Cylindrical Pin Profile Research Articles

Study of mechanical behaviour & microstructural properties on friction stir welded aluminium alloys 6082 - t6&8011

In this study 6082 T6 aluminium alloys and 8011 aluminium alloys of 5mm Thickness by using a friction stir welding procedure, plates were connected. weldments are carried out by varying various parameters such as Tool rotational rates are varies from(600 rpm,800 rpm,1000 rpm),Traverse speed are varies from(10 mm/min,20 mm/min,30mm/ min) Axial Forces are varies from (4 kn,6 kn,8 kn) and Tilt angle maintains 10.This process performed by nonconsumable tool as Hexagonal,cylindrical and square pin profiles to generate a heat energy and plastic atomic diffusion's are made in the weldments. The fractography microstructure of tensile specimen shows minimum failure when the tool rotational speed is 800rpm, traverse speed at 20 mm/min and axial force 8KN.

Влияние геометрии наконечника сварочного инструмента на характеристики растяжения соединений сплава АА8011, полученных сваркой трением с перемешиванием

Introduction. Aluminum alloys are in abundant demand of shipbuilding and aircraft industries. This study emphasizes on the effects of two different tool pin profiles on the tensile characteristics of welded joints made of AA8011 aluminum alloy welded joints. The joining technique used is friction stir welding (FSW) due to its unique characteristics such as very low heat affected zone when joining in a solid state. The microstructure and mechanical properties of the welded joint are influenced by the geometry of the tool and such parameters as rotational speed and traverse speed of the tool. The methods of investigation. The experiments on FSW were performed on universal milling machine with taper cylindrical and cylindrical threaded tool pin profiles using the three different combination of tool rotational and traverse speed (a) 320 rpm, 45 mm/min; b) 400 rpm, 50 mm/min; c) 575 rpm, 60 mm/min.). To analyze the joint characteristics, tensile tests were conducted and ultimate tensile strength as well as joint efficiency was calculated for individual joint. Results and Discussion. Based on the revised results, it is evident that higher RPM values have a positive impact on joint efficiency and tensile strength for both the taper cylindrical pin profile and the threaded cylindrical pin profile. The findings show that the joint efficiency and tensile strength are consistently higher for the threaded cylindrical pin profile compared to the taper cylindrical pin profile, regardless of the RPM and feed rate. From the results, it was found that joint efficiency and tensile strength is maximum at higher RPM irrespective of the tool pin profile i.e. 73.6 % and 123 MPa for taper cylindrical pin profile and 85 % and 142 MPa for threaded cylindrical pin profile at 575 rpm, 60 mm/min. These are the highest in comparison to 72.5 % and 119 MPa at 320 rpm, 45 mm/min and 70.1 % and 115 MPa at 400 rpm, 50 mm/min for taper pin profile tool and 82.6 % and 138 MPa at 320 rpm, 45 mm/min and 77.8 % and 130 MPa at 400 rpm, 50 mm/min for threaded cylindrical pin profile. Overall, the study demonstrates that joints obtained using the threaded cylindrical pin profile demonstrate higher joint efficiency and tensile strength than those prepared using the taper cylindrical pin profile. The highest joint efficiency and tensile strength of 84.5 % and 142 MPa, respectively, were achieved using the threaded cylindrical pin profile at 575 rpm and 60 mm/min.

The Influence of Tool Geometry on the Mechanical Properties and the Microstructure of AA6061-T6 Aluminum Alloy Friction Stir Spot Welding.

In this work, the influence of the tool geometry on friction stir spot welding (FSSW) was studied on sheets made of AA6061-T6 aluminum alloy. Four different AISI H13 tools with simple cylindrical and conical pin profiles and 12 mm and 16 mm shoulder diameters were used to perform the FSSW joints. Sheets of 1.8 mm thickness were used during the experimental work to prepare the lap-shear specimens. The FSSW joints were performed at room temperature. For each joining condition, four specimens were carried out. Three specimens were used to find the value of the average tensile shear failure load (TSFL), while the fourth one was used to examine the micro-Vickers hardness profile and to observe the microstructure of the cross-section of the FSSW joints. The investigation concluded that higher mechanical properties corresponding to the finer microstructure were obtained by the conical pin profile and the higher shoulder diameter compared with the specimens performed using the cylindrical pin tool and lower shoulder diameter due to the higher strain hardening and the higher frictional heat generation, respectively.

Influence of Welding parameters on Mechanical property during Friction Stir Welded joint on Aluminium Alloys: A Review

The friction stir welding (FSW) is widely used in the fabrication of Aluminium alloy and other non-ferrous alloy. It has good potential to be used in major industries such as automobiles, aerospace, shipbuilding and can be used in the joining of high strength alloys. The FSW process low distortion and heat affected zone (HAZ) with fine recrystallized microstructure which leads to better mechanical properties at the weld zone and produces great stability. In this study, the different FSW parameters such as weld speed, tool rotation speed, tool tilt angle, feed per min has been discussed. The different types of tool pin profile and shoulder have also been discussed and their impacts on mechanical and microstructural properties at welded joints. Among various welding parameters the rotational speed is the most influencing parameter in FSW. Increasing the rotational speed exhibits the increase at tensile strength and is supposed to improve the mechanical properties. The most affected tool pin profile would be considered to be tapered threaded cylindrical pin profile which makes the adequate mixing of material with better flow ability and provide the fine grains at nugget zone. Comparing the FSW with other arc welding processes, it shows a wide range of environmental benefits which are noticeable such as saving in consumable materials, decrease in consumption of filler material and reduction in grinding wastes. Harmful emissions created from arc welding causes a health hazard to the welder. For achieving the high joint-strength for aerospace aluminium alloys and high temperature sustainable metallic alloys, friction stir welding will be preferred.

An experimental study of friction stir welding parameters effect on joint properties of aluminium alloy and copper plate

Joining dissimilar metals like copper and aluminium is a complex area of research for the manufacturing industry. To effectively join the AA7075 with copper plates, an experimental investigation on friction stir welding was carried out. A straight cylindrical pin profile tool of H13 tool steel was chosen for this study. On the advancing direction, the AA7075 plates were fixed under the condition of zero tool offset. The tool was positioned at a 2° tilt angle for the entire experiment. Tensile test, microhardness test, SEM and EDS analysis were completed to investigate the effectiveness of the process parameters (tool traverse and rotational speed) in combination with a modified set-up on the microstructure, tensile strength and microhardness of the joint. Fractography was conducted on fractured specimens to identify the mode of failure. Complex microstructures of swirl and vortex-type material flow patterns were created in the stir zone. As a result of SEM analysis, one of the samples (S5) had finer grains at intermediate heat input, which produced excellent microhardness and tensile strength. Fractography identified ductile failure as the predominant mode of failure in the joints. The results of this study include an ultimate tensile strength value of 221.091 MPa with a joint efficiency of 95.05%, yield strength of 159.035 MPa, maximum elongation of 9.335% and a microhardness value of 271 HV for specimen welded at a traverse speed of 60 mm min−1 and a rotational speed of 1400 rpm.

Effect of Process Parameters on the Microstructure and Mechanical Properties of Friction Stir Welded Copper-MWCNT Joints

The main objective of this study is to investigate the influence of the tool rotation speed (TRS) and tool traverse speed (TTS) on the microstructure, microhardness and the tensile strength of the copper – MWCNT welded joints. MWCNT particles were successfully incorporated in the weld zone of the copper plate through the holes drilled at the sides of the abutting copper plates. The joints were welded using a tool with tapered cylindrical pin profile. The TRS was varied between 1200 and 1300 rpm. The TTS was varied between 50 mm/min and 100 mm/min. The parametric limits were fixed based on the trial runs conducted for obtaining defect free welds. The defect free welds were evaluated for microhardness in the nugget zone as per ASTM E384. The tensile strength of the joints was tested as per ASME Section IX-2019. Microstructural investigations revealed the formation of intercalated banded structures indicating homogeneous mixing and distribution of MWCNTs in the copper matrix. Maximum tensile strength of 175 MPa was achieved for the joint fabricated with 1200 rpm TRS and TTS of 30 mm/min. Weldment with maximum microhardness of 100.21 Hv was achieved for the same combination of process parameters. The sample processed at a higher TRS of 1300 rpm and lower TTS of 20 mm/min yielded the second best tensile and microhardness. The tensile strength of the welded joints was observed to increase with increasing the TTS and the TRS.

Investigation of microstructural and wear behavior of Al6061 surface composites fabricated by friction stir process using Taguchi approach

The surface composites of aluminum alloys have a higher scope of applications encountering surface interactions in the aerospace, automobile, and other industries compared to the base aluminum alloys. The friction stir process (FSP) is recently the preferred method to prepare aluminum-based surface composites due to its capability to produce improved physical properties and refined microstructure at the surface. The study examines the Al6061 alloy-based surface composite fabricated by FSP for their wear behavior and microstructure. In this study, the Al6061 alloy-based hybrid surface composites are prepared with varying weight% of copper and graphite microparticles mixture as reinforcement by FSP with two tools having unique pin profiles, i.e., threaded cylindrical and plain cylindrical. These prepared composites are investigated for the dry sliding wear test on a pin-on-disc test set-up. The experiments are designed using the L9 orthogonal array and analyzed by the Taguchi approach to obtain the influence of disc speed, load, and reinforcement weight% on wear rate. The significant parameters influencing the wear rate of the samples tested are obtained using ANOVA. Later the effects of the friction stir process and the wear tests on the microstructure of the workpieces are investigated using FE-SEM/EDS tests. It is concluded that the decrease in wear rate with the rise in reinforcement weight% (Cu + graphite) from 2% to 6%. The load has the maximum effect on the wear rate for the samples prepared by threaded cylindrical FSP tool pin profile, while reinforcement weight% affects significantly the wear rate of the samples prepared by FSP with plain cylindrical pin profile tool.

Fabrication of FSW Tool Pins Through Turning of H13 Tool Steel: A Comparative Analysis for Residual Stresses

In the present research, measurement of residual stress induced during turning and threading operations for the fabrication of two types of pin profiled friction stir processing/welding (FSP/FSW) tools, i.e. cylindrical profiled pin tool and cylindrical threaded profiled pin tool, is being dealt with. Workpiece was chosen to be H13 tool steel with a diameter of 22[Formula: see text]mm and 110[Formula: see text]mm length. Turning and threading was done on CNC machine tools using CNMG 12404-THM uncoated tungsten carbide cutting tool. For residual stress measurement of the workpieces, an XRD-based Pulsetec[Formula: see text]-X360n portable residual stress analyzer setup was used. The experimental results show that the cylindrical pin profile tool had a compressive residual stress of [Formula: see text][Formula: see text]MPa and compressive residual shear stress of [Formula: see text][Formula: see text]MPa, while the cylindrical threaded pin profile tool had a compressive residual stress of [Formula: see text][Formula: see text]MPa (51.8% more) and compressive residual shear stress of [Formula: see text][Formula: see text]MPa (40% less). It has been concluded that due to threading operation on the cylindrical threaded pin profile, the value of residual stress is more in it, and since the stress is compressive in nature, it would have a better positive impact while doing FSP/FSW than that of the cylindrical profiled pin tool.

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

Effect of friction stir welding tool profiles on mechanical properties of dissimilar welded aluminum alloy plates

PurposeThe main purpose of the present work is to study the effect of tool pin profiles on mechanical properties of welded plates made with two different aluminium alloy plates.Design/methodology/approachThe welded plates were fabricated with the three different kinds of pin profiled tools such as taper cylindrical, taper threaded cylindrical and stepped cylindrical pin profiles. Tensile properties of welded plates were evaluated using tensile testing machine at room temperature. Microstructures studies were carried out using scanning electron microscope.FindingsTensile properties were improved with the use of taper threaded cylindrical pin tool in friction stir welding process when compared with taper cylindrical and stepped cylindrical pin tools. This is due to refinement of grains and mixing of plasticized material occurred with generation of sufficient heat with the taper threaded pin tool. Through these studies, it was confirmed that friction stir welding can be used to weld Al6061 and Al2014 aluminium alloy plates.Research limitations/implicationsIn the present study, the friction stir welding is performed with constant process parameters such as tool rotational speed of 900 rpm, transverse speed of 24 mm/min and tilt angle of 1°.Practical implicationsAluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. These aluminium alloy blanks can be developed with friction stir welding method with better properties.Originality/valueVery limited work had been carried out on friction stir welding of aluminium alloys of Al 6061 and Al2014 with different tool pin profiles. Furthermore, this work analyzed with tensile properties of welded plates correlated with weld zone microstructures.

Optimization and Characterization of Friction Stir Spot Welding of Aluminum Alloy (AA 5754-H114) with Pure Copper Sheet

Friction stir spot welding (FSSW) was conducted to weld a sheet of an aluminum alloy (AA5754-H114) to a commercial sheet of pure copper (Cu) having (2 mm) thickness. It was performed at various tool rotating speeds (800, 1000, and 1250 rpm), times of plunging (30, 60, and 90 sec) using a tool pin geometry or profile (straight cylindrical, threaded cylindrical with the flute, and tapered cylindrical). The welding process parameters were optimized based on the Taguchi method relying upon the design of experiment (DOE). The used sheet is made of “aluminum alloy” overlapped upon copper sheets. The results manifested that the “maximum” shear forces were found at the best or optimum parameters of welding: (1000 rpm) rotational speed and (90 sec) plunging time when using the straight cylindrical pin profile. The Pareto chart of standardize influences of the tensile-shear outcomes elucidated that the time of plunging was the higher influential parameter than the other welding parameters, such as the speed of rotation and the profile of the pin.

Influences of welding parameters on friction stir welding of AA 6063 Al-alloy and copper plates – An experimental study

Friction stir welding is a solid state welding technique for the welding of metallic compounds. The Aluminium alloy 6063 and commercially available copper of 6 mm thickness are welded in circular butt joint geometry by friction stir welding (FSW) process, using vertical milling machine. The Friction stir welding was carried out at each rotational speed of 800 rpm and 1000 rpm for different travel speed 20 and 40 mm/min at constant probe depth of 2.9 mm, towards the trailing edge and a dwell time of 3 sec. One of the critical elements for the achievement of this method is the friction stir welding tool. It comprises of a distinct geometry cylindrical shoulder and a pin. The said instrument was intended for friction stir welding of the dissimilar metal plates in the experimental job with cylindrical pin profile. The results have been correlated with the micro structural characteristics at the bond interface using scanning electron microscopy. The results show the characteristics of different types of intermetallic compound formed at the interface derived from energy input.

Effect of revolution speed on the mechanical properties of dissimilar Aluminum alloy joined by friction stir spot welding

Friction stir spot welding (FSSW) method was performed for welding of aluminum alloys AA6061-T6 with pure aluminum AA1100 sheets having thicknesses of 2.4 and 3 mm respectively. FSSW procedure was accomplished at varied tool rotational speeds (1000, 1600, and 2000 rpm). The dwell time was (2, 4, and 6 sec) and the geometry of the tool pin was threaded cylindrical pin with a cylindrical and straight shoulder.The aluminum alloy AA6061-T6 sheet was overlapped on the pure aluminum AA1100 sheet. The tensile shear test was investigated for all specimens. It was deduced that the value of the maximum shear force is 1.95 kN. This value was obtained at the following welding factors: 2000 rpm spindle rotational speed, 4 sec dwell time and threaded cylindrical pin profile, the two other factors which were pin length and plunging time were kept as constant parameters through the tests at 3.2 mm and 40 sec respectively. It was also concluded that the fracture happens in the nugget zone mode at the highest lap-shear load.

Effect of Tool Rotational Speeds on Friction Stir Welded AA6082 T6 Aluminium Alloy Joints

In the current work, an attempt has been made to investigate the effect of tool rotational speed on microstructural and mechanical properties of friction stir welded AA6082-T6 aluminium alloy. Four different tool rotational speeds such as 500, 700, 900 and 1100 rpm were used to produce the joints while keeping the other process parameters constant. The tool used to fabricate the welded samples was tungsten carbide with straight cylindrical pin profile. The microstructural properties were examined using an optical and scanning electron microscope and found that the 700 rpm produced joint showed equiaxed grain structure with 14.3 μm average grain size. The mechanical characteristics such as tensile strength, impact strength and microhardness were evaluated and found the highest tensile strength of 265 MPa, impact energy of 10 J and micro hardness of 76 HV in the weld zone for the sample prepared with 700 rpm tool rotational speed. The fractographic studies were also carried out to study the mode of failure.

Role of tool pin profiles on wear characteristics of friction stir processed magnesium alloy ZK60/silicon carbide surface composites

AbstractPoor friction and wear resistance are the major drawbacks that restrict structural applications of ZK60 magnesium alloys. The surface properties of magnesium alloy can be enhanced by reinforcing particles in the surface using friction stir processing (FSP). Tool pin profile is the significant process parameters which influences the material flow, particle breakups and its distribution in the processed zone. In this study, an attempt was made in order to understand the major effects of tool pin profiles namely, cylindrical thread (CT), plain cylindrical (PC), plain tapered cylindrical (PTC) and square (SA) pin profiles on the microstructure characteristics and particle distribution of friction stir processed/silicon carbide particle surface composites. The surface composites fabricated by plain tapered cylindrical pin profile yield superior properties which is attributed to the higher shear force and balanced state of material flow and heat generation in the processed zone. The formation of smaller grains and hardness enhancement due to dispersion strengthening are the main causes to get better wear resistance of friction stir processed/silicon carbide particle magnesium alloy.

Optimization of process parameter for AA6061 alloy during friction stir processing

With the development of advanced technology the friction stir process (FSP) is being used in several engineering applications. It is an emerging approach to modify the various mechanical properties by creating high strain rate at temperature less than the melting point of material. Therefore the main objective of present work is to optimize the various mechanical properties of AA6061 material using different tool profiles. To optimize the process parameter Taguchi technique has been used. Experimental data have been collected according to Taguchi L9 orthogonal array and optimize using S/N analysis. The optimized results shows the significant improvement in mechanical properties by using square pin profile as compared to threaded cylindrical and cylindrical pin profile. It has been observed as transverse speed increases, Ultimate tensile strength (UTS) also increases.

Friction Stir Welding of Glass Filled Nylon 6 Composites

Nylons are high-performance, semi-crystalline thermoplastics with many attractive properties like chemical, physical, and mechanical properties. The aim of this research work is to investigate the feasibility of glass filled Nylon 6 composites by Friction stir welding (FSW). Glass filled Nylon 6 composites were fabricated by an injection molding process and joined by FSW technique with H13 tool steel having cylindrical pin profile. The effect of varying tool rotational speed (300, 600 and 900 rpm) and tool transverse speed (0.1, 0.2 and 0.3 mm/s) on the mechanical properties (ultimate tensile strength, percentile elongation, and Shore D hardness) and morphological properties of FSWed sections of glass filled Nylon 6 composites was investigated. The maximal tensile strength (40.32 MPa), which reached 51.32 % joint efficiency and percentage elongation (7.01%) was acquired at a tool rotational speed of 900 rpm and tool traverse speed of 0.1 mm/s with defect free welds. Tensile specimens of maximum weld tensile strength fractured occurred in TMAZ –HAZ at advancing side. There is a close relationship of tensile test results with fracture location and morphology

Numerical investigations of effect of input process parameters on heat generation in friction stir welding

This article investigates the effect of input process parameters on the heat generation in friction stir welding (FSW) using numerical techniques. The computational fluid dynamics (CFD) based numerical modeling technique is used to predict the heat generation, temperature distributions with consideration of tool pin profile, tool rotation speed and welding speed. To investigate the effect input process parameters on heat generation and temperature distribution, four different tool pin profile are used namely cylindrical, conical, cylindrical-conical and stepped-conical pin profile. The geometric modeling and numerical simulation is carried out using ANSYS Fluent software. The peak temperature produced by tool pin profile is used to predict the effect of input process parameter on the heat generation. The simulation results show that the peak temperature value directly proportional to the tool rotation speed. The magnitude of peak temperature produced by stepped-conical pin profile tool is highest among the all tool pin profile peak temperature along the thickness. The effect of tool rotation speed on peak temperature is highly significant but welding speed effect on peak temperature is insignificant for all tool pin profile at particular tool rotation speed along the thickness of the work piece.

Analyzing the Effect of FSW Process Parameter on Mechanical Properties for a Dissimilar Aluminium AA6061 and Magnesium AZ31B Alloy

Abstract In this work, dissimilar aluminium and magnesium alloy were Friction Stir Welded to analyze the effects of different process parameters on the tensile strength of welded joints. The FSW is performed by using cylindrical pin profile tungsten carbide tool. The experiment is designed according to the Taguchi L9 orthogonal arrays by varying of process parameter to determine the effects of process parameters on tensile strength of dissimilarly welded Al and Mg alloy. The regression model is developed based on the experimental results. ANOVA is a parametric statistical technique used to calculate the percentage of contribution of individual process parameter. The result of ANOVA analysis shows that welding speed (49.914 %) has higher percentage of contribution than the rotational speed (17.881 %) and tool tilt angle (30.611 %). The optimum process parameters for achieving maximum tensile strength were identified. The most significant process parameter was identified as welding speed

Multiobjective optimization of friction stir weldments of AA2014-T651 by teaching–learning-based optimization

This study focuses on optimization of process parameters, which may result in improved mechanical properties of the friction stir weldments of AA2014-T651. Plain taper and threaded taper cylindrical tool pin profiles were used for the study. A set of experiments was conducted at different levels of tool rotational and weld speeds using two tool pin profiles. Mechanical properties such as tensile strength, yield strength, impact strength, percentage of elongation, and hardness were measured. Objective functions are developed for the five mechanical properties in terms of input parameters. The input parameters were optimized using teaching–learning-based optimization algorithm technique to improve mechanical properties. The teaching–learning-based optimization algorithm suggested three best combinations such as combination-I (940 r/min and 32 mm/min), combination-II (1100 r/min and 40 mm/min), and combination-III (1205 r/min and 45 mm/min). The optimization is also validated with experimental results.