Friction Stir Welding Research Papers (original) (raw)

Metal matrix composites with high interface density are produced via severe plastic co-deformation of multiphase alloys. 1–15 Corresponding compounds are first prepared by liquid or powder metallurgy3–12 or through restacking solids of different composition. 2 Subsequent extreme straining, to promote intense microstructure refinement, proceeds by wire drawing, ball milling, accumulative roll bonding, damascene forging, equal channel angular extrusion, friction, or highpressure torsion. 7

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- Materials Engineering, Mechanical Engineering, Materials Science, Plasticity

International Journal of Offshore and Polar Engineering Vol. 14, No. 4, December 2004 (ISSN 1053-5381) Copyright © by The International Society of Offshore and Polar Engineers ... A Microstructural Study of Friction Stir Welded Joints of... more

- by HyunWoo Jin
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- Friction Stir Welding, Phase Transformation, Emerging Technology, Microstructures
- by Ghassan Kridli
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- Materials Engineering, Materials Science, Friction Stir Welding, Tensile Strength

In modern computational science, the interplay existing between machine learning and optimization process marks the most vital developments. Optimization plays an important role in mechanical industries because it leads to reduce in material cost, time consumption and increase in production rate. The recent work focuses on performing the optimization task on Friction Stir Welding process for obtaining the maximum Ultimate Tensile Strength (UTS) of the friction stir welded joints. Two machine learning algorithms i.e. Artificial Neural Network (ANN) and Decision Trees regression model are selected for the purpose. The input variables are Tool Rotational Speed (RPM), Tool Traverse Speed (mm/min) and Axial Force (KN) while the output variable is Ultimate Tensile Strength (MPa). It is observed that in case of the Artificial Neural Networks the Root Mean Square Errors for training and testing sets are 0.842 and 0.808 respectively while in case of Decision Trees regression model, the training and testing sets result Root Mean Square Errors of 11.72 and 14.61. So, it can be concluded that ANN algorithm gives better and accurate result than Decision Tree regression algorithm.

This article studies the properties of a wide range of friction-stir-welded joints with dissimilar aluminum alloys or thicknesses. Two aluminum alloys, namely, 2024-T3 and 7075-T6, are selected for the study and are welded in ten... more

- by Rinze Benedictus
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- Materials Engineering, Mechanical Engineering, Materials Science, Microstructure

Friction stir welding (FSW) is the fastest evolving joining technology and the principal
prospective technique for implementing integral fuselage structure in aircraft manufacturing.
The viability of FS welds is dependent upon mechanical properties and production turnovers,
which are dependent on welding rates and tool design. This dissertation is about the multiobjective
characterisation of aeronautical alloys (AA5083-H111, AA6056-T4, AA6082-
H111) friction stir welded using the standard FSW tools, scrolled shoulder Triflat tool, and
the Bobbin tool respectively.
The effects of defects and microstructure on the mechanical behaviour of AA5083-H111
welds made from the standard tool were examined. SEM analysis showed that tunnel defects
resulted from partial consolidation at the root of the weld, and the microstructure of the weld
zones determined the failure mechanisms along the weld.
The effect of welding and rotational speeds on the integrity of AA6056-T4 FS welds
produced with scrolled shoulder Triflat tool was studied. Increased welding speeds and
advance per revolution led to improvements in mechanical properties and reduction in
residual stresses maxima. The retreating side TMAZ, which was the microhardness minimum
and tensile residual stress maximum, was also the failure location in most of the welds, hence
the microstructure and properties in this region were critical to the integrity of the weld. Bend
properties of the welds from the Triflat tool were good, because of the absence of root flaws.
The influence of two different tool designs (standard tool and standard Bobbin tool) on
mechanical behaviour and microstructure of AA6082-T6 was also studied. The standard tool
produced welds with better static properties than the bobbin tool, but most of the specimens
failed prematurely, and root bending resulted in cracks, because of alumina rich layers in the
weld nugget and root flaws. Bobbin tool welds had lower mechanical properties (70% weld
efficiency), the bend strength was better, with no flaws.
In the welds, the microstructure and microhardness which were influenced by the welding
rates which determined static properties, failure locations and residual stress minima and
maxima. The study also supported previous findings that the nature and distribution of
precipitates in the 6XXX series aluminium FS welds was important for determining
mechanical properties, unlike the 5083-H111 FS welds where the Hall-Petch effect was more
influential.

- by Vencislav Grabulov
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- Friction Stir Welding
- by Preet Singh
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- Materials Engineering, Mechanical Engineering, Civil Engineering, Materials Science

Detailed study of the friction stir welding process has led to a better understanding of how the process works in terms of material flow and heat generation within the workpiece. However, no publications have comprehensively described the relationships between the different processing variables and how these variables affect key process conditions, such as temperature distribution, material conditions at the welding tool, etc. This paper seeks to describe the relationships between the independent process variables and the dependent process outcomes related to heat generation and dissipation. A conceptual model, proposed earlier, has been modified to specifically distinguish between heat generation due to plastic work and friction. A case study is used to confirm and explore the relationships expressed in the conceptual model.

- by Kevin Colligan
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- Friction Stir Welding

Cracks are surface or subsurface fissures that develop in a material. Propagation energy derived from mechanical, thermal, chemical, and metallurgical effects, or a combination of these may influence crack initiation and growth. Various types of cracks exist in metals and can be categorised as cooling, solidification, centreline, crater, grinding, pickling, heat treatment, machining tears, plating, fatigue, creep, stress corrosion and hydrogen cracks. Cracks can grow and lead to complete fracture of the component posing significant threats to component life and may lead to serious injuries or loss of life. Brittle fracture in metals occurs with little or no visible warning. Discovery of any cracks warrants immediate interventions to arrest the cracks before they propagate to the point of fracture. Several crack detection and repair methods in metals have been developed, characterised and validated through research. This paper reviews the repair techniques of cracks in metals.

- by Tawanda Marazani and +2
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- Functionally graded composites, Metal Matrix Composites, Friction Stir Welding, Jet Impingement Heat Transfer
- by Rajiv Shivpuri
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- Materials Engineering, Mechanical Engineering, FEM, Friction Stir Welding
- by Brent Webb
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- Machine Tools, Manufacturing Engineering, Friction Stir Welding, Flow Visualization
- by Edward Kenik
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- Materials Engineering, Mechanical Engineering, Neutron Diffraction, Friction Welding
- by Mohsen Hassan
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- Engineering, Materials, Friction Stir Welding

Friction Friction Stir Welding (FSW) process was invented and experimentally proven by The Welding Institute (TWI) in 1991 for joining Aluminium alloys. Friction Stir Spot Welding (FSSW) is a variant of the FSW which is found to be environmental friendly and an efficient process. FSSW technique has been gaining ground when compared to resistance spot welding (RSW) and could be used in various industries including, automobiles, ship building, aerospace, electrical and construction. FSSW has been successfully used to join several materials used in the above mentioned industries. In this review, FSSW studies are briefly summarised in terms of the evolving microstructure and mechanical properties between aluminium alloys and other materials such as copper, steel and magnesium.

- by Esther Akinlabi
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- Friction Stir Welding

This paper explains the precept and methodology of FSW. It covers some of the technical sides which influence the process and quality of FSW joint. Large advance has been accomplished in friction stir welding (FSW) of aluminum in every side of tool manufacture, microstructure properties estimate in the last decennia. With the development of reliable welding tools and precise control systems, FSW of aluminum has reached a new level of technical maturity. influence on butt joint arrangement is studied. Effect on welding quality of main parameters: rotation speed, travel speed, tool tilt angle, axial force and weld time has been studied. Finally, FSW is identified as an additional area for research can be carried out in the welding science.

- by IEREK press
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- Friction Stir Welding, Spindle Speed, Material thickness, Welding Speed
- by hamidreza nazari
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- Engineering, Simulation, Numerical Simulation, Mathematical Sciences

Heat Affected Zone (HAZ) simulation by Gleeble is a useful method for evaluating welding process parameters to improve the toughness of weld HAZ by optimizing process parameters. The HAZ Toughness in low alloy steels is strongly influenced by the welding parameters (as HAZ microstructure is influenced by the heat input and cooling rate). In the present work different regions of weld HAZ of API 5L X52 steel have been simulated by using Gleeble @ 3800 Thermal-Mechanical Simulator. Two cooling rates (t) 10 s to simulate low heat input 8/5 (LHI) welding conditions without preheating, (t) 40s to simulate high heat input (HHI) welding were used. 8/5 Charpy V-notch impact tests were conducted on the simulated as well as on the base material at room temperature (25º C) and at-40º C. Results showed that HHI simulated coarse grain HAZ (CGHAZ) region attributed highest Impact energy of 300 J in comparison to 199 J of base material at 25º C. In HAZ regions, lowest room temperature toughness was observed in sub critical HAZ (SCHAZ) for both HHI and LHI conditions. Lowest impact energy at-40º C was observed in fine grained HAZ (FGHAZ) for both HHI and LHI conditions. Hardness test showed that LHI samples exhibited slightly higher hardness than HHI condition and the hardness profile for HAZ regions was similar for both HHI and LHI conditions.

Two aluminum metal matrix composites (MMC) reinforced with 13 vol.% of SiC or B4C particles were made by stir casting followed by hot extrusion. Effects of sliding velocity on the wear, friction and tribochemistry of the worn surfaces of both composites sliding against a commercial phenolic brake pad have been investigated under dry condition. The wear tests were carried out using a pin-on-disc type apparatus at two linear sliding speeds: 1.62 and 4.17 m s-1 under a constant contact pressure of 0.75 MPa for a sliding distance of 5832 m. The coefficient of friction was recorded and wear rate of the MMC pins calculated from mass loss measurement. Scanning electron microscope (SEM) equipped with energy dispersive X-ray spectroscopy (EDX) was used to investigated the worn surface. It is observed that higher sliding velocity leads to lower wear rate and lower friction coefficient for both MMCs. Formation of a compact transfer layer has been identified in the matrix region of the worn surface of the MMCs. The transfer layer mostly consists of constituents of the phenolic pad material which acted as counterbody. The amount of the constituents of the counterbody in the transfer layer is seen to increase as sliding velocity increases. It is suggested that the transfer layer on MMC acts as a protective cover and helps reduce both wear rate and friction coefficient.

- by Abilio JESUS
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- Mechanical Engineering, Civil Engineering, Applied Mathematics, Microstructure

Friction Stir Welding is a solid-state joining process of two similar or dissimilar materials. The dissimilar joining of aluminum alloy Al6061 and Al5083 with the plates of 6 mm thickness was carried out by friction stir welding. The objective of this research is to enhance the mechanical properties by changing the advancing side material during welding and also optimizing the various process parameters such as tool rotation speed and traverse feed for higher joining strength. The influence of welding process parameters on strength of joint has been evaluated by means of tensile test. The tool rotational speeds were taken between 500 to 1000 rpm and tool traverse speeds were taken between 40 to 125 mm/min. The maximum tensile strength yielded 98.90 MPa when the Al6061 keep in a advancing side and 32 MPa when Al5083 keep in advancing side during weld joint at 1000 rpm and 50 mm/min. It was observed that the advancing sides of materials also play a key role for joint strength while keeping remaining process parameters constant during FSW.

- by Dr. KAUSHAL BHAVSAR
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- Friction Stir Welding

This work deals with application of friction stir welding (FSW). FSW procedure is used for joining the aluminum alloy AA6061-T0 and AA5052Plates in butt configuration with orthogonal combination of factors and their levels. The combination of factors involving tool rotation speed, tool travel speed and tool pin profile are Used in three levels. Find the optimum level of factors for optimizing UTS, ductility and hardness of joint. Experiments have been conducted with two different tool materials (HSS steel with two different materials) with various factors level combinations. For joining AA6063-T0 and AA5052.The influence of tool material is also studied. It mechanically intermixes the two pieces of metal at the place of the join, then softens them so the metal can be fused using mechanical pressure, much like joining clay, dough, or plasticine. It is primarily used on aluminum, and most often on large pieces that cannot be easily heat-treated after welding to recover temper characteristics. In this project, we have learned different welding techniques and now we are discussed about Friction stir welding. A parametric model with the weld plates and cutting tool is done in Pro/Engineer. Analysis is done in ANSYS software. Structural and Thermal Analysis is doing on the component for getting Maximum heat flux and Stress value. Tensile test, Hardness and Microscope testing is done on the welding pieces in Hyderabad Labs, Balanagar. Welding is done in Sri Venkateswara Industries,

In this paper a new technique for visualizing material flow patters in friction stir welds is presented. Based on measured results, it appears that in the upper portion of the path of the pin, material curls into the thread space. This material continues to flow into the threads and moves downward until the thread is filled. At that point the material within the thread begins to rotate with the tool, but at a lower speed. This material is deposited behind the welding tool pin as it moves downward. These results contribute to an understanding of the welding process, which may lead to improvements in welding tool design and process parameters.

- by Kevin Colligan
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- Friction Stir Welding
- by John Carsley and +1
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- Engineering, Mechanical Engineering, Materials Science, Friction Stir Welding

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.

- by Edwin Raja Dhas
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- Mechanical Engineering, Materials Science, Energy, Magnetic Materials
- by Swathi Byreddy
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- Engineering, Materials Engineering, Mechanical Engineering, Materials Science

Now-a-days the uses of thermoplastics have been increased in many fields due to its various properties. Joined thermoplastics find a wide application in most of the fields due to its mechanical properties and so a suitable method for joining should be adapted. Nylon 6 is the material which chosen to be welded and analyzed accordingly. Nylon 6 is a thermoplastic material which has good mechanical properties and has many applications in automobile and aerospace industries. One of the suitable methods of joining the polymer is Friction Stir Welding (FSW). The Friction Stir Welding is chosen due to its several advantages like easily automatable, energy efficient and also low environmental impact. Friction Stir Welding of thermoplastic can find a wide application in the industries, defense and also in medical operation along with production of the commercial products. In Friction Stir Welding of thermoplastics, traditional tools from a slit on the rear side of the welded specimen which leads to root defect which causes poor tensile strength in the joined material. Due to high transparency of this polymer, it will be possible to analyze the morphological changes induced by the welding process on the material in an easy manner.

- by Manivannan Sivaperuman Kalairaj and +1
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- Optimization techniques, Friction Stir Welding, Nylon
- by Laurent Dubourg and +3
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- Mechanical Engineering, Dynamic Simulation, Friction Stir Welding, Real Time Control
- by Michael Fitzpatrick
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- Engineering, Materials Engineering, Mechanical Engineering, Civil Engineering

The objective of this study was to determine the
effects of the tool pin diameter and tool rotation on the
fatigue behaviour of friction stir welded (FSW) lap joints.
FSW lap joints of AA 5754 aluminium alloy plates were
produced by means of a conventional semiautomatic
milling machine. Consequently, defect free FSW lap joints
were produced on alloy plates at a constant traverse speed
but with different tool pin diameter and tool rotation.
Therefore, within this study, tool rotation and the tool pin
diameter were accepted as variable parameters, while others
held fixed. The results of the tests performed, indicate that
an optimisation is required for the studied parameters, in
order to obtain reasonable fatigue strength. An index,
related to tool rotation, traverse speed, pin diameter, and
pin height can be identified and used to select optimum
parameters for FSW applications.

- by Mustafa KÜlekcÝ and +1
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- Welding Technology, Friction Stir Welding, Welding
- by rajesh mishra
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- Engineering, Materials Engineering, Mechanical Engineering, Materials Science

In this study, a study on welding aluminum weldings with techniques such as TIG welding, MIG welding, Friction Stir welding, Laser Beam welding is compiled. Problems such as porosity, weld seam cracks and unstable arc that may occur as a result of the mentioned welding techniques have been investigated. The main purpose of this study is to examine the weldability of aluminum alloys and the causes and solutions of damage during or after welding. Apart from this purpose, information about the welding of aluminum alloys with other materials can be obtained. The effects of welding parameters on obtaining smooth welding products are mentioned. At the same time, the effect of the internal structure and chemical components of the alloys used on the welding process is not ignored.

- by Ahmet Enes Önder
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- Welding and Joining, Laser Welding, Aluminum, Aluminium Alloys

The residual stresses in different welding methods are fundemental problems to consider. Friction stir welding is one of a solid state joining process, it is economical in that it permits joining together different materials, the specimens in this method (FSW) have excellent properties of mechanical as proven by tensile, flextural and fatigue tests, also it is environmentally friendly process minimizes consumption of energy and generate no gasses or smoke. In friction stir welding , there are two kinds of generated residual stresses: tensile stress and compressive stress. So, this study measuring the residual stresses by using a new method for measuring residual stresses depends on tensile testing and stress concentration factor, this method is a simple, fast and low cost, also it is not need special device. Design/methodology/approach: In previous studies, several techniques were used to predict the value of residual stress and its location, such as destructive, semi-destructive, and non-destructive methods. In this study, a simple, new, and inexpensive way was used based on the tensile test and stress concentration of the friction stir welding (FSW). Findings: By comparing the results obtained with the previous studies using the X-ray method, with the current research, it was found that the results are good in detecting the location and value of the residual stress of friction stir welding. The value of discrepancy of the residual stress in the results between those obtained by the previous method and the current method was about 3 MPa. Research limitations/implications: There are many rotational and linear feeding speeds used in this type of welding. This research used two plates from 6061 AA with 3mm thickness, 100 mm width, and 200 mm length. The rotational speed used in friction stir welding was 1400 rpm, and the feeding speed was 40 mm/min. Practical implications: The residual stress obtained with the new method is 6.2 MPa, and this result approximates other known methods such as the X-ray method in previus studies. Originality/value: Using a new simple method for measuring residual stresses of friction stir welding depends on stress concentration factor and tensile testing. This method is fast and low cost , also it is not need specialized device, compared to other methods such as x-ray or hole drilling methods.

- by Muhannad Al-Waily
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- Friction Stir Welding, Residual Stresses

A simulation model was developed for the monitoring, controlling and optimization of the Friction Stir Welding (FSW) process. This approach, using the FSW technique, allows identifying the correlation between the process parameters (input variable) and the mechanical properties (output responses) of the welded AA5754 H111 aluminum plates. The optimization of technological parameters is a basic requirement for increasing the seam quality, since it promotes a stable and defect-free process. Both the tool rotation and the travel speed, the position of the samples extracted from the weld bead and the thermal data, detected with thermographic techniques for on-line control of the joints, were varied to build the experimental plans. The quality of joints was evaluated through destructive and non-destructive tests (visual tests, macro graphic analysis, tensile tests, indentation Vickers hardness tests and t thermographic controls). The simulation model was based on the adoption of the Artificial Neural Networks (ANNs) characterized by back-propagation learning algorithm with different types of architecture, which were able to predict with good reliability the FSW process parameters for the welding of the AA5754 H111 aluminum plates in Butt-Joint configuration.

- by Matthew Peel
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- Materials Engineering, Mechanical Engineering, Microstructure, Neutron Diffraction

A solid state joining process Friction stir welding is one of the proven approaches in metal joining. Titanium is considered as material opted for all mechanical and bio transplants applications. Joining of materials with high strength by friction stir welding (FSW) is complicated due to severe tool wear and change in the shape/size of the tool. This review paper focus on the FSW process in titanium alloys highlighting its tool design, welding parameters, weld strength etc.

- by vivek cm
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- Titanium, Friction Stir Welding

Friction-stir welding (FSW)is a novel green solid state joining process particularly used to join high strength aerospace aluminum alloys which are otherwise difficult to weld by conventional fusion welding. Unlike other solid state joining technique, in Friction stir welding a third body contact by tool will generate the additional interface surfaces and finally all the surfaces are coalesced with each other by applied pressure and temperature and form solid state weld. This work shows overview of Friction stir welding which includes the basic concept of the process, microstructure formation, influencing process parameters, typical defects in FSW process and some recent applications. In this project, FEA analysis is performed for friction stir welding of different aluminum alloys. The welds are produced by varying the process parameters; the rotational speed was varied between 900 to 1800 rpm and the welding speed varied between 40 and 300mm/min. A parametric model with the weld plates and cutting tool is done in ProE. The effects of different (square and round) tool pin profiles on the friction stir welding are also considered for analysis. Different tool pin profiles are square, circular square with thread. We are using Vertical milling machine for doing welds. And also we are doing Tensile testing, Hardness and Microscopy for Structure at welding spots. Modeling is done in proe software and analysis is done in Ansys. The best parameters found from the experiments are 1800 rpm square is better for welding using HSS tool.

- by Ravindrasai A
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- Friction Welding, Aluminium Alloys, Friction Stir Welding, Fsw

Friction Stir Welding (FSW) is a solid-state joining process which possesses a great potential to revolutionize the aerospace industries. Distinctive materials are selected as aerospace alloys to withstand higher temperature and loads. Sometimes these alloys are difficult to join by a conventional welding process but they are easily welded by FSW process. The FSW process in aerospace applications can be used for aviation for fuel tanks, repair of faulty welds, cryogenic fuel tanks for space vehicles. Eclipse Aviation, for example, has reported dramatic production cost reductions with FSW when compared to
other joining technologies. This paper will discuss the mechanical and microstructure properties of various aerospace alloys which are joined by FSW process.

- by Akshansh Mishra and +1
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- Aerospace Engineering, Welding Engineering, Friction Stir Welding

Friction Stir Welding process is a novel green solid state joining process for soft materials such as aluminium alloys. The weld quality is governed by the proper selection of parameters such as forge force rotational speed of the tool, welding speed, backing plate material etc. Thermal boundary condition at the bottom of the work piece plays an important role for obtaining the sound joint. The backing plate material governs these thermal conditions. In this case study, high thermal diffusivity backing plate material which consisted of AA2099 was used for joining of the plates of Structural Aluminium alloy. It was observed that the tensile strength was improved.

- by Akshansh Mishra
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- Welding Engineering, Friction Stir Welding

Material flow in friction stir welding / processing under different process parameters with aluminium has been studied by many scientists. All such studies have been considered and a detailed review is presented in this paper. Results indicated friction stir welding / processing with aluminium and alloys may successfully utilised, because of the significantly improved strength in the
material and at the same time the ductility also retained, along with the substantiallyimproved hardness. FSP was found to be beneficial also in improving wear resistance.

- by V. Jeganathan
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- Friction Stir Welding, Friction Stir Processing

The study undertakes a three-dimensional finite element analysis of the friction stir welding (FSW) process of 6061-T6 aluminium alloy. The analysis investigates the temperature distribution and the fundamental knowledge of the process with respect to temperature difference in the material to be welded. HyperMesh ® and HyperView ® solver have been used from Altair Hyperworks ® to analyse the process. Different traverse and rotational speeds have been applied in the model. The results of the study create a better understanding for peak temperature distribution. In addition , the results illustrate that the peak temperature during welding increases as the rotational speeds rises and the effect of the transverse speed on the temperature is found to be insignificant. Finally, comparisons with some published papers has been done in order to compare the results of the different finite element packages and summarize the advantages and disadvantages of each software.

- by Bahman Malaki Meyghani
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- Finite Element Methods, Friction Stir Welding
- by aly el domiaty
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- Mechanical Engineering, Energy, Friction Stir Welding, Aluminum Alloys
- by R. Nobile
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- Automotive Industry, Friction Stir Welding, Materials Design, Residual Stress