Analysis of wear of tools made of 1.2344 steel and MP159 alloy in the process of friction stir welding (FSW) of 7075 T6 aluminium alloy sheet metal (original) (raw)
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Wear characteristics and defects analysis of friction stir welded joint of aluminium alloy 6061-T6
Eksploatacja i Niezawodność, 2016
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IRJET, 2020
The welding is the process of joining similar metals and dissimilar metals by melting the material with or without the use of filler material. Aluminum alloys are the major applications in welding process like aerospace industries, ship building industries. Friction stir welding is a novel technique for production of joints in solid state. The various process parameters are spindle speed, feed, load and geometry of the tool. The joining of similar Aluminum Alloys was carried out using friction stir welding (FSW) techniques are rotational speed, transverse speed, tool geometry. In this process aluminum alloy butt joint are prepared using Friction stir welding with varying process parameters are rotation speed, transverse speed by keeping constant load and tool geometry. The mechanical properties such as tensile strength, hardness and impact strength were evaluated. The microstructures of joints were analyzed using optical microscope and scanning electron microscope. The wear properties were also analyzed using pin and disk apparatus.
2015
A Simple Method for Evaluating Wear in Different Grades of Tooling Applied to Friction Stir Spot Welding Kirtis Frankland Kennard School of Technology, BYU Master of Science In this study tools consisting of a 5mm cylindrical pin and a 12mm shoulder held by a simple tool holder were used to compare the wear of 11 tooling materials. The objective was to determine if using these tools in a spot welding configuration to simulate friction stir welding could differentiate the potential performance of tooling materials. All tools were made of varying percentages of polycrystalline cubic boron nitride (PCBN), tungsten (W) and rhenium (Re). The materials are referred to herein as GV1, GV2, G1, G2, G3, G4, G5, G6, G7, G8 and G9. The tools were run to 205 welds if they did not fracture first. The grades averaged the following quantities of welds before fracture failure GV-1:0; GV-2:200; G1:82; G2:204; G3:205; G4:205; G5:96; G7:102.73; G8:21.2; G9:38.5. Of the tools that ran the full 205 welds...
IOP Conference Series: Materials Science and Engineering
Aluminium alloys are difficult to weld together under the standard welding techniques. Among the all welding processes, friction stir welding has proved its importance in joining of different aluminium grades. In the present work, joining of two dissimilar aluminium alloys AA6101 & AA6351 has been carried out by friction stir welding process with different rotational speeds and a constant welding speed. Radiography study of the weld joint explains the defects present in the welded zone. A good quality weld zone is due to the proper selection of tool rotational speed as it helps in uniform mixing. The micro hardness test and wear behaviour were studied for the weld zone. The higher tool rotational speed of FSW reduces the wear volume due the increase in hardness of the weld zone. The SEM analysis shows the different worn out behaviour of the weld surfaces. Better burr free surfaces are obtained with the weld zones welded at high rotational speed.
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.
Effect of Selected Friction Stir Welding Parameters on Mechanical Properties of Joints
Archives of Civil Engineering, 2019
The article discusses the basic issues related to the technology of friction stir welding (FSW). A short description of technology is provided. The following section provides the analysis of effect of technological parameters (tool rotation and welding speed) on the mechanical properties of the prepared joint (strength, ductility, microhardness). In both cases the analysis refers to aluminum alloys (6056 and AA2195-T0). The comparative analysis showed the phenomenon of the increase in weld strength along with the increase in the rotational speed of the tool during welding. Similarly, with the increase in welding speed, an increase in weld strength was observed. Some exceptions have been observed from the above relations, as described in the article. In addition, examples of material hardness distribution in the joint are presented, indicating their lack of symmetry, caused by the rotational movement of the tool. The analyses were performed basing on the literature data.
Regression analysis is a powerful tool used for determining the relationship between dependent and one or more independent parameters. In this paper, Friction Stir Welding (FSW) was carried out on 6082-T6-T651 aluminum alloy with the aim of deriving the regression equation for the dependent variables of Tensile strength, Hardness and Wear rate with respect to the independent variables of tool speed, tool feed and tool tilt angle using Taguchi analysis in Minitab 17 software. Plots for means and S-N ratios were also obtained for the above mentioned parameters of Tensile strength, Hardness and Wear.
Tool performance evaluation of friction stir welded shipbuilding grade DH36 steel butt joints
The International Journal of Advanced Manufacturing Technology, 2019
Tool wear is a key issue in the friction stir welding of high strength materials like steel-, titanium-, and nickel-based alloys. The wear assessment is an important aspect for developing or modifying the existing tool materials and tool designs. In this study, two different grades of tungsten carbide tools, i.e., tool A (WC-6 wt.% Co) and tool B (WC-10 wt.% Co), were used to join DH36 steel plates. Pre-and post-welded tungsten carbide tools were characterized using different techniques like microstructure analysis, weight measurement, profile measurement, and X-ray diffraction phase analysis. It was observed that the degradation mechanisms strongly depend on the tool material composition and welding conditions. During this study, tool A was degraded by intergranular failure caused by the separations of tungsten carbide grains which promoted further cracks inside the tool. Different degradation mechanisms such as adhesion, abrasion, crack initiation, diffusion, and oxidation were observed for tool B. Progressive wear in tool B was strongly affected by the process temperatures. Minimum wear was observed at low rotational speed and high traverse speed.
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.