Development Of Friction Stir Welding Research Articles

A Review of Recent Developments in Friction Stir Welding for Various Industrial Applications

Friction stir welding (FSW) has been recognized as a revolutionary welding process for marine applications, effectively tackling the distinctive problems posed by maritime settings. This review paper offers a comprehensive examination of the current advancements in FSW design, specifically within the marine industry. This paper provides an overview of the essential principles of FSW and its design, emphasizing its comparative advantages when compared with conventional welding techniques. The literature review reveals successful implementations in the field of shipbuilding and offshore constructions, highlighting design factors as notable enhancements in joint strength, resistance to corrosion, and fatigue performance. This study examines the progress made in the field of FSW equipment and procedures, with a specific focus on their application in naval construction. Additionally, it investigates the factors to be considered when selecting materials and ensuring their compatibility in this context. The analysis of microstructural and mechanical features of FSW joints is conducted, with a particular focus on examining the impact of welding settings. The study additionally explores techniques for mitigating corrosion and safeguarding surfaces in marine environments. The study also provides a forward-looking perspective by proposing potential areas of future research and highlighting the issues that may arise in the field of FSW for maritime engineering. The significance of incorporating environmental and economic considerations in the implementation of FSW for extensive marine projects is emphasized.

Friction Stir Welding of Dissimilar Al/Al and Al/Non-Al Alloys: A Review

Friction stir welding is a solid-state welding technique that has many advantages over traditional fusion welding, and has been widely adopted in the aerospace and automotive industries. This article reviews research developments in friction stir welding of dissimilar alloys systems, including combinations of aluminum alloys with Mg alloys, Cu, and steel. Microstructural evolution, hardness, tensile and fatigue properties, residual stresses, and corrosion behavior of dissimilar welds will be reported. The effects of processing parameters such as tool rotation and traverse speeds, tool position, material position, and tool geometry on the weld quality are also presented. Discussions on future research directions in friction stir welding will also be provided in the context of existing literature and future high-integrity applications.

Friction-stir welding and processing of Ti-6Al-4V titanium alloy: A review

In this work, the current understanding and development of friction-stir welding and processing of Ti-6Al-4V alloy are briefly reviewed. The critical issues of these processes are addressed, including welding tool materials and design, tool wear, processing temperature, material flow, processing window and residual stresses. A particular emphasis is given to microstructural aspects and microstructure-properties relationship. Potential engineering applications are highlighted.

Multi-Objective Optimization of Friction Stir Welding Process Parameters of AA6061-T6 and AA7075-T6 Using a Biogeography Based Optimization Algorithm.

The development of Friction Stir Welding (FSW) has provided an alternative approach for producing high-quality welds, in a fast and reliable manner. This study focuses on the mechanical properties of the dissimilar friction stir welding of AA6061-T6 and AA7075-T6 aluminum alloys. The FSW process parameters such as tool rotational speed, tool traverse speed, tilt angle, and tool offset influence the mechanical properties of the friction stir welded joints significantly. A mathematical regression model is developed to determine the empirical relationship between the FSW process parameters and mechanical properties, and the results are validated. In order to obtain the optimal values of process parameters that simultaneously optimize the ultimate tensile strength, elongation, and minimum hardness in the heat affected zone (HAZ), a metaheuristic, multi objective algorithm based on biogeography based optimization is proposed. The Pareto optimal frontiers for triple and dual objective functions are obtained and the best optimal solution is selected through using two different decision making techniques, technique for order of preference by similarity to ideal solution (TOPSIS) and Shannon’s entropy.

Friction-stir welding of aluminum alloy with an iron-based metal as reinforcing material

Abstract The fabrication of a durable and usable aluminum matrix composite poses a challenge because it is hard to obtain defect-free welds by using conventional fusion welding methods. The development of friction-stir welding (FSW) provides improved microstructure modification. As there are no melting problems associated with it, liquid-solid reactions are eliminated. The objective of this study was to attempt FSW of an AA6061 alloy reinforced with an iron-based metal and to determine the properties of the joints. The effects of FSW parameters, especially the tool rotation speed, are presented first. Then, the application of the technique in manufacturing and microstructure modification of particle-reinforced composite materials is discussed. Finally, interfacial microstructural changes and the associated mechanical properties are evaluated.

An Experimental Investigation of Temperature Distribution and Joint Properties of Al 7075 T651 Friction Stir Welded Aluminium Alloys

The 7xxx series aluminum alloys provides the highest strength of all aluminum alloys and are considered to be a family of high strength aerospace alloys. Its weldability with conventional fusion welding techniques is extremely poor. The development of friction stir welding (FSW) process has made these aluminum alloys join satisfactorily in a reliable manner. The heat generation during the process dictates the weld quality, the tool life and the residual stresses in the workpiece. The tool geometry plays a vital role in the determining the amount of heat generation during FSW. In the present work, different tool shoulder diameters were used to practically explore the thermal histories in the workpiece during the FSW process of Al 7075 T651 joints. The transient temperatures during FSW were measured with different thermocouple layouts. A detailed discussion on temperature distributions in the workpiece is presented. Evaluation of the tensile strength of the welded joints was carried out alongwith the metallographic characterization and they were put in relation with the temperature data recorded during the friction stir welding process.

Multi-objective Optimization of FSW Process Parameters of Aluminium Alloy Using Taguchi-Based Grey Relational Analysis

The advantages of friction stir welding (FSW) of aluminium alloys have promoted research in the area of FSW of aluminium. The recent developments in FSW are focused on optimisation of process parameters for multi-response characteristics. Experiments were conducted using the tool shoulder diameter, rotational speed, welding speed and the axial load as typical process parameters for multi-objective optimisation in FSW of AA 8011. The grey analysis was adopted to obtain grey relational grade for FSW process with multiple-characteristics, namely, tensile strength, microhardness and power consumption. Analysis of variance was used to study significance of process variables on grey relational grade which showed rotational speed and welding speed to be most significant parameters. Other than rotational speed and welding speed, tool shoulder diameter and axial load were also found to be significant. To validate the study, confirmation experiments were carried out at optimum set of parameters and predicted results were found to be in good agreement with experimental findings.

Recent Developments in Friction Stir Welding of Al-alloys

The diversity and never-ending desire for a better life standard result in a continuous development of the existing manufacturing technologies. In line with these developments in the existing production technologies the demand for more complex products increases, which also stimulates new approaches in production routes of such products, e.g., novel welding procedures. For instance, the friction stir welding (FSW) technology, developed for joining difficult-to-weld Al-alloys, has been implemented by industry in manufacturing of several products. There are also numerous attempts to apply this method to other materials beyond Al-alloys. However, the process has not yet been implemented by industry for joining these materials with the exception of some limited applications. The microstructures and mechanical properties of friction stir welded Al-alloys existing in the open literature will be discussed in detail in this review. The correlations between weld parameters used during FSW and the microstructures evolved in the weld region and thus mechanical properties of the joints produced will be highlighted. However, the modeling studies, material flow, texture formation and developments in tool design are out of the scope of this work as well as the other variants of this technology, such as friction stir spot welding (FSSW).

The Effect of Base Metal Conditions on the Final Microstructure and Hardness of 2024 Aluminum Alloy Friction-Stir Welds

Aircraft aluminum alloys, such as 2024, generally present low weldability by traditional fusion welding processes. The development of friction-stir welding (FSW) has provided an improved alternative way to produce satisfactory aluminum joints in a faster and more reliable method. It has been demonstrated that the FSW process involves dynamic recrystallization, which leads to ultrafine and equiaxed grain structures due to the high temperatures and strains occurring during the process. In this study, the 2024 Al-alloy with annealed (O) and artificial aged (T6) conditions were friction-stir welded. Grain size distribution, hardness, and temperature profiles in the welded zones were determined to obtain the relationship between the base metal’s initial and final microstructures in these regions. The results showed that in both samples, the average grain sizes in the weld nugget were almost identical. The hardness of nugget zones in both samples was nearly the same due to their similar microstructures. According to the obtained results, the initial microstructure showed no considerable effect on the final microstructure and hardness of the weld nuggets. This may be attributed to the continuous dynamic recrystallization phenomenon that occurs during the FSW of aluminum alloys.

Prediction and Optimization of Wear Resistance of Friction Stir Welded Dissimilar Aluminum Alloy

Aluminum alloys generally present low weldability by traditional fusion welding process. Development of Friction Stir Welding (FSW) has provided an alternative improved way of producing aluminum joints, in a faster and reliable manner. The quality of a weld joint is stalwartly influenced by process parameters used during welding. In this paper an attempt has been made to develop an empirical relationship between FSW process parameters to predict wear resistance of friction stir welded dissimilar aluminum alloys. Four factors, five levels central composite rotatable design has been used to minimize the number of experiments. The FSW parameter considered for experiments are tool pin profile, tool rotational speed, welding speed and axial force. Analysis of variance (ANOVA) technique has been used to check the adequacy of the developed model. The effect of these FSW parameters on wear resistance of the welded joints has been analyzed and the predicted trends are discussed. The FSW process parameters are optimized using Response Surface Methodology (RSM) to maximize the wear resistance. The optimum FSW welding parameters have been identified to maximize the wear resistance.

Mechanical and Micro-structural Study of Friction Stir Welding of Al-alloy

The present study is on the development of friction stir welding (FSW) of commercial grade Al-alloy to study the mechanical and microstructural properties. The proposed research will include experiments related to the effect of FSW optimum process parameter on weldability of Al alloy. The present paper has been subdivided in to two different sections: 1. Study of Mechanical properties and 2. Study of micro-structural properties. Section1 describes the tensile strength of welded sample and distribution of microhardness in different zones of FSW weld specimen and section2 contains the microstructure characterization of different zones of friction stir welds.

Development of friction stir welding of high strength steel sheet

For friction stir welding (FSW) of advanced high strength steel (AHSS) sheets with tensile strength grades between 590 and 1180 N mm−2, the appropriate welding condition range and the influence of welding conditions on microstructures and mechanical properties of the welds were investigated. The appropriate welding conditions to avoid defects such as the incomplete consolidation at the bottom of the weld were obtained for the steel sheets up to 1180 N mm−2 grade. The higher tool rotation speed evidently resulted in the larger volume fraction of martensite and higher hardness in the stir zone (SZ), attributed to an increase in the peak temperature of its thermal cycle. The tensile strength of the weld joint was as high as that of the base metal for the steels up to 980 N mm−2 grade, but slightly lower than that of the base metal for the steel of 1180 N mm−2 grade due to the heat affected zone (HAZ) softening.

English

The present study is on the development of friction stir welding (FSW) of commercial grade Al-alloy to study the effect of tool geometry on mechanical and micro-structural properties. The proposed research will include experiments related to the effect of FSW optimum process parameter on weldability of Al alloy. The present paper has been subdivided in to two different sections: 1. Study of Mechanical properties and 2. Study of micro-structural properties. Section-1 describes the effect of tool geometry on tensile strength and distribution of micro-hardness in different zones of FSW weld specimen and section-2 contains the microstructure characterization of different zones of friction stir welds. Two types of tool geometries have been used in the present work such as straight cylindrical (SC) and tapered cylindrical (TC). Tensile results shown an increase in ductility for welded joints compared to base metal. SC tools shown better strength compared to TC tools.

C1020/Al6063 이종 합금의 맞대기 마찰교반접합의 접합특성

The Friction Stir Welding (FSW) has mainly been used for making butt joints in Al alloys. Development of FSW would expand the number of applications. The FSW is a relatively solid-state joining process. This study possibility of a welding between C1020 and Al6063 by means of FSW has fundamentally clarified. The primary process parameters, such as a rotating speed, rotating direction of tool and off-set of pin periphery from materials interface were optimize, respectively.

高張力薄鋼板の摩擦攪拌接合(FSW)技術の開発（第1報） 適正接合条件の検討

高張力薄鋼板の摩擦攪拌接合(FSW)技術の開発（第1報） 適正接合条件の検討

高張力薄鋼板の摩擦攪拌接合(FSW)技術の開発（第2報）:590～1180N/mm2級高張力鋼の継手特性

高張力薄鋼板の摩擦攪拌接合(FSW)技術の開発（第2報）:590～1180N/mm2級高張力鋼の継手特性

Current state and development of friction stir welding (review). Part 2. Improvement of tools and welding method

Current state and development of friction stir welding (review). Part 2. Improvement of tools and welding method

Terminology in friction stir welding

In an attempt to avoid confusion and duplication, TWI proposed an initial basic terminology at an early stage of the development of friction stir welding (FSW). This terminology has since been revised and extended in consultation with licensees and other interested parties, to the form summarised in this paper. A definitive standard on FSW is being prepared by Working Group B1 of Commission III of the International Institute of Welding, and it is expected that this will be adopted as an ISO standard.

ISTIR—Analytical thermal model for friction stir welding

Light-weight components are of crucial interest for all industries producing moving masses. The aim of reducing weight is closely followed by high production efficiency and component performance. Friction stir welding (FSW) offers the possibility to produce welds in light metals with the advantages offered by fusion welding but in addition they also give a significant reduction in distortion and improve metallurgical transformations, with inherent improvement in performance. The development of FSW has been advanced in the industrial sector typically characterized by large companies. The risks associated with this technology transfer into main stream industry however is still high due to a lack of fundamental understanding over the mechanics of material transport and the influence that tool design and process parameters have on ultimate joint properties. FSW encompasses complex phenomena related with plastic flow deformation resulting from the stirring of the workpieces materials. The development of a process model would significantly contribute towards a better understanding of joint formation and resultant mechanical properties. iSTIR is a thermal analytical model for 2D and 3D cases when FSW similar and dissimilar materials. The model allows simulation of asymmetric heat field developed below the tool shoulder due to the composition of the rotation and linear speeds, and the hot-to-cold welding conditions, considered in the establishment of the thermal field generated resulting from all the energy sources, i.e., viscous and interfacial friction dissipation. The iSTIR application field is reviewed and the advantages and limitations of the model are discussed. The analytical formulation is described and an application sample based on a friction stir weld produced under cold conditions for butt-welded AA6056-T4, in 3.9 mm of thickness is evaluated.

Joint characteristics and dissimilar materials joining of pure-Al/5083 by friction stir welding

Friction stir welding (FSW)1,2, developed in 1991 by The Welding Institute, UK is a joining process which overthrew welding concepts which existed at the time; its application has been progressed not only for soft alloys including aluminium, but also, in recent years, for steel.3 Sato and others carried out friction stir welding on 1080-O and 5083-O materials and investigated variations in the hardness.4 Ten years or so have passed since the development of friction stir welding, the process has been globally investigated and widely employed in various sectors such as vehicles, ships and the aerospace industry. Furthermore, investigations have also been carried out into the manufacture of dissimilar metal joints. For example, Enomoto studied 2024/AC4C cast alloy and reportedly obtained satisfactory joints.5 Li and others have investigated 2024/6061 and reported that both alloys are distributed at the weld zone in a stratified and complex manner.6