Friction Stir Welding Research Papers (original) (raw)

2025, Asian Review of Mechanical Engineering

Friction Stir Welding (FSW) is fairly a recent technique that uses a non-consumable rotating welding tool to generate frictional heat and plastic deformation at the welding location while the material is in solid state. The principal advantages are low distortion, absence of melt related defects and high joint strength. Tool design and material plays a vital role in addition to the important parameters like tool rotational speed, welding speed and axial force. Friction Stir Welding (FSW) is a solid state welding process to join materials by generating frictional heat between a rotating tool and materials being welded. It was invented at The Welding Institute (TWI), Cambridge (U.K.) in 1991. Since then FSW has become a major joining process in the aerospace, railway and ship building industries especially in the fabrication of aluminium alloys. It is difficult to weld the aluminium alloys, using arc welding, gas welding and other welding processes. Friction Stir Welding on the other ...

2025, Asian Review of Mechanical Engineering

It is challenging to obtain defect free welded joints of Aluminum Alloys with the help of fusion welding processes. In fusion welding, oxide layer of aluminum alloys penetrate inside, which has the tendency to thicken at higher temperatures, which in turn results in the defects like porosity and cracks in the weld joint. In contrast, Friction Stir Welding (FSW) is proved to be a very good solid state welding technique, which has got a worldwide attraction, especially in aerospace industry. FSW doesn’t involve actual melting of the materials, rather the welding is done at visco-plastic state of the materials, which helps to reduce the heat affected zone in the weld joint and original characteristics of material are protected from getting changed, as far as possible. Combination of 2xxx series and 6xxx series of aluminum alloys are highly used in aerospace and automobile industry due to their good-strength to weight ratio, mechanical properties and anti-corrosion properties. The work ...

2025

Friction Stir Welding (FSW) and Friction Stir Spot Welding (FSSW) are new techniques of welding. Since the process of friction stir welding (FSW) differs from friction stir spot welding (FSSW), the appearance and characteristics of the microstructure would be probably different. Therefore, the differences need to be characterized and documented. The main objective of the project is to characterize the microstructure of friction stir spot welding (FSSW) aluminum alloy and friction spot welding (FSW) aluminum alloy using Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Field Emission Scanning Electron Microscopy (FESEM). This work focused on the weldment area of the welded plates. Both FSW and FSSW sampleswere prepared using the optimum parameters prior to undergoing metallography process. Both thefriction stir welding (FSW) and friction stir spot welding (FSSW) are found to produce microstructural variations across the weld, due to the thermomechanical treatment involved in the process.Eventually, both samples are undergone Energy Dispersive X-ray Spectroscopy (EDS) to identify elemental composition of both sample.

2025

Two Friction stir welding models are presented -a global thermal model using the temperature dependent heat source and a local material flow and heat generation model allowing for detailed investigation of different contact conditions. The two models are coupled into a larger local-global model. The flow model includes frictional dissipation from the contact between the workpiece and the tool as well as plastic dissipation.

2025, International Journal of Material Forming

The manufacturing research has been focusing on the improvement of product performance and lightweight design. The synergic effects between material properties and manufacturing solutions have been considered, extensively. Specifically, joining techniques have been developing with the aim to propose new suitable solutions considering dissimilarities in the properties of the materials that have to be combined. Setting of new manufacturing routes is, therefore, a demanding task. In this direction, there are several methods available in the scientific literature that are focused on sensitivity analysis or optimization/minimization techniques to reduce the necessary attempts or to find a solution/correlation among big data. In this work, the goal of obtaining high joint efficiency between Aluminum and Polycarbonate sheets by the Friction Spot Joining process is considered as a case study. This process must face two main issues, i.e., the mechanical, physical and chemical compatibilities between the parts and the integrity protection of the polymeric sheet near the joining area. The process parameters influences were analysed using numerical simulations performed by a commercial FE code. The number of executed analyses was reduced with a planned DoE. From these results, the Code2Vect algorithm was employed with the aim to visualize, efficiently, high-dimensional data and to evaluate the influences of some identified parameters on the process answer. Finally, a transfer function involving the input and output quantities of interest was derived in a compact representation by a Newton Raphson minimization technique.

2025, 14th WCCM-ECCOMAS Congress

Nowadays, the manufacturing research efforts have to be conceived in such a way that the product performance criteria are achieved in a lightweighting design concept. Taking these extensions to their extreme, the material properties and the manufacturing solutions have to be considered together in a revolutionary body concept, which should result in an ideal sight to the use of the most performing material in the right place depending on the product requirements. Polymer matrix composites (PMCs) belong to this new material category. The development of joining techniques available to connect PMCs and lightweight alloys has been considered as a key enabling solution in making innovative and sustainable products. The goal of obtaining high joint efficiency must face two main problems, i.e. to deal with the polymeric matrices to get mechanical, physical and chemical compatibilities and to attain or preserve the integrity of reinforcements across the joints customizing the fiber distribution in the joining area. The understanding of current and emerging joining technologies, e.g. the friction stir based techniques, with an optimization of the process parameters needs performant numerical tools to be employed, efficiently. In the work herein proposed, a polymeric base plate was joined to an aluminum alloy part simulating the friction lap joint sequences. Numerical tests have been set by a commercial FE code (DEFORM 2D TM ) and a DoE, generated using hypercube sampling, was defined to perform a sensitivity analysis of specific investigated variables on some process outputs. A further objective is to create transfer functions involving the input and output quantities of interest. Particularly, the sparse Proper Generalized Decomposition (sPGD) is the implemented numerical algorithm that making use of two ingredients, the separation of

2025, International Journal of Material Forming

2025, Key Engineering Materials

In this study, the mechanical properties of welded joints of AA 6005 aluminum alloy obtained with friction stir welding (FSW) and conventional metal inert gas welding (MIG) are studied. FSW welds were carried out on a semi-automatic milling machine. The performance of FSW and MIG welded joints were identified using tensile and bending impact tests, as far as the environmental aspects are also included in the discussion. The joints obtained with FSW and MIG processes were also investigated in their microstructure. The results indicate that, the microstructure of the friction stir weld is different from that of MIG welded joint. The weld nugget consists of small grains in FSW than those found in MIG weld. Taking into consideration the process conditions and requirements, FSW and MIG processes were also compared with each other to understand the advantages and disadvantages of the processes for welding applications of studied Al alloy. Better tensile and bending strength were obtained ...

2025, Journal of Materials Processing Technology

The forming of the completed aluminium foam sandwich (AFS) panels would determine an improvement in the manufacturing of parts and panels. In this paper the authors have investigated the formability of AFS through experiments and numerical simulations. As far as the former are concerned, commercially prepared panels have been considered and bending and stamping processes have been taken into account. In addition, FEM analyses have been developed, utilizing a porous material model following the evolution of the material density throughout the forming processes.

2025, International Journal of Material Forming

Industrial interest about Incremental Sheet Forming (ISF) process is growing in the last years. Up to a few years ago, two main investigation ways were proposed, the former aimed at analysing the process mechanics, the latter at reproducing some "case study" geometries. In industrial applications, if the long cycle-time can be neglected in small batches manufacturing, geometrical accuracy represents a relevant drawback, especially when the product has to be coupled to one another. For this reason, in the opinion of the authors, the low accuracy is the most relevant defect of ISF processes today. Among the techniques already set-up to reduce inaccuracy, the use of different material supports or the use of "arbitrarily modified" tool trajectories are probably the most known. In this paper a simple approach is proposed, based on the process self capability to correct inaccuracy when different steps of Incremental Sheet Forming are carried out on both the part surfaces. In particular, it is demonstrated that a relevant increasing in accuracy is obtainable at the second repeated step, while new ones do not reduce the inaccuracy sensitively. The above approach builds a new scenario since it allows to keep the basic equipment (without any support) and does not require any further knowledge concerning the material behaviour after the punch action. These aspects are deeply discussed in the next chapters.

2025, International Journal of Material Forming

2025, IOP conference series

The applications of laser stitch welding are increasing used in assemblies engineering products such as automotive structures due to its efficiency and re-liability in connecting a light weight material. In order to understand the vibration effect of the laser stitch weld towards the assembled structure, it is important to analyse its dynamic behaviour. However, they are relatively difficult to be analyse numerically as the laser stitch welded joints are found to be complex and have many uncertainties. This paper presents the investigation of finite element model for laser stitch welded structure. The reconciliation method of finite element model updating is used to improve the dynamic behaviour of the initial finite element model as close to experimental data. In this work, the finite element model of the laser stitch welded is developed by employing area contact model (ACM2) connector. Meanwhile, the experiment dynamic behaviour is obtained using an impact hammer and roving accelerometer with free-free boundary conditions. Later, the finite element model updating method is carried out in order to reduce the discrepancies of initial predicted models based on the experiment data. Based on the result, it was found that the ACM2 connector can be used to represent as la-ser stitch welds accurately by updating the most sensitive selected parameters.

2025

properties as compared to TIG welded joints. From the micro structure analysis, it was observed that fine and equiaxed grains were observed in the friction stir welded joints and coarse grains were observed in TIG welded joints.

2025, Journal of Materials Research and Technology

A hybrid Mg composite filled with micro Al2O3 and nano TiO2 is manufactured through a blend press sinter powder metallurgy route. To appraise the significance of filler incorporation on the mechanical and corrosion strength, the composite is undergoing a series of characterizations. Initially the filler distribution was analyzed through electron microscopes. Static mechanical tests as per ASTM are conducted to measure the influence of fillers on the tensile and compression properties. The corrosion characteristics were studied by immersing the composites into the laboratory synthesized stimulated body fluid (SBF). Through the Tafel Polarization, the corroded surfaces are examined. The corrosion resistance of the composites exhibited a change that closely resembled that of pure magnesium. Based on the experimental findings, it appears that the composite being examined is well-suited for various biomedical applications, particularly in the field of dental implants.

2025, Journal of Advanced Joining Processes

Resistance welding of crossed wires, e.g. used in the electronics industry or in fabrication of wire meshes, is analyzed by both experiments and numerical modeling using an electro-thermo-mechanical finite element formulation. Welding machine characteristics are discussed and the necessary requirements to the type of welding machine are concluded. Cross-wire welding of stainless steel, structural steel and aluminum are presented, and differences in the welding process and flash formation are discussed. It is shown that the joints are primarily due to solid-state bonding and local melting. The simulations compare well to the experiments at low weld settings, while remaining challenges for simulation of high weld settings are identified in terms of requirements to the mesh and detailed description of the machine follow up of the electrode force and movement.

2025, Materials Science and Technology

An attempt was made for the first time to fabricate tailor-welded blanks (TWBs) through the feasibility of selective alloying in the solid state of vertical compensation friction stir welding (VCFSW) technique. The results revealed that the production of TWBs by VCFSW technique had higher homogeneity without any defects when compared to the production of TWBs by conventional FSW process at constant tool rotational speed 2000 rpm, traverse speed 20 mm min−1 and an inclination angle 2.5°. The maximum mechanical properties of the fabricated TWBs were obtained when the width of compensation strip 1.5 mm was used. The fracture surface of TWB at the width of compensation strip 1.5 mm showed ductile fracture mode.

2025, Journal of Al-Azhar University Engineering Sector

2025, IOP Conference Series: Materials Science and Engineering

Gas Metal Arc Welding (GMAW) process is used in fabrication of structures and weld ing of pressure vessel components because of some advantages, such as higher weld metal deposition rate, requirement of lower welder skill, and good quality of weld in versat ile positions. Further, GMAW process can be automated for achieving higher rate of production. In present work, GMAW process is automated using an articulator that can control welding speed. Experiments are carried out using welding process specificat ion p repared as per ASME section-IX. Weld samples are manufactured using single "V" butt weld joint design. Welding parameters, such as welding current, open circuit voltage and welding speed , are varied in the range of values as per ASME section-IX. Further, the test samples are subjected to physical and chemical testing for evaluating welding process capability. Desirable quality characteristics of weld are assessed based on the value of ultimate tensile strength, chemical composition and root penetration. An effective range of welding current, open circuit voltage and welding speed is identified fo r sound quality of weld with constraint over maximu m heat input.

2025

This paper presents a study to assess the relationship between the tool design and vibro-acoustic signals of the friction stir welding process in the aluminium AA1050. The characterization in time and frequency domains of vibroacoustical signal and the statistical analysis have been carried out in order to correlate them with the design of two different tools (Jimenez-Macias et al., 2010). Vibro-acoustical signals have been filtered in order to eliminate the noise of the friction stir welding machine. Additionally, the Wavelet Transform has been used as an efficient tool for filtering vibration signal waveforms. The statistical analysis has confirmed that the vibro-acoustical signals were significantly affected by the tool design. It was found that there is valid information to assess changes in the tool profile in the frequency range of 0 to 100Hz. Analysis techniques based on the Wavelet Transform constitute a tool that can be efficiently used in the assessment of changes in the tool profile.

2025

To meet the rising global demand for copper, advanced and automated welding techniques are crucial in industrial manufacturing. Copper’s high electrical conductivity and thermal properties present unique challenges requiring specialized welding. This paper explores various welding techniques, including Tungsten Inert Gas (TIG) Welding, Friction Stir welding (FSW), and Laser Beam Welding (LBW). In TIG welding, automation ensures consistent results, while using fluxes helps prevent oxidation and enhances weld quality, minimizing defects such as cracks and porosity. FSW improves welding quality by monitoring real-time temperatures of the rotating shoulder and weld zone with thermal imaging cameras. LBW, known for its deep penetration and precise control, is well-suited for copper because it can handle high-intensity lasers effectively. High laser power and short pulses are vital for achieving quality welds in copper. This review addresses the technical challenges and essential processes in TIG, FSW and LBW for copper welding, highlighting the importance of accurate parameter control to produce defect-free, robust joints. It also underscores the need to select the appropriate welding technique based on copper’s unique properties to maximize efficiency and accuracy in industrial applications.

2025, Journal of Manufacturing Processes

In this study, the Ti-4Al-0.005B (TA5, Chinese brand) titanium alloy was used in a specially designed T-joint joined by friction stir welding, where two plates served as the skins and one plate served as the stringer with two separate welds. The base material (BM) has a typical rolling microstructure, consisting of α grains deformed along the rolling direction. The grains in the heat-affected zone (HAZ) are coarser than those in the BM, while the grains in the thermo-mechanically affected zone are deformed along the shear direction. When the temperature is higher than the β transus in the welding process, there are lamellar α phase structures in the stir zone (SZ). When the temperature is lower than the β transus in the welding process, there are fine equiaxed grains in the SZ due to sufficient dynamic recrystallization, while the grains in the first weld are slightly larger than those in the second weld due to their longer exposure to the thermal cycle of the second weld. The microhardness of the first weld decreases following the second weld, and the area of lowest microhardness occurs in the HAZ on the advancing side near the first weld. The microhardness of SZ at the position of 0.5 mm from the upper surface is slightly higher in the thickness direction. In the tensile tests, the initial position of the fracture occurs in the area where the skin and the stringer are joined by FSW. With the increase of tool rotation speed from 450 rpm to 850 rpm, the tensile strength increases first and then decreases along the direction of skin and stringer. In addition, a coupled Eulerian-Lagrangian (CEL) numerical model is developed to investigate the temperature distribution and material flow during FSW, showing stronger correlation with the experiments.

2025, Materials Science and Engineering: A

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2025

directeur du mémoire Département de génie mécanique à l'École de technologie supérieure M. Jacques Lanteigne, codirecteur Institut de Recherche d'Hydra-Québec M. Marc Thomas, président du jury Département de génie mécanique à l'École de technologie supérieure M. Hakim Bouzid, membre du jury Département de génie mécanique à l'École de technologie supérieure

2025

The study of cam-tappet tribochemistry is on the rise due to the need for a better understanding of how nanoscopic tribofilms reduce friction (improved engine efficiency) and wear (durability) in internal combustion engine. Environmental legislation on exhaust gas emissions have further stimulated research on the use of less phosphorus and sulphur containing additives because phosphorus clogs the catalytic converters in an engine exhaust system. Current tests evaluate the resultant surface films formed on the contact by the additive package which has made understanding of the test conditions crucial due to the increased complexity of tribochemistry. Diamond Like Carbon (DLC) surface coatings are also receiving significant attention even though their interaction with conventional lubricants additives is still unclear. A vast majority of published studies look at these systems under steady-state conditions whereas, dynamic conditions are predominant. In this work, a newly modified ‘SL...

2025

In this study, the tribological properties of steel, Mn-phosphate, Si doped (S1s), and hydrogenated tetrahedral amorphous carbon (ta-C:H) diamond like carbon (DLC) coatings were investigated in a pin on reciprocating plate tribometer and single cam test rig. S1s and taC-H DLC coating architectures were obtained with plasma assisted chemical vapor deposition technique with hardness 20 ± 4 GPa and 35 ± 7 GPa respectively. All materials had a centre-line average surface roughness (Ra) of 0.02-0.03 µm except for the Mn(PO3)2 which had Ra of 0.30 µm. The S1s showed severe delamination after tests on the reciprocating tribometer while spots of wear flakes were observed in the bench test. Both single cam rig and reciprocating tests have shown similar wear and friction results which can be used to rank materials, surface coatings and lubricants for optimum performance of valve train components.

2025, International Journal of Technical Research and Applications

The results of the investigation indicate the welding current to be the most significant parameter controlling the weld tensile strength as well as the nugget diameter. The contribution of welding current holding time and pressure to tensile strength are 61%, 29%, 4% respectively and the contribution of these parameters to nugget diameter are 81%, 17%, 1.7% respectively. Relationship graph have been plotted between tensile strength and nugget diameter with parametric variations according to orthogonal array Keywords— resistance spot welding, taguchi method, tensile strength, nugget diameter, annova etc

2025, IntechOpen eBooks

Friction Stir Welding (FSW) has emerged as an effective method for joining composite materials, revolutionizing the field of composite welding. This chapter provides an in-depth exploration of FSW's potential applications, advantages over conventional methods, and the associated challenges. By comparing FSW to existing welding techniques, current chapter demonstrate how it overcomes issues like porosity, distortion, and poor mechanical properties. Drawing from relevant literature, we delve into case studies of FSW-welded composite materials, investigating the weld joint quality and resulting material properties. The discussion extends to the identification of metal matrix composites that can be effectively joined using this innovative method, shedding light on its versatility. However, limitations are also considered to provide a comprehensive perspective. This chapter serves as a valuable resource for researchers, engineers, and practitioners in the field of materials science and engineering, offering insights into the promising future of FSW in the realm of composite material welding.

2025, Liquid Metals

Today is an era of metals including Aluminum alloys owing to a fundamental paradigm shift in research objectives. In addition to superior performance and lightweight criteria that are used to define the innovations of yore, scientists today are compelled to take into consideration the environment-friendliness of the new and novel materials being developed due to the concerns of maintaining a sustainable and safe existence. The solid-state Friction stir welding process has immense potential in the areas of automobiles, aerospace and construction industries due to its overwhelming advantages over the conventional fusion welding process of aluminum alloys. The thesis presents an experimental investigation of friction stir welding of dissimilar aluminum alloys AA7075T651 and AA6082T651. Mathematical modeling equations are developed to predict the tensile strength, impact strength, elongation, and micro-hardness of the dissimilar FSW joints AA7075T651 and AA6082T651. The process paramete...

2025, Materials Today: Proceedings

Today the manufacturing advanced process in Friction stir welding process (FSW) are widely used for various industries like aerospace industries, automotive, etc. The process has high quality well fine grain size and lower power consumption of maintenance is low of joinings weld has a large design is done in all directions easy to operate and free pollution of environment and having alloys of aluminum with welds of free defects for finding the factors of different mechanical properties of welding processes because of cleanliness, accurate results, prompt expansion of FSW process with factors of tool rotational speed, welding speed, tilt angle, and the quality optimum values shows the development for the industries to run smooth with current research and technologies incorporated. The FSW process mainly interferes with the design of the tool plays a major role in the quality of welding with frictional heating done with a square tool for the experimental design planned as per the literature. The selection of material is also creative nature of aluminum alloys AA7075T651 and AA6082T651 for examining the different factors of tool rotational speed, welding speed, tilt angle for the quality of welding and by using design expert on responses of tensile strength, impact strength, elongation using response surface methodology (RSM). This research mainly useful for the process parameters effects and interactions of different models for quality of welding for the aerospace and automotive industrial applications.

2025, Cogent Engineering

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2025, Zavarivanje i zavarene konstrukcije

Corrosion behaviour of friction stir welded (FSW) AlMg6Mn alloy was comparred to corrosion behaviour of as-hot rolledalloyby means ofNAMLT and ASSET tests. Corrosion testing revealed that base metal (hot rolled state) is more susceptible to intergranular corrosion (IGC) than FSW specimens. Surface morphology of the base metal after NAMLT revealed sevire intergranular corrosion, while IGC resistance of AlMg6Mn alloy after FSW was significantly improved. It was attributed to different microstructure developped during welding, i.e. due to redistribution of β-phase particles and grain refining. On the other hand, both base metal and weld showed good exfoliation resistance evaluated by ASSET test.

2025, Springer eBooks

2025, Materials Today: Proceedings

In this work, a three-dimensional heat transfer model based on Abaqus/CAE 2017 finite element (FE) software package was developed to examine the effect of heat flux from tool shoulder and pin on the temperature distribution during FSW of low carbon steel sheet. Heat flux distribution models for shoulder and pin were developed by assuming the shoulder portion as a surface heat source and the tool pin as a volumetric heat source. These non-uniform heat flux models were embedded in a Fortran code and fed to Abaqus/CAE via DFLUX subroutine. In the FE model, temperature-dependent thermal properties of low carbon steel were incorporated. The influence of traverse speeds (i.e., 300 mm/min, 450 mm/ min and 600 mm/min with the constant rotational speed of 450 rpm) on transient thermal history at varying distance from the weld center line was studied. It was observed that the higher heat input increases the peak temperature with a decrease in traverse speed. The transient thermal profile obtained from the FE analysis and experiment were matched fairly well with a percentage error of 6.4% for maximum temperature.

2025, International Journal of Current Engineering and Technology

Friction stir welding (FSW) has been the most attracting solid state welding process as it serves numerous advantages like good mechanical, metallurgical properties etc. Non weldable alluminium alloys like 5XXX, 7XXX series can be joined easy using this process. In this present study, experiments were successfully performed to evaluate mechanical properties of FSW on dissimilar alluminium alloys i.e. AA 5083 to AA1100. Tensile strength and micro hardness for different process parameters are reported. It was noticed that in FSW of this combination of dissimilar alloy with tool made of H-13 tool steel, friction is the major contributor for the heat generation. It was seen that tool rotational speed and traverse speed have significant effect on tensile strength of FSW.

2025, Journal of the Brazilian Society of Mechanical Sciences and Engineering

In this research, numerical as well as experimental analysis on friction stir welding (FSW) of dissimilar steels, i.e. DH36 steel and AISI 1008 steel, was performed. A 3D heat transfer FE model based on Abaqus/CAE using Fortran code via DFLUX subroutine was developed to investigate the effect of FSW parameters (i.e. rotational speed and traverse speed) on temperature distribution during the welding. It was observed that decreasing the traverse speed, increasing the rotational speed and shoulder diameter enhanced the peak temperature due to higher heat input. Based on the experimentally obtained sound quality welding parameters, the FE model was successfully validated with a maximum percentage error of 5.57% for peak temperature. Experimental results revealed that the higher heat generation reduced the grain size by increasing the rotational speed and decreasing the traverse speed. The inhomogeneous hardness distribution was observed across the weld cross section due to grain size variation. The higher grain refinement at a rotational speed of 600 rpm with a traverse speed of 70 mm/min produced the maximum value of the hardness and impact toughness. The tensile weld samples were fractured in the base metal zone (i.e. AISI 1008 steel) and experienced the tensile strength within the range of the AISI 1008 steel. The microstructure in the SZ exhibited the Widmanstatten ferrite in AISI 1008 steel and acicular-shaped bainite ferrite in DH36 steel. EDS analysis of the fractured surface of impact specimens confirmed the embedment of tungsten carbide particles in the weld zone due to the tool wear. Friction stir welding • Dissimilar welding • Numerical analysis • Heat flux • Thermal history • Mechanical properties Technical editor: Adriano Fagali de Souza.

2025, Welding in the World

In the present work, DH36 steel and AISI 1008 steel sheets were joined using friction stir welding (FSW) process to investigate the influence of the rotational speed, traverse speed, and tool offset on temperature distribution, z-force, microstructure, and mechanical properties of the welded specimens. At a traverse speed (v) of 50 mm/min with a rotational speed (ω) of 600 rpm and tool offset of 2 mm, the maximum impact toughness and hardness were obtained due to higher grain refinement. The transverse tensile test specimens fractured in the weaker material (i.e., AISI 1008 steel) and exhibited the ultimate tensile strength values at least on the level of the weaker material. The impact toughness and hardness were highly dependent on the grain size variation. The effect of pitch ratio (ω/v) on grain size variation was more as compared with that on tool offset. Increasing the pitch ratio reduced the grain size and improved the impact toughness and hardness. Stir zone exhibited the acicular-shaped bainitic ferrite in DH36 steel and Widmanstatten ferrite grains in AISI 1008 steel. The higher hardness values were observed in thermomechanically affected zone of both steels due to significant grain refinement. Increasing the rotational speed and decreasing the traverse speed result in a higher welding temperature, which reduced the z-force.

2025, Journal of Materials Engineering and Performance

In the present study, dissimilar friction stir welding was carried out between stainless steel (UNS S30400) and mild steel (UNS G10080) plates of 4 mm thickness using a tungsten carbide tool. The influence of tool rotational speeds (600, 875 rpm) and tool offsets (0.6, 1.2 mm) on mechanical properties, i.e., hardness, tensile strength, and impact toughness of welded joints was investigated. Maximum tensile strength of the joint was about 107.6% of the mild steel under rotational speed of 875 rpm and tool offset of 1.2 mm. The maximum hardness reached in the stir zone was about 281 HV 0.5 due to the phase transformations and grain refinement. CharpyÕs notch toughness of the welded joints was observed lower than the base materials. The microstructural characterizations were carried by using an optical microscope, and FESEM-EDS analysis which revealed the complex material mixing and material movement during the welding. Tungsten-rich bands were observed in the weld micrograph especially toward the advancing side. During this study, various wear mechanisms like oxidation wear, abrasive wear, and adhesion wear were responsible for the degradation of tungsten carbide tool.

2025, The International Journal of Advanced Manufacturing Technology

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. Keywords WC-Co tools . Weight measurement . Profile measurement . Microstructure . Surface roughness . XRD phase analysis Highlights • Performance evaluation of two different grades of tungsten carbide tools, i.e Tool A (WC-10 wt.%Co) and Tool B (WC-6 wt.%Co) was carried out during friction stir welding of high strength DH36 steel. • No pilot hole, preheating of work piece material and shielding of tool were done during welding. All trials were carried out to establish the robustness of the tool in the ambient environment condition. • Degradation mechanism for the tool A was observed as catastrophic failure and degradation mechanism for the tool B was observed as progressive wear. • Process parameters namely the welding speed and the rotational speed had a significant effect on the peak temperature attained by the tool which affected wear rate. • Higher surface roughness was observed at the tool pin as compared to that of the tool shoulder. • Metallographic characterization revealed the various modes of wear mechanism responsible for the degradation of the tungsten tool.

2025, Journal of Manufacturing Processes

Friction stir welding is a solid-state joining process which proved to be very effective for similar low strength materials. However, the joining of dissimilar materials is far complex than the similar materials because of divergent material properties. The need to study friction stir welding of dissimilar materials is inevitable due to increasing demand of modern industries. In the current study, the joining of aluminium alloy (AA-6061) and copper alloy (Cu-B370) plates is accomplished for studying the material flow movement throughout welding zone. A novel material flow model for dissimilar material friction stir welding is proposed based on the temperature and strain rate dependent material properties. The model used the volume of fluid (VOF) approach in the commercial FVM package ANSYS fluent 14.5. Experiments are also conducted to validate the model with thermal profiles and optical micrographs. Furthermore, the effect of tool rotational and the welding speed are studied on the material movement. It is found that process parameter had a huge impact on the nugget zone formation during the welding. The tool rotaion and welding speed directly affect the amount of platisized material mixing.

2025, Journal of Marine Science and Application

In marine application, marine grade steel is generally used for haul and superstructures. However, aluminum has also become a good choice due to its lightweight qualities, while rusting of aluminum is minimal compared to steel. In this paper a study on friction stir welding of aluminum alloys was presented. The present investigation deals with the effects of different friction stir welding tool geometries on mechanical strength and the microstructure properties of aluminum alloy welds. Three distinct tool geometries with different types of shoulder and tool probe profiles were used in the investigation according to the design matrix. The effects of each tool shoulder and probe geometry on the weld was evaluated. It was also observed that the friction stir weld tool geometry has a significant effect on the weldment reinforcement, microhardness, and weld strength.

2025, International Journal of Manufacturing Research

Effect of friction stir welding (FSW) tool geometries on aluminium welds were investigated using different tool shoulder and pin probe geometry profiles. A combination of 27 tool shoulder and pin profile geometries were used for the experimental purpose using a design matrix. The effect of these tool geometries on the friction stir welds like the weld strength, weld cross-section area and grain sizes were investigated. The effects of the tool geometries were predicted using artificial intelligence techniques such as artificial neural networks (ANN) and fuzzy logic modelling. It was observed that, for a combination of FSW tool geometries, the ANN model was not so effective in predicting the FSW weldment characteristics, while the fuzzy logic model was able to predict the same with much lower percentage of error for the test cases.

2025

The paper deals with distortion of hull cross-sections of large modern tankers with one longitudinal bulkhead subjected to bending in the vertical plane of symmetry. The cross-section distortion is considered in the limit case. It is assumed that hull panels — bottom, deck, sides and longitudinal bulkheads — are hinged along their longitudinal edges. The additional stresses and displacements due to distortion with respect to the stresses and displacements of the ordinary hull girder bending theory are analysed. The assumption of “ hinged cross-sections” is opposite to the assumption of “ rigid cross-sections” . Both are limiting cases of stresses and deformations of actual hull structures, particularly in the case of large tankers. A comparison with the results of the finite element analysis is provided.

2025

This study investigates the impact of 0.25 wt% B4C addition on the microstructure, phase stability, and mechanical properties of metastable Fe40Mn20Co20Cr15Si5 (at.%) high-entropy alloys (HEAs) fabricated via laser powder bed fusion (LPBF). A comparative analysis between B4C-containing (BC) and B4C-free (CS) alloys explored the influence of varying LPBF parameters. Electron backscattered diffraction (EBSD) revealed a strong dependence of microstructure on laser power and scanning speed in CS alloys, with significant variations in grain size and morphology. Conversely, BC alloys exhibited enhanced microstructural stability, indicating a more robust grain growth mechanism due to the influence of B4C. B4C addition also promoted grain refinement and stabilized the γ-f.c.c. phase. Mechanical testing showed a substantial increase in yield strength (YS) from 508 MPa (CS) to 670 MPa (BC) and a moderate increase in ultimate tensile strength (UTS) from 843 MPa (CS) to 854 MPa (BC). However, ductility decreased from 25 % to 5 %. Critically, synchrotron X-ray diffraction revealed deviations from the ideal c/a ratio (1.633) for both alloys. CS alloys showed an increase in c/a ratio after tensile deformation, indicative of a deformation-induced phase transformation, while BC alloys exhibited a decrease, suggesting a distinct deformation mechanism. This novel observation provides key insights into the role of B4C in controlling the deformation behavior of this HEA.

2025

Pengelasan gesek (friction welding, FW) proses penyambungan terjadi akibat panas yang ditimbulkan oleh gesekan antara dua bagian logam yang disambung. Keduabagianlogam yang akan disambung disatukan dibawah pengaruh tekanan aksial, kemudian salah satu diputar sehingga pada permukaan kontakakan timbul panas (mendekati titik cair logam), maka setelah putaran dihentikan akan terbentuk sambungan logam. Keuntungan pengelasan gesek dapat menyambung dua bahan yang berbeda (dissimilar metal). Tembaga (Cu) dan aluminium (Al) merupakan bahan yang akan disambung pada penelitian ini. Dua metoda penyambungan dengan proses las gesek, yaitu penyambungan yang secara langsung dan penyambungan dengan menusuk (Shock). Penyambungan dengan cara menusuk merupakan proses penyambungan Cu dan Al untuk mendapatkan kekuatan sambungan yang lebih besar. Metoda yang telah dilakukan peneliti dengan kontak langsung pada kedua permukaan bahan uji. Penelitian ini tentang penyambungan baha...

2025, LIGHT

Welding procedure seems simple, but actually requires knowledge of appropriate definition of the welding. Metallurgical bonding of metal in a liquid state is a fundamental principle in welding. The welding process can cause changes in the mechanical properties, physical and material structure in the weld so that it can affect the strength of the weld. The decline in the quality of welding is generally caused by improper welding way. Welding procedures actually have a standard, but the standard is not a guarantee of quality. The strength of welded joints in steel plates ST 42 KS BKI determined by the ability of welders (skills), welding position and the type of electrode. This study uses a steel plate ST 42 KS BKI with webbed arc welding (SMAW) with electrodes AWS E 6013 / E 7018 Heinmoller PTE LTD and welding position 5G. Tensile test object adapted to ASTM standards. The position of the test specimen using a standard ASME SECTION IX. Testing tensile test specimens using a tensile testing machine. From the results of this study showed the average value of 401.186 MPa tensile stress. This proves that the tensile strength of welded joints of steel plates ST 42 KS BKI position 5G welding electrodes AWS E 6013 / E 7018 can be said that the above-mentioned electrode in accordance with the specifications issued by the certifcate industrial.Kandungan carbon element for specimens A and C by 6.18% and 6.66% while industrial certificat Only 0.10%, which could lead to connection will be harder but it has a low ductility. The content of Mn specimens A and C of 0.41% while Cert industry by 1.6%.

2025, VIVA-Tech International Journal for Research and Innovation

FSSW is an advanced and popular solid-state material welding method, which has achieved a different variety of popularity in service in industries and automotive. FSSW method (technique) is used for joining similar or dissimilar materials like aluminium, titanium, magnesium and copper alloys etc. This paper presents finite element modeling of friction stir spot welding (FSSW) process using Abaqus/Explicit as a finite element solver. Three-dimensional coupled thermal-stress model was used to calculate thermo-mechanical response of FSSW process. The various factors such as rotational speed, transverse speed and profile of the tool plays a very significant role in the joining quality of material using FSSW. The main target of this analysis is to observe the variation of tool profile and welding quality of Ti 6Al 4V alloy as the tool speed varies. Two Ti 6Al 4V were lapped and provided with support to the bottom of the plate known as a back anvil to constrain the motion. This is where we analyzed the material flow due to friction of heat generation in the weld zone. Ti 6Al 4V is one of the most commonly used materials and its applications, where low density and excellent corrosion is applied in a wide range of resistance, are necessary in industries such as aerospace industry and biomechanical, marine, chemical industries, gas turbine, etc.

2025, Congreso Internacional de Metalurgia y Materiales

2025

Welding is a process which helps to join metals by adding metals between weldments by diffusion process.. One of the process by which metals are joined by creating friction on metals. It is called solid state welding. A rotating hard cylindrical pin is pressed on metals to be welded by friction. In FSW, there are only three process variables to control: rotation speed, travel speed and pressure, all of which are easily controllable. Four rotational speeds were used keeping the feed rate constant. The plunge depth is related directly to the pressure was varied depend on the work material. Analysis was carried by measuring surface roughness (R A ), tensile, micro hardness and metallographic tests. At rotational speed of 1925 RPM, aluminum to aluminum welding had given ultimate tensile strength up to 86 percent. Copper to copper joint process resulted that at rotational speed of 2275 RPM is the best result. Tensile value of 74 % was obtained compared to copper base material. The surface roughness Ra value low compared to copper base metal. The Vickers hardness value was high compared to base metal. Aluminum to copper metal joint the best resulted at 2275 RPM. The result was the lowest compared to similar metal joints. The value of 427 MPa of ultimate tensile strength (UTS) was archived. The metallographic test showed that a crack occurred at the bottom of welding joint. The hardness test showed that the hardness at the joint increased drastically. At high rotational speed of 2975, low surface roughness was obtained in all the weldments at low feed rate and low plunge depth.

2025, IJIEM - Indonesian Journal of Industrial Engineering and Management

It is difficult to improve the quality of friction stir welded joints of AA5052-H32 material because of scarce metrics on its concurrent optimization and prioritization. However, the objective of this article is to obtain optimal parametric values and identify important parameters using the Taguchi-Pareto method during the friction stir welding process of AA5052-H32 material. Then the ranks, delta values and optimal parameters are determined. The critical parameters identified for the friction stir welding process are the tool pin, rotational speed, welding speed and tool angle. When comparing the results of these parameters using the Taguchi method and Taguchi-Pareto method, the rotational speed retained its first position in both methods; the tool tilt angle gained the second position in the Taguchi-Pareto method from its third position when only the Taguchi method was considered. The welding speed became the third position in the Taguchi-Pareto method against the second position ...

2025, International Journal of Innovative Research in Science, Engineering and Technology

This paper presents the vibration analysis of sandwich panels and a comparison of natural frequencies using various theories. A simple software has been developed for calculating the natural frequency of panels. The software was validated... more