Abstract
Background/Objectives: In friction stir welding, tools with flat faced pin delivers better weld quality than cylindrical pin. In flat faced pin, improper selection of process parameters often results premature tool failure. Being easily controllable process parameters, proper selection of tool rotation speed with respect to the tool advancing speed not only avoids unwanted weld defects but also enhances tool life. Methods: An integrated experimental and numerical comparative study is made between air and water cooled processes to understand the effects of heat dissipation through the boundaries on temperature distribution. Findings: Optimum range of Pseudo Heat Index (PHI) is achieved by comparing the obtained temperature distribution with material softening temperature. Optimum range of weld speed with respect to the tool rotation speed is derived through the optimum Pseudo heat index. Experimental study on the joint strength validates the proposed optimal process parameter ranges. Novelty : This study outlines a novel approach to develop an optimum process window based on PHI for air and water cooled friction stir welding using tools with flat faced pin. Keywords: Optimization; friction stir welding; thermomechanical; pseudo heat index; experimentation; numerical modeling
Highlights
Friction stir welding (FSW) is a metal joining process primarily developed to join readily oxidising materials in molten stage
Torque produced by the rotating tool, stirs the plasticised material to flow around the pin which develops a thermo-mechanically affected stir zone under the tool shoulder in the dwell stage
Effect of air and water cooling on temperature distribution during the process in stir and heat affected zone is estimated through an integrated experimental and numerical analysis
Summary
Friction stir welding (FSW) is a metal joining process primarily developed to join readily oxidising materials in molten stage. This is achieved by carrying out the entire metal joining process below solidus temperature of the material to be joined. Up to this stage it is called as plunging in which the entire tool pin inserted into the parental metal. Proper selection of tool sliding velocity retains the maximum process temperature throughout the process
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