A detailed process design for conventional friction stir welding of aluminum alloys and an overview of related knowledge

El-Moayed, Mohamed H.; Shash, Ahmed Y.; Rabou, Mahmoud Abd; El‐Sherbiny, M.

doi:10.1002/eng2.12270

Cited by 4 publications

(2 citation statements)

References 56 publications

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“…The tool was heat-treated to increase its hardness and strength. The tool dimensions were calculated in terms of specimen thickness, as suggested by El-Moayed et al 9 and Zhang et al 10 The tool shoulder diameter was 18 mm, whereas its pin diameter was 6 mm. A pin clearance of 0.3 mm was left at the welding root to avoid the tool rubbing against the backing plate.…”

Section: Methodsmentioning

confidence: 99%

A coupled experimental and numerical analysis of AA6063 friction stir welding

Shash

El-Moayed

Rabou

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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In the present research, a coupled Eulerian–Lagrangian model is developed to predict the forces and defects produced from AA6063 friction stir welding process. Furthermore, the obtained results from the developed model were validated experimentally by performing the welding process at different rotational and welding speed values. The results revealed an appearance of tunnel defect at all welded joints with surface flash. The current model successfully predicted both defects’ evolution. Additionally, it also generated force measurements comparable to those obtained experimentally. In addition, the developed Coupled Eulerian–Lagrangian model successfully predicted the generated force and the defects during friction stir welding process with maximum error of 14% and 18%. However, it failed in predicting the tunnel positions. In terms of the tensile strength, the largest tensile strength value was at 1250rpm and 50 mm/min, whereas the lowest one was at 1000 rpm and 25 mm/min. Moreover, the fracture locations were at the advancing side of all the welded joints.

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Section: Methodsmentioning

confidence: 99%

A coupled experimental and numerical analysis of AA6063 friction stir welding

Shash

El-Moayed

Rabou

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

Self Cite

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“…For commercial applications of this alloy, it is essential to know the specific FSW process. Many advantages are associated with the FSW process, but there is no guarantee of producing defect-free welds and the challenges to produce quality joints are enormous, being fundamental the knowledge of the parameters involved 9,16,17 and according to Albannai 2 the improper application of any parameters will generate visible or hidden defects.…”

Section: Introductionmentioning

confidence: 99%

Effect of Friction Stir Welding on Microstructure and Mechanical Properties of uns C19400 Alloy Plates

Martins,

Varasquim,

Cruz Junior

et al. 2023

Mat. Res.

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The welding of metallic materials by the Friction Stir Welding (FSW) method is a very attractive process for preserving their characteristics, especially for copper and its alloys that require high heat input and present many distortions by traditional methods. However, it is a great challenge to produce welds free of defects and maintain or improve their mechanical properties. In the current literature data on FSW parameters for copper and its alloys are scarce. In this study, tests were performed with a combination of four tool rotations (750, 850, 950, 1050 rev.min -1 ) and two welding speeds (20 and 60 mm.min -1 ), maintaining the tool inclination angle in 3° and waiting time of 5 seconds. The objective of this work is to analyze the microstructure and mechanical performance of lap joints of the UNS C19400 alloy joined by FSW. The process temperature was monitored to trace the heating profile of the process, in addition to microhardness and shear strength tests, in addition to optical microscopy for analysis. The joints welded by the parameters Ω 950 rev.mm -1 𝛖 20mm.min -1 obtained a mechanical performance of 73% compared to the characteristics of the base metal and despite the appearance of volumetric defects at the microstructural level, the metallurgical transformations of recovery and recrystallization of the grains observed in the microstructure played a key role in the result.

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Basic Tool Design Guidelines for Friction Stir Welding of Aluminum Alloys

Hoyos

Serna

2021

Metals

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Friction Stir Welding (FSW) is a solid-state welding process that has multiple advantages over fusion welding. The design of tools for the FSW process is a factor of interest, considering its fundamental role in obtaining sound welds. There are some commercially available alternatives for FSW tools, but unlike conventional fusion welding consumables, their use is limited to very specific conditions. In this work, equations to act as guidelines in the design process for FSW tools are proposed for the 2XXX, 5XXX, 6XXX, and 7XXX aluminum series and any given thickness to determine: pin length, pin diameter, and shoulder diameter. Over 80 sources and 200 tests were used and detailed to generate these expressions. As a verification approach, successful welds by authors outside the scope of the original review and the tools used were evaluated under this development and used as case studies or verification for the guidelines. Variations between designs made using the guidelines and those reported by other researchers remain under 21%.

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A detailed process design for conventional friction stir welding of aluminum alloys and an overview of related knowledge

Cited by 4 publications

References 56 publications

A coupled experimental and numerical analysis of AA6063 friction stir welding

A coupled experimental and numerical analysis of AA6063 friction stir welding

Effect of Friction Stir Welding on Microstructure and Mechanical Properties of uns C19400 Alloy Plates

Basic Tool Design Guidelines for Friction Stir Welding of Aluminum Alloys

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