Effect of friction stir welding tool on temperature, applied forces and weld quality

Papahn, Hossein; Bahemmat, Pouya; Haghpanahi, Mohammad; Aminaie, Iman Pour

doi:10.1049/iet-smt.2014.0150

Cited by 19 publications

(12 citation statements)

References 23 publications

(28 reference statements)

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“…For more details regarding the effect of welding parameters on the temperature and applied force through the FSW process, see Refs. [25][26][27][28]. These two parameters compete with each other to reach a trade-off, which determines RS level induced by the underwater FSW process.…”

Section: Resultsmentioning

confidence: 99%

Effect of cooling media on residual stresses induced by a solid-state welding: underwater FSW

Papahn

Bahemmat

Haghpanahi

2015

Int J Adv Manuf Technol

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In this article, the effect of cooling media on the residual stresses (RS) induced by a solid-state welding process is scrutinized through measuring and comparing RS caused by friction stir welding (FSW) underwater and in open air using the non-destructive ultrasonic method for aluminum AA7075-T6. Underwater FSW as a solid-state welding method can extend the application of solid-state welding techniques in marine industry. Results reveal that the longitudinal and transverse RS reduce under the water compared to open air. This reduction in the longitudinal RS is the maximum within the nugget zone (about 17 %). Meanwhile, such reduction for the transverse RS reaches 70 % within the heat-affected zone. In addition, under both air and water, the longitudinal RS is several times greater than the transverse RS and is in tensile and compressive states inside and outside the nugget zone, respectively.

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Section: Resultsmentioning

confidence: 99%

Effect of cooling media on residual stresses induced by a solid-state welding: underwater FSW

Papahn

Bahemmat

Haghpanahi

2015

Int J Adv Manuf Technol

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“…[7][8][9][10] Furthermore, Kumar et al and Papahn et al demonstrated that F z is dependent on the shoulder and probe diameter. 7,11 F z increased by an enlargement of the shoulder and probe diameter, whereas the last-mentioned means, that the shoulder diameter is more significant than the probe diameter with regard to F z . F x acts along the welding direction (see Figure 1) and can be affected by both rotational and welding speed as well as the tool geometry.…”

Section: Introductionmentioning

confidence: 89%

Reduction of friction stir welding setup loadability, process forces and weld seam width by tool scaling

Grätzel

Hasieber

Löhn

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part L:

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Friction stir welding is an increasingly used method to join similar and dissimilar materials with excellent mechanical weld seam properties. However, in certain cases, friction stir welding is restricted by high mechanical loads as a result of high forces and torques during the welding process. This relates in particular stiffness-reduced machine concepts which may cause path deviations, massive vibrations and insufficient tool plunging. Against this background, this investigation demonstrates a method to reduce forces and torques by tool scaling. Due to the stepwise diameter reduction of shoulder and probe and a simultaneous adjustment of the process parameters, a significant force and spindle torque reduction was achieved. Furthermore, it could be shown that tool scaling does not affect the mechanical strength properties. The experimental investigations were carried out with EN AW 5754 H11 with a sheet thickness of 8 mm. The weld seams were performed on a robotized friction stir welding setup (KUKA KR500) with a maximum axial force of 10 kN. Based on a 26-mm shoulder and a 10-mm pin diameter, it could be demonstrated that the general weldability of 8 mm EN AW 5754 H11 is restricted (incomplete tool plunge) by the maximum axial force of the robotized friction stir welding setup (10 kN). Due to the stepwise reduction of the shoulder and probe diameter from 26 mm to 20.8 mm and 10 mm to 8 mm, respectively, a general weldability and weld seams without irregularities could be achieved by the equal robotized friction stir welding setup. Furthermore, it could be shown that an axial force and spindle torque reduction from 10 kN to 4 kN and 29 Nm to 10 Nm, respectively, was obtained due to further reduction of the tool diameters.

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“…The T1 thermocouple was installed beneath the workpiece, while the others are located on the upper surface of the workpiece. 38 As mentioned earlier, to evaluate the accuracy of the simulated results, the RS during the in-air and underwater FSW is measured through a non-destructive method called ultrasonic method. In a study done by the authors, the practical application of ultrasonic method on the measurement of RS induced by the inair FSW has been evaluated and approved.…”

Section: Rs Measurement and Temperature Acquisitionmentioning

confidence: 99%

Study on residual stresses caused by underwater friction stir welding: FE modeling and ultrasonic measurement

Salimi

Bahemmat

Haghpanahi

2018

Proceedings of the Institution of Mechanical Engineers, Part E:

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Predicting residual stresses arising from the thermal and mechanical loading history during engineering processes including welding would be a viable tool to reach the optimum process parameters. In the present article, an elastothermo-visco-plastic model has been employed to estimate the residual stress caused by the underwater friction stir welding, which are resulted by large thermo-mechanical deformations on one hand and rapid cooling arising from the enormous non-uniform boiling heat convention of water on the other hand. Finally, the numerical results are compared with experimental data acquired by the ultrasonic method to evaluate the accuracy of the simulation process. Regarding the low temperature during underwater friction stir welding, the employed constitutive equations result in acceptable residual stress fields, while for in-air case, the amount of error increases significantly due to experience of high temperatures and intensification in hardening precipitation phenomena.

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Effect of friction stir welding tool on temperature, applied forces and weld quality

Cited by 19 publications

References 23 publications

Effect of cooling media on residual stresses induced by a solid-state welding: underwater FSW

Effect of cooling media on residual stresses induced by a solid-state welding: underwater FSW

Reduction of friction stir welding setup loadability, process forces and weld seam width by tool scaling

Study on residual stresses caused by underwater friction stir welding: FE modeling and ultrasonic measurement

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