Bobbin Tool Friction Stir Welding of Aluminum Using Different Tool Pin Geometries: Mathematical Models for the Heat Generation

Ahmed, Muhammad Adeel; Habba, Mohamed I. A.; Jouini, Nabil; Alzahrani, Bandar; Seleman, Mohamed M. El-Sayed; El-Nikhaily, Ahmed E.

doi:10.3390/met11030438

Cited by 23 publications

(17 citation statements)

References 35 publications

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“…In order to study the feasibility of the AFSD of A356 (hypoeutectic Al-7.3Si) alloy, three continuous-deposited multi-layers were produced at a constant rotation rate of 1200 rpm and different feeding speeds of 3, 4, and 5 mm/min using the consumable rod of A356 alloy. The AFSD process was performed using a full-automatic friction stir welding machine (EG-FSW-M1) [32,33]. Before starting the deposition process, the consumable A356 rods were gripped to the machine shank, and the aluminum substrate was fixed on the machine table.…”

Section: Am Process and Evaluation Of The Produced Materialsmentioning

confidence: 99%

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

et al. 2021

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In the current investigation, additive friction stir-deposition (AFS-D) of as-cast hypoeutectic A356 Al alloy was conducted. The effect of feeding speeds of 3, 4, and 5 mm/min at a constant rotational speed of 1200 rpm on the macrostructure, microstructure, and hardness of the additive manufacturing parts (AMPs) was investigated. Various techniques (OM, SEM, and XRD) were used to evaluate grain microstructure, presence phases, and intermetallics for the as-cast material and the AMPs. The results showed that the friction stir deposition technique successfully produced sound additive manufactured parts at all the applied feeding speeds. The friction stir deposition process significantly improved the microstructure of the as-cast alloy by eliminating porosity and refining the dendritic α-Al grains, eutectic Si phase, and the primary Si plates in addition to intermetallic fragmentation. The mean values of the grain size of the produced AMPs at the feeding speeds of 3, 4, and 5 mm/min were 0.62 ± 0.1, 1.54 ± 0.2, and 2.40 ± 0.15 µm, respectively, compared to the grain size value of 30.85 ± 2 for the as-cast alloy. The AMPs exhibited higher hardness values than the as-cast A356 alloy. The as-cast A356 alloy showed highly scattered hardness values between 55 and 75.8 VHN. The AMP fabricated at a 3 mm/min feeding speed exhibited the maximum hardness values between 88 and 98.1 VHN.

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Section: Am Process and Evaluation Of The Produced Materialsmentioning

confidence: 99%

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

et al. 2021

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“…Moreover, the vertical load which represents the downward force (applied pressure) by the tool will be used to calculate the heat input in the welding process. Considering the friction force between the tool (pin surfaces and the pin shoulder) and considering an average friction coefficient (µ) equal to 0.5 [47][48][49] and using the applied vertical force (F), the rotational speed (ω) and the heat input (Q) are calculated as follows [50]:…”

Section: Heat Input In the Fssw Processmentioning

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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“…To avoid these difficulties, precise control of the weld chemical composition and working temperature are often recommended during the welding process. As a solid-state technique, friction stir welding (FSW) facilities [15,16] have been developed and used extensively to weld ferrous [17][18][19] and nonferrous [20][21][22] alloys in similar [19,23,24] and dissimilar [25][26][27] joints in various industrial applications. The FSW technique is recommended to join 2205 DSS.…”

Section: Introductionmentioning

confidence: 99%

“…They reported that the yield strength (YS), ultimate tensile strength (UTS), and elongation (E%) of the FSWed joints are enhanced over the GTAW joints by 21%, 41%, and 66%, respectively. The tool design and material are important parameters to achieve sound joint in FSW [22,31]. As mentioned in the above brief literature, many studies succeeded in friction stir welding of DSS at the thickNess less than 5 mm; however, still FSW of this material due to the increasing demand in the petroleum industry at a thickness of 5 mm or higher is a challenge in selecting processing parameters and tool material and design.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Friction Stir Welded 2205 Duplex Stainless Steel Butt Joints

et al. 2021

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Friction stir welding (FSW) as a solid-state process is an excellent candidate for high softening temperature materials welding; however, extending the tool life is required to make the process cost-effective. This work investigates the use of a high pin to shoulder ratio (65%) tungsten carbide (WC) tool for friction stir welding of 5 mm thick 2205 DSS to extend the tool life of this low-cost tool material. In addition, the effect of FSW parameters in terms of rotational rates, travel speeds, and downward forces on the microstructural features and mechanical properties of the welded joints were investigated. Characterization in terms of visual inspection, macro and microstructures, hardness, and tensile testing was conducted. The obtained results indicated that the combined rotational rate, travel speed, and downward force parameters govern the production of defect-free joints. The 2205 DSS friction stir welds show an enhancement in hardness compared to the base material. The stir zone showed a significantly refined grain structure of ferrite and austenite with the reduction in the average grain size from 8.8 µm and 13.3 µm for the base material to 2.71 µm and 2.24 µm, respectively. Moreover, this joint showed higher yield strength and ultimate tensile strength compared to the DSS as-received material.

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Bobbin Tool Friction Stir Welding of Aluminum Using Different Tool Pin Geometries: Mathematical Models for the Heat Generation

Cited by 23 publications

References 35 publications

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

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

Microstructure and Mechanical Properties of Friction Stir Welded 2205 Duplex Stainless Steel Butt Joints

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