Effect Of Pin Profile Research Articles

The Effects of Pin Profile on HDPE Thermomechanical Phenomena during FSW.

Friction stir welding (FSW) of polymeric materials has recently attracted significant attention. Herein, we present the effect of the tool pin profile on the FSW of high-density polyethylene (HDPE) joints through joint experimental analysis and thermomechanical simulations. For analysis of pin profile effects on the thermomechanical properties of HDPE joints, frustum (FPT), cubic (CPT), and triangular (TPT) pin shapes were selected in this study. This research investigated the heat generation of the parts of the different tools as well as heat flux (internal and surface). The results revealed that the heat generation in pins with more edges (cubic (96 °C) and triangular (94 °C)) was greater than in pins with a smooth shape (frustum (91 °C)). The higher heat generation caused the heat flux on the surface of the HDPE from the cubic pin profile to be greater than for other joints. Due to the properties of HDPE, higher heat generation caused higher material velocity in the stirring zone, where the velocity of the materials in TPT, CPT, and FPT pins were 0.41 m/s, 0.42 m/s, and 0.4 m/s, respectively. The simulation results show sharp-edged pins, such as triangular and cubic, lead to over-stirring action and internal voids formed along the joint line. Furthermore, the simulation results indicated that the size of the stirred zones (SZs) of the FPT, TPT, and CPT samples were 17 mm2, 19 mm2, and 21 mm2, respectively, which is around three times the corresponding values in the HAZ.

Effect of Tool Pin Profile on Material Flow in Double Shoulder Friction Stir Welding of AZ91 Magnesium Alloy

The double shoulder friction stir welding of AZ91 magnesium alloy is numerically modeled based on the Eulerian method using the ABAQUS software. The material flow in the integrated form is demonstrated properly and the shoulder driven and pin driven zones are predicted very well. The effects of pin profile on the temperature and strain distributions, material flow, material coalescence, grain size and tensile properties are investigated. Results show that, the material flow patterns in the shoulder driven and pin driven zones are different. While the material moves from the advancing side toward the retreating side in the pin driven zone, it is reverse in the shoulder driven zone. Although the trigonal pin comprises the longest sweeping lever and can move larger boxes of material, the most uniform material movement with the best material coalescence is produced by hexagonal pin tool. The inward conical pin tool produces the weakest material flow pattern leading to generation of tunnel cavity in the welding zone. However, the outward conical pin tool generates a subsidiary material flow and improves the material coalescence and consequently results in a higher strain, smaller grain size and superior mechanical properties compared to those of the inward conical pin tool.

Vpliv oblike trna na mehanske lastnosti vrtilno-torno varjenega AA5383 in AA7075

Vpliv oblike trna na mehanske lastnosti vrtilno-torno varjenega AA5383 in AA7075

Effect of Pin Profile on Mechanical Properties of 6061 Al Alloy Welded Joints Prepared by Friction Stir Welding

Effect of Pin Profile on Mechanical Properties of 6061 Al Alloy Welded Joints Prepared by Friction Stir Welding

Determination of the traverse force in friction stir welding with different tool pin profiles

ABSTRACTA methodology is developed for the estimation of the traverse force in friction stir welding (FSW) for various pin profiles by combining the results of numerical modelling and experimental monitoring. The effect of pin profiles on the traverse force is evaluated by introducing a modified ratio of the plastic deformation zone, which is obtained by numerical modelling. The formula is validated with the experimental data in the literature and indicates that the traverse force decreases exponentially with increasing ratio of the plastic deformation zone. The proposed methodology provides a concise approach for the estimation of the traverse force for various pin profiles in FSW and can be adopted for the design and assessment of the FSW tool.

Effect of pin profile on microstructure and mechanical properties of friction stir spot welded Al-Cu dissimilar metals

Pin profile exerts an important influence on heat production and material flow in friction stir spot welding, thereby affecting microstructure evolution and mechanical properties of the welded joint. Thus, the relationship between pin profiles and resultant microstructure of the joint as well as the mechanical properties needs to be revealed. In the present study, three types of tools with different pin profiles were designed to join aluminum and copper by friction stir spot welding. Optical microscope, scanning electron microscope and X-ray diffraction were conducted to characterize macrostructure and microstructure in welded joints. Tensile shear and microhardness test were used to evaluate the mechanical properties of joints. Well-formed joints were obtained using different tools under proper process parameters. Higher heat generation and temperature were produced during welding process by using threaded pin tool. Several intermetallic compounds, including CuAl2, CuAl and Al4Cu9, were formed at the interface between aluminum and copper. No distinct difference was observed for microhardness distribution in the joints using various pin profiles. The tensile shear failure load was largely dependent on the pin profiles with the maximum value got in the joint obtained by using threaded pin. The tensile shear fracture of joint by using featureless pin presented the brittle fracture characteristics, and other welded joints showed the mixed fracture characteristics.

Tensile Shear Properties of the Friction Stir Lap Welded Joints and Material Flow Mechanism Under Pulsatile Revolutions

The aim of the present article is to offer insight into the effects of pin profiles on interface defects, tensile shear properties, microstructures, and the material flow of friction stir lap welded joints. The results indicate that, compared to the lap joints welded by the single threaded plane pin, the three-plane threaded pin, and the triangle threaded pin, the lap joint obtained by the conventional conical threaded pin is characterized by the minimum interface defect. The alternate threads and planes on the pin provide periodical stress, leading to pulsatile material flow patterns. Under the effect of pulsatile revolutions, an asymmetrical flow field is formed around the tool. The threads on the pin force the surrounding material to flow downward. The planes cannot only promote the horizontal flow of the material by scraping, but also provide extra space for the material vertical flow. A heuristic model is established to describe the material flow mechanism during friction stir lap welding under the effect of pulsatile revolutions.

Investigation on the Effect of Tool Pin Profiles on Mechanical and Microstructural Properties of Friction Stir Butt and Scarf Welded Aluminium Alloy 6063

In the present study, friction stir welding (FSW) of butt and scarf joints of Al 6063-T6 were investigated. Five different tool pin profiles (cylindrical, tapered cylindrical, square, triangular, and hexagonal) were applied for performing welding. Scarf joint, being a new joint configuration, was used and effect of pin profiles was investigated on this type of joint configuration. The effect of pin profiles on microstructure, micro-hardness, impact and tensile properties of friction stir welded Al 6063-T6 was investigated. Scanning electron and optical microscopy were employed to characterize the different zones of welded joints. A thorough discussion on correlation between mechanical properties and microstructure has been made. In addition, the formation of various defects during the FSW was discussed with the help of fractography of the fractured surfaces.

Effect of pin profile and rotational speed on microstructure and tensile strength of dissimilar AA8011, AA01-T6 friction stir welded aluminum alloys

Aluminum alloys are mainly focused on shipbuilding and aerospace industries due to its unique characteristics and it has low cost, high reliability and severe service conditions. The tool geometry and parameters play a vital in the performance of the similar and dissimilar friction stir welding process to improve the microstructure and mechanical properties of the joints. Due to the complex behavior of material flow on dissimilar different grades of aluminium alloys welding, the study is desired to examine the material flow behaviour and the mechanical properties. The aim of this research work is to investigate the influence of the pin profiles and rotational speed on microstructure and tensile strength of dissimilar friction stir welding of AA8011 and AA6061-T6 aluminum alloys. The FSW process parameters such as rotational speed, Plunge depth, welding speed and three different pin profiles (square, pentagon and hexagon) are selected for this investigation. The microstructural analysis is applied on the dissimilar FS welded joints using scanning electron microscope and optical microscope. The defect free welds are found for the optimum settings of rotational speed 1500 rpm, plunge depth of 2.5 mm with a welding speed 40 mm/min for hexagonal tool pin profile and also the hexagon pin profile gives the superior properties of the welded joints related to other pin profiles.

Effect of Pin Profile and Process Parameters on the Properties of Friction Stir Welded Al-Mg Alloy

In Friction stir welding (FSW), weld quality is predominantly affected by welding process parameters. The welding parameters such as tool shoulder diameter, tool rotational speed, welding speed and axial force play a major role in deciding the joint strength. In present work, FSW have been carried out on the 6 mm thick Aluminum alloy plate. Friction stir welding parameters such as the tool rotational speed and the welding speed were investigated together with the different pin profiles; the results show that the straight square pin profile leads to better mechanical properties of welded specimens. The pin profiles used in this work were the straight square (SS), straight cylindrical (SC), and taper cylindrical (TC). It was found that the straight square pin profile improves the material flow behavior and the uniform distribution of plastic deformation and reduces the formation of macroscopic defects on the welded zone. Also, it was observed that the pin profile exhibits more influence on tensile strength followed by tool rotation speed and traverse speed

Correction to: Microstructure and mechanical properties of joints welded by friction-stir welding in aluminum alloy 7075-T6 plates for aerospace application

This paper focuses on the effect of welding parameters on microstructure and tensile strength of joints welded by friction-stir welding (FSW). The effects of pin profile (threaded conical, non-threaded conical and triangular pin), tool rotational speed (800, 1000, 1250 and 1600 r·min−1) and welding speed (63, 80, 100 and 125 mm·min−1) on the mechanical and microstructural properties of joints welded in 5-mm 7075-T6 were investigated. The results depict that the pin profile has a major role in the shape and grain size of the weld nugget zone (WNZ). In other words, a wider weld nugget and a finer grain size by threaded conical pin are obtained in WNZ. The attained data of tensile tests show that the maximum ultimate tensile strength (UTS) belongs to the threaded conical pin which is attributed to a finer grain size generated in the weld nugget zone. Additionally, it is found that the tensile strength increases with the welding speed increasing, whereas rotational speed has a bilateral effect on the tensile strength. The microhardness tests show that the minimum hardness is obtained in the heat-affected zone (HAZ).

Material stirring during FSW of Al–Cu: Effect of pin profile

ABSTRACTFriction stir welding (FSW) joins the material in solid state, and it gets evolved as a new and effective technique to join dissimilar materials such as aluminum and copper. FSW tool design and configuration critically affect the joint quality. This study has evaluated the effect of different pin profiles used during FSW of AA5754 Al alloy and commercially pure copper in a butt configuration on the microstructure, material movement, and microhardness for the different joints. The joining is performed through the different pin profiles of cylindrical, taper, cylindrical cam, taper cam, and square shape at the rotational and welding speed of 900 rpm and 40 mm/min respectively. Among all joints, the square pin profile provides good joining and microhardness. Square tool pin profile facilitates good amount of mixing at nugget zone, which consequently increases the hardness. The material movement in square tool pin profile joint is also studied on the longitudinal plane to understand the effect of pulsating and stirring action on the material mixing pattern in dissimilar FSW. It is evident that the softer material in the stir zone gets more stirring, and the flow lines are clearly visible for the stirred material.

The effect of reinforcement type on the microstructure, mechanical properties, and wear resistance of A356 matrix composites produced by FSP

Fabrication of particle-reinforced aluminum matrix composites has been pursued with a keen interest recently. However, a comparison of the effect of different reinforcements on the mechanical properties and wear resistance of A356 matrix composites fabricated by FSP is of great interest to be considered. In the present work, the microstructural, mechanical, and wear properties of A356 matrix composites reinforced by SiC, TiC, ZrO2, and B4C particles are investigated. Moreover, the effect of pin profile on distribution of reinforcing particles in the stir zone of the FSPed specimens is investigated. Hardness and wear tests are performed in order to investigate mechanical and wear properties of the composites. The composite reinforced by TiC particles exhibits higher hardness value compared with other reinforcements due to the excellent bonding between TiC and metal matrix as well as higher hardness value of reinforcement itself than other reinforcements. Moreover, wear test results show that the wear resistance of the composite is significantly improved compared with that of the base metal.

The effect of pin profiles on the microstructure and mechanical properties of underwater friction stir welded AA2519-T87 aluminium alloy

AA2519-T87 is a new armour grade aluminium alloy employed in the fabrication of light combat military vehicles. Joining of this material using fusion welding processes, results in the formation of solidification defects like porosity, alloy segregation and hot cracking. In order to overcome the solidification related problems, solid state welding processes such as friction stir welding (FSW) can be used. Though the joining takes place below the melting temperature of the material, the thermal cycle experienced by the thermo-mechanical-affected zone (TMAZ) and heat-affected zone (HAZ) is causing grain coarsening and precipitates dissolution in the age-hardenable aluminium alloys, which deteriorate the joint properties. To get rid of this problem, underwater friction stir welding (UWFSW) process can be employed. The water cooling reduces the heat, and thus, the thermal softening required taking place in TMAZ and HAZ. Therefore, the material flow is entirely different in FSW and UWFSW. In this investigation, a comparative study is made to understand the influence of tool pin profiles, namely straight cylindrical (STC), taper cylindrical (TAC), straight threaded cylindrical (THC) and taper threaded cylindrical (TTC) on stir zone characteristics and the resultant tensile properties of both FSW and UWFSW joints. From this investigation, it is found that the joint made by taper threaded pin profiled tool underwater cooling medium exhibited higher tensile properties of 345 MPa and joint efficiency of 76 %. The enhancement in the strength is attributed to the precipitation hardening, grain boundary strengthening and narrowing of lower hardness distribution region (LHDR).

Effect of tool pin profile on distribution of reinforcement particles during friction stir processing of B4C/aluminum composites

Boron carbide /aluminum composites have been produced on an aluminum–silicon cast alloy using friction stir processing. Effect of pin profile on the distribution of boron carbide in the stir zone of the friction stir processed specimens was investigated experimentally and numerically. The material flow generated by the threaded and circular tool pin profiles, being the main reason for the distribution of particles in the metal matrix, was numerically modeled using a thermomechanically coupled three-dimensional finite element model. Numerical and experimental results show that threaded pin profile produces a more uniform distribution of B4Cp than other pin profiles. Hardness tests were performed in order to investigate mechanical properties of the composites. Wear resistance of the composite was evaluated and obtained results showed that the hardness and wear resistance of the composite significantly improved.

Effect of pin profile and process parameters on microstructure and mechanical properties of friction stir welded Al–Cu joints

In friction stir welding (FSW), pin profile has more influence on material flow especially in welding of dissimilar materials with different yield strengths. In the dissimilar welding of aluminium and copper, the material flow behaviour is complex to understand and thus a study is needed to reveal the mechanism of flow behaviour and the resultant mechanical properties. Three pin profiles, whorl pin profile (WPP), plain taper pin profile (PTP) and taper treaded pin profile (TTP) were chosen. The effects of pin profile on the microstructure, microhardness and tensile properties were studied. Optical microscope, scanning electron microscope, X-ray diffraction and EDS analysis were used to characterize the microstructural features. Among the three pin profiles, PTP profile results in defect-free stir zone and maximum joint properties of yield strength of 101 MPa, tensile strength of 116 MPa and joint efficiency of 68% compared with the other pin profiles. However, the microhardness plots are more or less identical for all the pin profiles but follows fluctuating trend. This is attributed to the heterogeneous distribution of hard Cu particle. The superior joint properties are mainly attributed to the defect-free stir zone formation and dispersion strengthening.

Effect of Pin Profile on Defects of Friction Stir Welded 7075 Aluminum Alloy

In this work, effect of the pin profile on defects of FSWed 7075 alloy was investigated. Three pins with cylindrical, square and triangle geometry were used for welding. Microstructure of the welding zone showed that the tunnel hole produced by triangle pin has smaller dimensions compared to cylindrical pin. On the other hand, results of optical microscope indicated that the size of grains resulted from square pin is smaller than the other kinds of tools. Also, the results showed that when the pin is cylindrical, tunnel, kissing bond, and zigzag line defects are formed. On the other hand, when the pin is triangle, original joint line with severe plastic deformation and crack defects are created.

The Effect of Helical Pin Profiles on the Friction Stir Welding Performance of Aluminium Alloy AA6082

Abstract In this study, one of the solid state welding methods, friction stir welding, was studied with the AA6082 aluminum alloy. Two types of pins with a special geometry were used to investigate the effect of pins profile, tool rotational speed, and welding speed on the mechanical properties of welded joints. The pin profile was associated with weld joint properties such as tensile strength, elongation, bending strength, bending force, hardness distributions and temperature. Results have shown that the friction surface area of the pin has a significant role on the mechanical behaviour of the joint. The results of tensile tests associated with the pin profile indicate that the helical two-flute pin has a high tensile strength and elongation compared to the helical four-flute pin. Discrepancies in the tensile strength of the welded samples of the two pin profiles have been found between 37–55 % at the same welding conditions. Despite the relatively poor static properties, the helical four-flute pin has better bending properties. Higher bending strength and force (260.634 MPa and 347.513 daN) were obtained at test conditions of 2000 rpm and 100 mm/min. Bending without any defect on the joint was achieved at 2000 rpm and 200 mm/min. The effect of welding parameters on the hardness profile was not clear, and it has been observed that, in comparison, the helical two-flute pin did not create a remarkable difference with regard to hardness.

Effect of Pin Profile on Friction Stir Welded Aluminum Matrix Composites

To clarify the role of pin profile geometry on some properties of friction stir welded of the considered aluminum matrix composites (Al-4 wt% Mg, reinforced with 1 wt% SiC and 1 wt% graphite particles) plates of 8 mm thickness were fabricated by compocasting method then annealed at 400°C for 2 h. Tools with different pin profiles (square, hexagonal, and octagonal) were manufactured to be used for friction stir welding (FSW) of aluminum matrix composites plates at four different levels of welding (transverse) and rotational speeds. The effects of these pin profiles on microstructure and some mechanical properties of the friction stir welded joints were studied. The results show that the plates welded by square head pin have better properties compared to the other pin profiles. This pin seems to cause better grain refinement and redistribution of SiC and graphite particles in the welded nugget zone (NZ) than the other two types. This has led to better improvements in the considered mechanical properties. Also, these properties were improved by increasing welding speed, while increasing the rotational speed has a diverse effect on them.

Effect of Tool pin Profile and Axial Force on Tensile Behavior in Friction Stir Welding of Dissimilar Aluminum Alloys

Aluminium alloys generally has low weldability by traditional fusion welding process. The development of the Friction Stir Welding (FSW) has provided an alternative improved way of producing aluminium joints, in a faster and reliable manner. FSW process has several advantages, in particular the possibility to weld dissimilar aluminium alloys. This study focuses on the behavior of tensile strength of dissimilar joints of AA6351-T6 alloy to AA5083-H111 alloy produced by friction stir welding was analysed. Five different tool pin profile such as Straight Square (SS), Tapered Square (TS), Straight Hexagon (SH), Straight Octagon (SO) and Tapered Octagon (TO) with three different axial force (1tonne, 1.5tonne, 2 tonne) have been used to weld the joints. The effect of pin profiles and axial force on tensile properties and material flow behaviour of the joint was analyzed and it was found that the straight square pin profile with 1.5 tonne produced better tensile strength then other tool pin profile and axial force.