Design and Experimental study of Friction stir welding of AA6061-T6 Alloy for optimization of welding parameters by using Lathe Machine (original) (raw)
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Friction stir welding is a new solid state welding process for joining metallic alloys and it is useful in serve industries for joining aluminium, magnesium and copper alloys. The various parameter such as rotational speed, transverse speed and tool tilt angle play important roles in FSW process and quality weld. The aim of this study is to know the relation between the effects of different transvers speed and tool profile on the weld quality of AA6061-T6 aluminium. The geometry of the pin tool along with the process parameters plays an important role in dictating the path that the material takes. The tool geometry was carefully chosen and fabricated to have a nearly flat welded interface pin profile. In this work, an attempt has been made to analyze the effect of various tool profiles on mechanical properties of aluminium alloy. Various tool profiles have been used to fabricate joints by using varying thickness work piece of Aluminium alloy. Numerical techniques particularly, the finite element method for the simulation of FSW for thermal, mechanical and thermo-mechanical modelling has been investigated. The current studies also aim to understand mechanical properties during the FSW.
Friction stir welding (FSW) process is a solid state joining process in which a non-consumable tool is used to generate frictional heat in the abutting surfaces. The welding parameter such as welding speed, tool rotational speed, and tool profile plays a major role in deciding the weld joint strength. In this investigation, effect of welding parameters and tool pin profile on Mechanical properties in AA6061 aluminium alloy was studied. Friction stir welding of aluminium alloy plates with a thickness of 6 mm are used to perform Friction Stir Weld joints. Tapered cylindrical, and square pin profiles have been used to fabricate the joints at three different rotational speeds i.e. 1500, 2000 and 2500 rpm with two traverse speeds of 20 and 40 mm/min. The mechanical properties (tensile strength, hardness) of the joints have been evaluated and analysed. It has been observed that the design of tool pin profile has considerable effect on tensile properties. Square pin profile tool produces the best tensile properties compared to tapered cylindrical tool pin profiles.
Smart Innovation, Systems and Technologies, springer, 2023
The friction stir welding (FSW) process is used in various industries, which includes railways, marine, aerospace, automotive to join copper, aluminum, and magnesium alloys. It is used to combine two similar or dissimilar plates. Different tool pin profiles such as triangular tool, square tool, taper threaded cylindrical tools and cylindrical grooves tool are used at different process parameters and friction stir welding is performed on Aluminium AA6061 plates. Testing of the weldments is done to find tensile, yield strengths, elongation, hardness, and energy absorbed by the weldments. The impact of different tool pin profiles while welding with different process parameters on the mechanical properties of the weldments are evaluated. Destructive and non-destructive tests are conducted on the weldments and based on results it was observed that square tool performed more efficiently followed by cylindrical grooves tool.
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.
Periodica Polytechnica Mechanical Engineering
This paper presents research work conducted to experimentally establish the process response of two diverse shaped tool-pin profiles for friction stir welding (FSW) AA6082-T6 aluminium. The dwell time was optimised by plunging each tool-pin into a plate sample until the spindle torque stabilised thus ensuring sufficient plasticised material in contact with tool shoulder and the tool-pins. The welds were conducted by employing the optimised dwell time, which in turn revealed a minimised process response time and distance to reach weld stability with respect to (1) the force exerted on the tool-pin in the welding direction, Fx , and (2) the spindle torque, T, during the welding process. Both Fx and T stabilised well within the set (pre-determined) ramp-up distance of 20 mm, indicating that the effective (useful) weld length is maximised. The macrographs also revealed good dynamic material flow within the nugget zone regions and more evident in the nugget zone of the flared tool.
International Journal for Research in Applied Science & Engineering Technology (IJRASET), 2022
Friction stir welding (FSW) is a solid-state joining process that uses the frictional heat generated by the rotating tool to soften the metals to form the joint. It is an effective technique for joining dissimilar aluminum alloys and finds its application in various fields such as aerospace and automotive industries. FSW process is energy efficient and environment friendly process. This FSW can produce joints with higher mechanical and metallurgical properties. Formerly, FSW was adopted for low melting metals like aluminum alloys. The various FSW parameters play a vital role in determining the quality of the welded joint. The parameters included in the study of different tool pin profiles (circular, pentagon and taper). FEA analysis will be performed for friction stir welding of Aluminum alloy 5052 and AA6063 at different tool pin profiles using ANSYS. This paper mainly focuses on studying the effect of different tool pin profiles on the microstructure and mechanical properties of the dissimilar AA5052 and AA6063 aluminum alloy joints. The weld quality characteristics like microstructure, micro-hardness, and tensile properties of the joints are analyzed and presented for three different tool pin profiles. It is observed from the result that the joint fabricated using three different tool pin profiles exhibits the better mechanical properties when compared to other joints.
mantech publications, 2023
This Article Considers Investigation Procedure for Friction Stir attachment in aluminum Alloy, via management of tool Profiles. FSW process allows the benefits of solid-state joining for fabrication of continuous linear welds, the most common form of weld joint configurations. The key element of the method is that the specially designed rotating tool that has two essential parts. The primary part is the profiled pin (or probe) extending on the axis of the rotating part. The second a part of the tool is that the Shoulder. The shoulder is that the working surface of the tool, normal to the axis of rotation. The project aim is to weld two plates of aluminum Alloy using different tool profiles and different welding parameter like Rotation speed, Traverse speed, Axial load and to optimize the strength of joint.
2015
Friction Stir Welding (FSW) is a solid state welding process. In this process, the heat produced due to the relative motion between tool and workpiece is used for joining similar or dissimilar metals. In FSW, the weld quality depends on, tool rotations, tool tilt angle, axial pressure and welding speed. In this study, the effect of tool type, tool tilt angle, and rotational speed on mechanical properties of AA6082 aluminum alloy is studied. Taguchi technique is used for doing the analysis. Use of L9 orthogonal array is made for performing the experimentation. The FSW welded specimens are tested using Universal Testing Machine (UTM) for its tensile strength. After performing the experimentation and testing it was observed that, the transverse tensile samples failed at the nugget/TMAZ boundary due to localized softening. Hexagonal tool pin profile welds have shown the highest tensile strength compared to other tool pin profile welds.
AJER
Friction stir linear welding (FSLW) uses a non consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as rotational speed, welding speed, axial force, tool tilt angle, etc., and tool pin profiles play a major role in deciding the joint properties. In this paper, an attempt has been made to study the effect of four different tool pin profiles on mechanical properties of AA 6061 aluminum alloy. Four different profiles have been used to fabricate the butt joints by keeping constant process parameters of tool rotational speed 1200RPM, welding speed 14mm/min and an axial force 7kN. Different heat treatment methods like annealing, normalizing and quenching have been applied on the joints and evaluation of the mechanical properties like tensile strength, percentage of elongation, hardness and microstructure in the friction stirring formation zone are evaluated. From this investigation, it is found that the hexagonal tool profile produces good tensile strength, percent of elongation in annealing and hardness in quenching process.
Friction Stir Welding has many benefits when applied to welding of aluminum alloys and dissimilar materials which were difficult to weld. In order to prevent defective welded joints, utmost care should be taken during the selection of welding parameters. Tool pin diameter and taper of the pin, flute design which includes number, depth and taper angle and pitch of any thread form on the pin are the important parameters in addition to the tool rotational speed (TRS), weld speed (traverse speed/WS) and the axial force (F). The main parameter considered in the present work is variation of properties with the variation of tool geometry and tool rotational speed and weld speed. Experimental results obtained are analyzed. The joints are obtained by using various tool profiles with varied process parameters. An ANN model is developed using MATLAB and optimization of process parameters in carried out by comparing the results obtained by Design of Experiments (DOE) and experimental values. Using each tool, Friction Stir Welding is carried out at various parameters on different materials AA6061, AA6351 and AA6082.