Tool Shoulder Diameter Research Articles

Friction stir welding of AA2024-T3 and SS304 alloys: microstructural analysis, microhardness evaluation, and tensile performance

This study examines the feasibility of friction stir welding (FSW) for dissimilar butt joints formed between 3 mm thick 2024-T3 aluminum alloy and AISI 304 stainless steel. It explores the impact of operational parameters, particularly traverse speeds of 20 and 40 mm min−1, a fixed tool rotation speed of 450 rpm, a tool pin offset of 1.5 mm, and a tool shoulder diameter of 18 mm, on microstructure, microhardness, and tensile strength. A traverse speed of 40 mm min−1 resulted in a lower peak temperature of 257.75 °C, while optimal conditions at a speed of 20 mm min−1 led to peak temperatures of 356.5 °C. This higher temperature facilitated material deformation, improved flow, enhanced mixing, and contributed to grain refinement, with an average grain size of 4.2 μm. Vickers microhardness tests revealed a maximum hardness of 339 Hv at a traverse speed of 40 mm min−1 and 413 Hv at 20 mm min−1. The ultimate tensile strength (UTS) reached 338 MPa, resulting in a joint efficiency (JE %) of 76.81% for the weld performed at optimal conditions.

Effect of tool rotational speeds on material flow and strain rates during friction stir butt welding of AA2219-T87 plates

ABSTRACT Friction stir welding (FSW) process is widely used for joining Al-Cu alloy (AA2219-T87) plates because of its high joint efficiency and low residual stresses in contrast to fusion-based joining techniques. A two-way coupled, 3D thermal-material flow model has been developed in COMSOL software, and the effect of tool rotational speeds on thermal and material flow fields, strain rates, thermal histories, and size of weld zones are being studied. The non-uniform net heat generation during the FSW process is due to the friction between workpiece and tool materials and the deformation energy of plasticized material flow sheared by the rotating tool. An approximate range of temperatures for the weld zones has been proposed and found to be appropriate because the predicted sizes are in good agreement with the experiments. Furthermore, the authors suggested that a quality FSW joint must have the nugget zone smaller and the heat-affected zone larger than the tool shoulder diameter.

Effect of shoulder diameter, tool rotation speed, and arrangement of plates on mechanical and metallurgical properties of dissimilar aluminum 2024-T3 and 7075-T6 friction stir spot welding (FSSW)

In most studies conducted on friction stir spot welding, the focus has been on process parameters and the tool pin geometry. One of the influential parameters in this process, which has received less attention, is the tool shoulder diameter. The spread or concentration of the weld can significantly affect the weld strength and mechanical properties of the joint. In this research, two tools made of H13 hot-work steel with different shoulder diameters of 20 and 25 mm were prepared. Three rotation speeds of 1000, 1600, and 2400 rpm were considered for the welding process. The arrangement of aluminum plates on top of each other was varied in two configurations, parallel and overlapped. Mechanical properties, including tensile shear strength and Vickers micro-hardness, were investigated. The microstructure of different weld zones was also examined using an optical microscope. The results showed that increasing the tool shoulder diameter could enhance the breaking force and tensile shear strength of the joints. Meanwhile, the rotation speed had an optimal value, and with its increase, the breaking force initially increased and then decreased. Placing the 2024-T3 aluminum plate on top of the stack also increased the tensile shear strength of the samples. The fracture mode of the broken specimens was entirely nugget pull-out, which became more pronounced during the use of optimal parameters. Micro-hardness in the region influenced by heat decreased, reaching a minimum in the thermo-mechanically affected zone. In the stir zone, micro-hardness increased significantly due to intense plastic deformation and material compression. The microstructure in the nugget region appeared fine-grained and compact, while the region affected by coarse grain experienced significant heat effects. Increasing the tool shoulder diameter led to an increase in the nugget zone and the length of the bonded region. However, it did not have a significant effect on grain size in the nugget region.

The Influence of Multi-Pass Friction Stir Processing on the Microstructure Evolution and Mechanical Properties of IS2062 Steel

The motive of present work is to explore the variation in the material characteristics of steel upon multi-pass friction stir processing. Steel plates (IS2062) that were 3 mm thick, were subjected to friction stir processing in a multi-pass manner. The selected transverse speed was 150 mm/min, along with a tool rotation of 800 RPM when using a tungsten carbide tool (shoulder diameter—10 mm). Steel plates were processed using the single-pass, double-pass, and triple-pass travel of the rotating tool to observe the impact of multi-pass processing on the properties of steel plates. Multi-pass friction stir processing resulted in a higher micro-hardness of 175 VHN after the second pass, in comparison to the unprocessed metal, which had a micro-hardness of 130 VHN, owing to the collective effect of the plastic flow of the material due to the rotation of the tool and frictional heat, which also leads to grain refinement. The second pass evidenced an average grain size of 22 microns, whereas the unprocessed material had an average grain size of 57 microns. The results of EBSD and SEM characterization showed reasonably improved material properties of the processed work materials.

The influence of tool shoulder size and plate position on the characteristics of friction stir welded different aluminum alloys

ABSTRACT Welding is a main manufacturing method for fabricating various engineering components. Fusion welding techniques encounter solidification associated problems while joining light weight structures. Friction stir welding is a solid state welding technique that is developed to address these shortcomings. As the superior conductive properties of AA6101-T6 and AA1350 aluminum alloys, they are frequently utilized in electrical industries. The goal of this study is to examine how the plate position and tool shoulder diameter (D) affect the qualities of these dissimilar Al-alloys joints. It is discovered that plate positioning is the most influential welding parameter in determining the tensile properties of weldment. Furthermore, the joint fabricated with AA6101-T6 as an advancing side material and a 15 mm tool shoulder diameter produces sufficient weld reaction temperature, better plastic flow and tensile properties. However, the joint fabricated with AA1350 as an advancing side material and 12 mm tool shoulder diameter generates inadequate reaction temperature, poor plasticization, and tensile properties. The formation of precipitates as well as the interface layer at the weld nugget is greatly dominated by the tool shoulder size, which affects the wear properties of weldment.

Impact of the tool shoulder diameter to pin diameter ratio and welding speed on the performance of friction sir-welded AA7075-T651 Al alloy butt joints

This study investigates the friction stir welding (FSW) of aluminum alloy 7075-T651, mainly focusing on managing heat generation during the process. The critical parameters influencing heat amount and the material flow including FSW tool shoulder diameter (SD) and travel speed (TS) were investigated. Two far different SD of 10 mm and 20 mm with constant pin diameter (PD) of 5.70 mm that resulted in PD: SD ratios of 1:1.75 and 1: 3.50, respectively, were employed. Furthermore, three different travel speeds of 25, 50, and 75 mm min−1 at a constant rotation rate of 600 rpm were used in combination with the two PD: SD ratios. The macrographic and radiographic results indicated that the smallest PD: SD ratio has successfully achieved sound friction stir welded (FSWed) joints for the same travel speeds. Results also indicated that a significant amount of material deformed under a high PD: SD ratioat a high TS of 75 mm min−1, while flash increased with reducing PD: SD ratio.Mechanical properties were compared, revealing that hardness in the nugget zone (NZ) decreased with a lower TS of 25 mm min−1. A small PD: SD ratioallowed for more symmetrical heat distribution, supported by the hardness map. The ultimate tensile strength decreased with increasing TS, and the highest ultimate strength, reaching 319 MPa, was observed with a 1:1.75 ratio and TS of 25 mm min−1. X-ray diffraction analysis (XRD) found an increase in peaks with increasing shoulder diameter and the number of peaks increased with decreasing travel speeds.

Double side friction stir Z shape butt lap welding of dissimilar titanium aluminum alloys

Achieving excellent mechanical performance of medium-thick Ti/Al dissimilar joints is important in many industrial applications. However, due to the inherent heat generation mode associated with conventional friction stir welding (FSW), it is impossible to achieve sound medium-thick Ti/Al dissimilar joints. Although double side friction stir welding (DS-FSW) has been reported to solve the problems of conventional FSW. The inherent problems of forming hook structure and interface cracking in the center of the DS-FSW joints significantly weaken the joint performance. Therefore, an innovative double-side friction stir Z shape butt-lap welding (DS-FSZW) process was proposed to eliminate the inherent problems of conventional DS-FSW. The research objective of this work was to reveal the physical mechanisms of the novel DS-FSZW by the combination of numerical simulation and experimental characterization for optimizing the welding parameters. The influence of tool shoulder diameter on the heat generation, heat transfer, plastic material flow, microstructure evolution and mechanical properties of medium-thick dissimilar Ti/Al DS-FSZW joint has been systematically studied. The results indicate that the innovative DS-FSZW process lowers the axial force compared to the conventional DS-FSW, and the centerlines of the first and the second sides welds are staggered. Those are beneficial to inhibiting the cracking of the first-side weld at the interface. In addition, the DS-FSZW method eliminates the hook structures and cracks at the center of the conventional DS-FSW joint and also adds a lap joining interface, which significantly enhances the tensile strength of the joint from 150.7 MPa to 262.5 MPa, which is increased by 74%. Optimization of the shoulder diameter of DS-FSZW from 18 mm to 12 mm reduces the welding heat input and significantly thins the thickness of the IMCs layers at the Ti/Al interface. This helps to suppress the cracking at the Ti/Al lap interface and refine the grains. As a result, thus the tensile strength of the DS-FSZW joint increases from 262.5 MPa to 312.5 MPa, which is increased by 19%. The medium-thick Ti/Al dissimilar DS-FSZW joint at the tool shoulder diameter of 12 mm fracture at the SZ. It proves that the novel DS-FSZW is a suitable welding method for joining medium-thick dissimilar Ti to Al alloys.

Microstructure and Mechanical Properties of Refill Friction Stir Spot-Welded Joints of 2A12Al and 7B04Al: Effects of Tool Size and Welding Parameters.

To solve problems in dissimilarly light metal joints, refilled friction stir spot welding (RFSSW) is proposed instead of resistance spot welding. However, rotation speed, dwell time, plunge depth, and the diameter of welding tools all have a great influence on joints, which brings great challenges in optimizing welding parameters to ensure their mechanical properties. In this study, the 1.5 mm thick 2A12Al and 2 mm thick 7B04Al lap joints were prepared by Taguchi orthogonal experiment design and RFSSW. The welding tool (shoulder) diameters were 5 mm and 7 mm, respectively. The macro/microstructures of the cross-section, the geometrical characteristics of the effective welding depth (EWD), the stir zone area (SZA), and the stir zone volume (SZV) were characterized. The shear strength and failure mode of the lap joint were analyzed using an optical microscope. It was found that EWD, SZA, and SZV had a good correlation with tensile-shear force. The optimal welding parameters of 5 mm diameter joints are 1500 rpm of rotation speed, 2.5 mm of plunge depth, and 0 s of dwell time, which for 7 mm joints are 1200 rpm, 1.5 mm, and 2 s. The tensile-shear force of 5 mm and 7 mm joints welded with these optical parameters was 4965 N and 5920 N, respectively. At the same time, the 5 mm diameter joints had better strength and strength stability.

Ispitivanje i optimizacija površine zavara i mehaničkih performansi termoplastičnih delova proizvedenih aditivnom proizvodnjom i zavarenih zavarivanjem trenjem

This study presents an experimental investigation into the weldability of ABS M30 (acrylonitrile butadiene styrene) plates produced by Additive Manufacturing (AM) using Friction Stir Welding (FSW). The effects of FSW process parameters on the yield stress and their optimal levels were determined using the Taguchi method. The optimal welding parameters were found to be a 16 mm tool shoulder diameter, 800 rpm tool rotation speed, and 10 mm/min traverse speed. The weld area of each sample welded using FSW was examined at a macroscopic level. The direction of tool rotation significantly affects the quality and strength of the FSW. When the FSW was performed with a clockwise rotation of the welding tool, a perfect weld could not be achieved. The tunnel effect resulted in gaps in the weld area of the samples at high rotation speeds. Differences were observed in the density between the weld area of the samples and the main parts.

Optimization of friction stir processing parameters for improving structural and mechanical properties in in situ AA5083-H111/Al–Fe composites

The primary focus of this study is the application of friction stir processing to produce surface composites of in situ AA5083-H111/Al–Fe. These composites were fabricated by mixing mechanically alloyed Fe–40 wt% Al powder for 40 h. The AA5083 substrate underwent a two-pass friction stir processing with changes in the tool’s movement direction during fabrication. This experiment used Taguchi’s L9 orthogonal array design to gather and analyse data efficiently. Following each friction stir processing pass, the fabricated aluminium metal matrix composite microstructure, hardness and ultimate tensile strength were conducted. In this study, the maximum tensile strength of 225.8 MPa after the first pass and 253.6 MPa after the second pass. Additionally, microhardness measurements indicated values of 123.3 and 128.3 Hv after the first and second passes, respectively. These impressive mechanical properties were achieved by optimizing specific process parameters, including a tool shoulder diameter of 21 mm, a tool rotational speed of 900 rpm, a tool traverse speed of 63 mm/min and a tilt angle of 1.5°. Furthermore, examining the fracture surface of the friction stir processed sample revealed ductile failure behaviour, suggesting that the material experienced deformation and stretching before fracture. This observation aligns with the inherent ductile nature of the AA5083/Al–Fe composite.

An experimental method for choosing the tool pin profile and shoulder size to join dissimilar aluminum alloys AA7075-T651 and AA6061-T6 joints

Many military and light weight aircraft designs call for joints between two different grades of aluminium alloy. This present study looked at the effect of tool shoulder diameter and tool pin profile on the tensile strength properties of dissimilar aluminium alloy AA6061-T6 and AA7075-T651 joints created by friction stir welding. The joints were fabricated utilizing three distinct tool shoulder diameters 15 mm, 20 mm and 25 mm along with two distinct tool pin profiles namely taper and square. The microstructure and microhardness of weld stir zone (WSZ) were examined and linked with the strength parameters of the joints. Adequate frictional heat generation from 20 mm shoulder diameter and pulsating stirring action of square pin revealed the formation of very fine grains in the weld nugget zone (WNZ). Due to enhanced material flow and the production of a defect-free stir zone, the joint created using a tool with a 20 mm shoulder diameter and square pin profile had the maximum hardness of 117 HV and the highest tensile strength of 284 MPa. The ductile mechanism of fracture is revealed by the presence of fine dimples accumulating in the tensile fractured surface of the joint fabricated by 20 mm tool shoulder diameter and square pin.

Numerical assessment of temperature and stresses in friction stir welding of dissimilar Mg-Al-Zn alloys

ABSTRACT Magnesium (Mg) alloys are used more frequently as a replacement for heavier structural materials because of their advantageous specific strength and eco-friendly attributes. Their fusion welding is a difficult process, but the friction stir welding (FSW) offers a potential solution to these issues. In this study, a thermal analysis is carried out to obtain the temperature distribution and residual stresses related to FSW of different Mg-Al-Zn series Mg alloys under different processing conditions. The highest temperature recorded at the centre of the weld was 544.04°C, while the average von Mises stress during welding was 185.07 MPa. These values were achieved with a tool rotational speed of 1000 rpm, welding speed of 40 mm/min, and a tool shoulder diameter of 21 mm. The temperatures obtained through the numerical model were validated by comparing them with experimental data. During the experimental analysis, small cracks were observed at the centre of the welded joint, resulting from the formation of MgO. The welded joint exhibited a maximum tensile strength of 234.86 MPa, which is approximately 90% of the stronger AZ31 Mg alloy.

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.

An experimental study of the friction stir welding of Al 5083 H321 plates by using different process parameters

ABSTRACT In this study, 4 mm thick Al 5083 H321 plates were joined with Friction Stir Welding (FSW) method using different process parameters. In order to reveal the effects of different process parameters (Tool Shoulder Diameter, RPM, Direction of Rotation, Feed Rate), a total of 36 tests were carried out from 4 test parameters in a full factorial test setup. Tensile tests were performed with the test specimens cut from the welded plates, and their strength and mechanical properties were examined. In addition, the welding quality was subjected to an X-ray test, and quality control was passed. The ductility of the weld joints was demonstrated by the three-point bending test performed separately from the butt and root parts. Welded joints maintain their ductility without welding defects on bending tests by bending up to a 150° bending angle. On the other hand, it has been determined that the Al5083-H321 plate was pre-hardened by cold deformation; the heat generated during FSW causes recrystallization during welding, which resulted in a joint efficiency of 56%. The microstructural investigation and hardness tests proved the recrystallized regions.

Development of Aluminium Metal Foams via Friction Stir Processing by Utilizing MgCO3 Precursor

Aluminium foams possess multi-functional properties and a low specific weight, making them one of the most suitable choices in the application domain of the automobile and aviation sectors, vibrating machining, and structural parts. Compared to traditional fabrication routes, friction stir processing (FSP) is gaining acceptance as it is a cost-effective, highly efficient, and innocuous process to fabricate the foam precursors from the bulk substrate. In the current study, FSP was utilized to develop a precursor with MgCO3 powder acting as the blowing agent. The FSP experiments were performed as per Taguchi’s L8 orthogonal array. The precursor was heat treated in an electric furnace at a holding temperature of 650 °C for 10 min. After the post-heat treatments, this precursor resulted in a porous structure due to the evolution of CO2 gas from the composite. The simultaneous effect of tool rotation speed, traverse speed, and shoulder diameter was investigated on the pore size and porosity of the foam produced. The composite parameter “unit stirring” is found to be closely related to the processed zone (PZ) and volume processing rate of the processed zone, pore size, and the degree of porosity. The highest porosity of 16.67% was obtained with an average pore size of 10.5 µm. The largest pore size, 17.8 µm, was observed to be associated with a porosity of 14.40%. The analysis of the Kiviat plot revealed that the values of the PZ area and volume processing rate possess a polar symmetry with unit stirring. The pore size and pore density were both found to be symmetrically distributed about the unit stirring.

Multi-objective optimization of friction stir spot welded Al 6061-T6 incorporated with silicon carbide using hybrid Grey Rational Analysis-Taguchi technique

The present research investigation focused on multi-objective optimization of friction stir spot welding process for attaining an optimal combination of process parameters in order to obtain stronger welds. Experiments were designed using Taguchi L9 orthogonal array on process parameters such as, tool pin profile, tool shoulder diameter and shoulder plunge depth. The output quality characteristics measured were tensile-shear strength and micro-hardness. Multi-objective optimization was done using Hybrid Grey Rational Analysis-Taguchi technique. The significance of parameters was determined using Analysis of variance technique. The optimality of results was verified by confirmatory test.

Corrosion and Tribological Characteristics of FSPed Aluminum Alloy AA5052

Friction stir processing (FSP) is a solid-state and effective process for surface modification of aluminium alloys. In this study the AA5052 alloy, widely used in marine applications, has been subjected to FSP. The FSP trials have been carried out by altering the FSP process parameters (tool rotation speed, tool traverse speed, and shoulder diameter). The friction stir processed specimens have been characterised / tested for microstructure, microhardness, sliding wear, immersion corrosion, and electrochemical corrosion. The hybrid polynomial – radial basis function-based models have been developed to determine the relationship between the process parameters and the evaluated properties. Furthermore, the optimum parameters for obtaining high hardness, wear resistance, and corrosion resistance have been determined. Microstructure evaluation in the friction stir processed specimens has shown refinement and uniform dispersion of β particles throughout the α-Al matrix. The results show that the improvement in properties is a result of the homogeneous dispersion of secondary β phase particles in the matrix. Friction stir processing of AA5052 alloy has improved hardness by ~14.5%, wear resistance by ~83%, and corrosion resistance ~87%. The optimum process window for friction stir processing of AA5052 alloy is tool rotation speed between 500 rpm and 900 rpm, tool traverse speed between 10 mm/min and 30 mm/min, and tool shoulder diameter of 18 mm and 21 mm.

Supervised and Unsupervised Machine Learning Algorithms for Forecasting the Fracture Location in Dissimilar Friction-Stir-Welded Joints

Artificial-intelligence-based algorithms are used in manufacturing to automate difficult activities and discover workflow or process patterns that had never been noticed before. Recent studies deal with the forecasting of the fracture location in dissimilar friction-stir-welded AA5754–C11000 alloys. Four types of supervised machine-learning-based classification algorithms i.e., decision tree, logistic classification, random forest, and AdaBoost were implemented. Additionally, in the present work, for the first time, a neurobiological-based unsupervised machine learning algorithm, i.e., self-organizing map (SOM) neural network, is implemented for determining the fracture location in dissimilar friction-stir-welded AA5754–C11000 alloys. Tool shoulder diameter (mm), tool rotational speed (RPM), and tool traverse speed (mm/min) are input parameters, while the fracture location, i.e., whether the specimen’s fracture is in the thermo-mechanically affected zone (TMAZ) of copper, or if it fractures in the TMAZ of aluminium. The results show that out of all implemented algorithms, the SOM algorithm is able to predict the fracture location with the highest accuracy of 96.92%.

Heat Index Based Optimisation of Primary Process Parameters in Friction Stir Welding on Light Weight Materials

In friction stir welding, tool shoulder diameter and its rotational speed are the major influencing parameters than others. A simple novel correlation is proposed to select the optimum range of tool shoulder diameter with respect to the chosen rotational speed and vice versa. The conditions to apply derived correlation were defined through process heat index number as the joint efficiency in the friction stir welding depends on the effective heat supply to the volume of material deformed in the stir zone. Weld speed is the key parameter through which generated heat can be regulated towards optimum heat supply to attain defect-free weld in the stir zone. Effective heat input also has obvious effect on grain growth and corresponding property eradication in the heat affected zone. The experimental study was carried out on AA2024-T3 plates to understand the effect of process heat index on the prescribed optimum range of tool shoulder and rotational speed defined in the correlation. Eventually, a novel relationship was attained between the first order process influencing parameters to deliver maximum joint efficiency.

Influence of process parameters on mechanical and microstructural properties of friction stir welded AA5052

ABSTRACT The current research work explores the process parameters namely tool shoulder diameter, tool pin design, tool rotational and welding speed and its influence on mechanical and metallurgical qualities of aerospace-grade 5052 aluminium alloy. The research observation shows that the intermediate extent of process parameters indicates enhanced mechanical qualities compared to the lower and higher regimes. When considering different individual tool pin profiles, square pin (SQ) tool geometry yields the highest ultimate tensile strength in comparison with threaded cylindrical, tapered cylindrical and straight cylindrical tools. A set of the best combination of process parameters with 24 mm shoulder diameter SQ pin tool geometry at tool rotational speed of 1000 rev/min along with the welding speed of 40 mm/min produced defect-free joint with excellent mechanical characteristics with an ultimate tensile strength of 92% compared to the base metal. Microstructural analysis of the best welded specimen (considering the above parameters) revealed 81% finer grain compared to base material that leads to enhanced mechanical attributes. Fractography detects ductile fracture of the welded specimen. The effects of individual process parameters on grain size, micro-hardness, flexural strength, bending angle and percentage of elongation of each sample are represented in this research article.