A review on Friction Stir Welding of various metals and its variables

Venu, Borigorla; BhavyaSwathi, I.; Raju, L. Suvarna; Santhanam, Gopal

doi:10.1016/j.matpr.2019.06.304

Cited by 17 publications

(14 citation statements)

References 11 publications

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“…In 1991, friction stir welding (FSW) was initially introduced by TWI in the United Kingdom as a newly developed solid-state welding process, particularly for joining aluminum alloys with specific requirements that should be fulfilled [1,2]. Then friction stir spot welding (FSSW) was developed as one of its variant for local joining of similar and dissimilar sheets [3][4][5][6][7][8][9] as a promising technique with similarities to the basic concepts of linear FSW with a specific requirement where no lateral movement of the tool is required [10].…”

Section: Introductionmentioning

confidence: 99%

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

et al. 2022

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In the current study, a 2 mm thick low-carbon steel sheet (A283M—Grade C) was joined with a brass sheet (CuZn40) of 1 mm thickness using friction stir spot welding (FSSW). Different welding parameters including rotational speeds of 1000, 1250, and 1500 rpm, and dwell times of 5, 10, 20, and 30 s were applied to explore the effective range of parameters to have FSSW joints with high load-carrying capacity. The joint quality of the friction stir spot-welded (FSSWed) dissimilar materials was evaluated via visual examination, tensile lap shear test, hardness test, and macro- and microstructural investigation using SEM. Moreover, EDS analysis was applied to examine the mixing at the interfaces of the dissimilar materials. Heat input calculation for the FSSW of steel–brass was found to be linearly proportional with the number of revolutions per spot joint, with maximum heat input obtained of 11 kJ at the number of revolutions of 500. The temperature measurement during FSSW showed agreement with the heat input dependence on the number of revolution. However, at the same revolutions of 500, it was found that the higher rotation speed of 1500 rpm resulted in higher temperature of 583 °C compared to 535 °C at rotation speed of 1000 rpm. This implies the significant effect for the rotation speed in the increase of temperature. The macro investigations of the friction stir spot-welded joints transverse sections showed sound joints at the different investigated parameters with significant joint ligament between the steel and brass. FSSW of steel/brass joints with a number of revolutions ranging between 250 to 500 revolutions per spot at appropriate tool speed range (1000–1500 rpm) produces joints with high load-carrying capacity from 4 kN to 7.5 kN. The hardness showed an increase in the carbon steel (lower sheet) with maximum of 248 HV and an increase of brass hardness at mixed interface between brass and steel with significant reduction in the stir zone hardness. Microstructural investigation of the joint zone showed mechanical mixing between steel and brass with the steel extruded from the lower sheet into the upper brass sheet.

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Section: Introductionmentioning

confidence: 99%

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

et al. 2022

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“…Friction welding is a technology that allows two or more identical or dissimilar materials with different melting points to be welded using the heat generated by friction, and also the mechanical mixing of the materials at the joint surface. Friction welding makes it possible to obtain strong welded joints of various alloys containing elements such as titanium, aluminum, magnesium, etc., as well as to obtain welded joints of steels [1][2][3][4].…”

Section: Introductionmentioning

confidence: 99%

“…In modern engineering practice, two modifications of friction welding technology are used Linear Friction Welding (LFW) and Friction stir welding (FSW) [1][2][3][4][5][6][7][8][9][10][11].…”

Section: Introductionmentioning

confidence: 99%

“…FSW is one method of solid-state joining titanium and its alloys that can prevent the mechanical properties of titanium welded joints from deteriorating by other welding processes [1,2,[12][13][14].…”

Section: Introductionmentioning

confidence: 99%

“…The results of experimental studies of friction welding processes have become the basis for validating the methods for modeling physical processes that underlie these technologies [1][2][3][4][5]. Various types of numerical methods were used for numerical simulation of LFW and FSW processes [15][16][17][18][19][20][21][22][23][24].…”

Section: Introductionmentioning

confidence: 99%

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Modeling of Titanium Alloys Plastic Flow in Linear Friction Welding

et al. 2021

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The article presents the results of the analysis of the plastic flow of titanium alloys in the process of the Linear Friction Welding (LFW). LFW is a high-tech process for joining critical structural elements of aerospace engineering from light and high-temperature alloys. Experimental studies of LFW modes of such alloys are expensive and technically difficult. Numerical simulation was carried out for understanding the physics of the LFW process and the formation laws of a strong welded joint of titanium alloys. Simulation by the SPH method was performed using the LS DYNA software package (ANSYS WB 15.2) and the developed module for the constitutive equation. The new coupled thermomechanical 3D model of LFW process for joining structural elements from alpha and alpha + beta titanium alloys was proposed. It was shown that the formation of a welded joint occurs in a complex and unsteady stress-strain state. In the near-surface layers of the bodies being welded, titanium alloys can be deformed in the mode of severe plastic deformation. A deviation of the symmetry plane of the plastic deformation zone from the initial position of the contact plane of the bodies being welded occurs during a process of LFW. Extrusion of material from the welded joint zone in the transverse direction with respect to the movement of bodies is caused by a pressure gradient and a decrease in the alloy flow stress due to heating. The hcp-bcc phase transition of titanium alloys upon heating in the LFW process necessitates an increase in the cyclic loading time to obtain a welded joint.

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Experimental and optimization studies of ultrasonic-assisted friction stir weldments of AA2014-T651 using graph theory

Lam

Venu

2022

Int J Adv Manuf Technol

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Joining of Al-Cu based alloys such as AA2014-T651 is very difficult by fusion welding techniques due to liquefaction and solidification cracks. Therefore, solid state welding namely Friction Stir Welding (FSW) is most suitable to join these alloys. The main objective of this work is to identify the most influenced process parameters such as rotation speed of the tool, and tool traverse speed and their levels for fabricating the weldments by FSW process with using ultrasonic vibrations (UAFSW). A set of experiments were carried out using the plain cylindrical and taper threaded cylindrical tool pin profile at different levels of process parameters and experimental results were collected. A graph theory and utility concept was proposed and found an optimal working condition for better weldment properties. The UAFSW process enhanced the AA2014-T651 weldment mechanical characteristics at 1100 rev/min of tool rotation speed, and 40 mm/min of tool traverse speed. The tensile strength, yield strength, percentage of elongation, impact strength and micro hardness were found to be 431.69 MPa, 307.47 MPa, 11.66 %, 8.32 J, and 139 HV respectively at optimal working condition. The weld joint obtained using a taper threaded tool pin profiled with ultrasonic vibration exhibits 95% joint efficiency compared to the weldments made by plain cylindrical taper tool pin profile with ultrasonic vibration. The measured characteristics have been correlated with microstructure and fracture features. The optimized responses were verified by the validation test.

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A review on Friction Stir Welding of various metals and its variables

Cited by 17 publications

References 11 publications

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

Modeling of Titanium Alloys Plastic Flow in Linear Friction Welding

Experimental and optimization studies of ultrasonic-assisted friction stir weldments of AA2014-T651 using graph theory

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