.015
1
Case-4
325
414
0.2
0.015
1
Case-5
369
684
0.73
0.0083
1.7
Fig- 3: Effect of Johnson-Cook material constants at case 1, 2, 3 and 4 respectively; (a) Improper flow of material around the tool and poor formation of weld zones, (b) High flash
With considering μ=1 and with right Johnson-Cook constants (i.e. case-5 values) for AA2024-T3 work material, the Fig- 4 and 5 shows the capability of model in simulating defect and defect free welds for particular process
4. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 06 | June-2014, Available @ http://www.ijret.org 4
parameters. Here the only rotational speed is varied and all
other parameters are as stated under modeling details. The
results show that a defect is generated at 850 rpm and it
reduces as the rotational speed increases. The same effects
were also observed in the experimental conditions. Also
after considering appropriate Johnson-Cook material
constants, the temperature, torque and force on tool
predicted by FE model were close to experimental results.
Fig- 4: Experimentally seen and numerically predicted
defect at 850 rpm; (a) Root flaw defect, (b) Surface galling
Fig- 5: Experimentally and numerically seen weld zones at
950 rpm with no defects
5. CONCLUSIONS
Based on the results and discussion, the following
conclusions are drawn:
(i) With Johnson-Cook material constants, A=369 MPa,
B=684 MPa, n=0.73, C=0.0083, m=1.7, Tmelt = 502 °C
and Troom =25 °C for AA2024 help in obtaining results
close to experimental outputs.
(ii) The simulation results showed that the effect of change
in Johnson-Cook material constants have a major role in
accurate simulation of FSW.
(iii) The selection of correct numerical values of Johnson-
Cook material constants for a particular material
demonstrates the FE modeling capable in getting
required results and predicting processing conditions
successfully.
(iv) The study can be performed on modeling of other
manufacturing processes undergoing severe plastic
deformation, to see the effects in particular process and
conditions with variation in Johnson-Cook material
constants.
(v) FE modeling with plastic data also have the effect on
the results and it will be taken up as future study.
ACKNOWLEDGEMENTS
The authors wish to thank Department of Mechanical
Engineering, Indian Institute of Science, Bangalore, for
providing research facilities and National Institute of
Technology Karnataka, Surathkal, for constant help and
encouragement.
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BIOGRAPHIES
Sanjeev N K is M.Tech (Research) scholar at National Institute of Technology Karnataka, Surathkal, Mangalore, India. His research interests include Finite Element Analysis, Process Modeling, Friction Stir Welding and CAD/CAM. He is having 2 years industrial experience in Mechanical Design and Engineering Support Sector. He is having 2 international journal and conference publications. (E-mail: sanjeevkumaraswamy@gmail.com).
Vinayak Malik is research scholar at Indian Institute of Science, Bangalore, Karnataka, India. His research interests are Modeling of Manufacturing Processes, Friction Stir Welding and Material Science. He is having a couple of international conference and journal publications. (E-mail: vinayakmalik008@gmail.com).
H. Suresh Hebbar is Professor of Mechanical Engineering at National Institute of Technology Karnataka, Surathkal, Mangalore, India. His research interests include Kinematic Synthesis, Fracture Mechanics, Ergonomics, Processing and Tribology of Composite Materials, Machinability, Metal Forming. He is having more than 10 research publications.