Effect of tool traverse speed on high strength structural AA6092/17.5 SiCp-T6 AMC friction stir welding

Acharya, Uttam; Banik, Abhijit; Mwema, Fredrick; Akinlabi, Stephen; Akinlabi, Esther; Roy, Barnik Saha

doi:10.1016/j.mtcomm.2024.108040

Cited by 2 publications

(4 citation statements)

References 27 publications

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“…To estimate approximate values of energy input, the welding power is divided by the TTS as shown in Eq. 2 [14]. This approach allows for an estimation of the energy input involved in the welding process, essential for understanding the relationship between tool movement, power, and energy input across varying TRS conditions.…”

Section: Spindle Torque and Force Analysismentioning

confidence: 99%

“…This could lead to decreased heat conduction, potentially caused by the heat-absorbing characteristics of SiC [25]. The additional energy might be utilized for particle fragmentation and tool wear, as documented in various studies for similar type of works [10,14]. This combination of tool wear and particle fragmentation could possibly contribute to an energy drain, resulting in a decrease in temperature as welding progresses.…”

Section: Weld Thermal Pro Lementioning

confidence: 99%

“…While some fragmented studies have highlighted diverse ndings across different directions, indicating the promising potential of FSW in joining advanced next-generation materials [12][13][14], a signi cant research gap remains. Speci cally, there is a lack of a systematic approach to comprehensively investigate various welding facets (thermal effects, torque and force dynamics, critical structural examinations, and mechanical properties) and their interrelationships in the context of the high-strength aerospace-grade AA6092/17.5 SiCp-T6 AMC.…”

Section: Introductionmentioning

confidence: 99%

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A comprehensive investigation on various welding facets for FSW of advanced structural AMC

Acharya,

Choudhury,

Sethi

et al. 2024

Preprint

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The study comprehensively explores various welding facets for FSW of advanced structural AMC (AA6092/17.5 SiCp-T6) by varying the Tool Rotational Speed (TRS). Thermal variations, force-torque distribution, structural evolution, and joint mechanical characteristics were evaluated. At 1000 rpm, welding temperature increases along the welding direction, contrasting with other TRS. The cooling rate escalates as welding progresses. The temperature gap between the Advancing Side (AS) and the Retreating Side (RS) widens with higher TRS. Increasing TRS leads to decreased spindle torque and Z-force, with X-force fluctuations evident at lower TRS. Additionally, the TRP exhibits a direct linear relationship with the energy input during the welding process. Microstructural analysis reveals diverse SiC particle aggregation in the Nugget Zone (NZ) across all the TRS conditions. Notably, at 1500 rpm, an onion ring width of 80 µm is observed. At 1750 rpm, iron particles indicating tool wear and an Al2O3 mud-cake-like formation is traced out. Furthermore, as TRS rises to 1500 rpm, there is a decrease in the particle size, succeeded by an increase, aligning with variations in the grain size. Welds display lower hardness than the BM, following a 'W' shape profile with the AS-HAZ region consistently showing the lowest hardness across all conditions. Hardness peaks at 1500 rpm, then decreases. The Tensile samples mostly fracture outside the weld zone, except at 1700 rpm. UTS values range from 308 MPa to 358 MPa, with joint efficiency peaking at 87% for 1500 rpm before decreasing to 74%. Welding at 1500 rpm exhibits greater elongation compared to the Base Metal, with fractographic analysis indicating predominantly ductile failure, except at 1750 rpm, displaying a mixed mode of failure.

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Section: Spindle Torque and Force Analysismentioning

confidence: 99%

Section: Weld Thermal Pro Lementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A comprehensive investigation on various welding facets for FSW of advanced structural AMC

Acharya,

Choudhury,

Sethi

et al. 2024

Preprint

Self Cite

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show abstract

“…The weld zone of joints exhibited enhancement in hardness due to a widmansatten structure caused by greater stirring action by the FSW tool, resulting in overmatched tensile properties. Though friction stir welding can be used, it has disadvantages such as tool wear due to cold conditions during the plunging phase, slower welding rates, and larger welding forces, which mandate rigid and precise welding apparatus for joining high melting temperature materials [15,16].…”

Section: Introductionmentioning

confidence: 99%

Role of oscillation frequency and amplitude on the microstructure and properties of linear friction welded nickel aluminium bronze joints

A K,

Selvam

et al. 2024

Phys. Scr.

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This study explores the influence of oscillation frequency and amplitude on the quality of linear friction welded joints using as-cast nickel aluminium bronze. Welding was conducted at 30 Hz, 50 Hz, and 70 Hz oscillated frequencies and amplitudes of 1.5 mm, 2 mm, and 3 mm. The joint’s performance was thoroughly investigated through systematic analysis, including macrostructure examination, peak interfacial temperature measurement, microstructure evaluation, strain assessment, cooling rate determination, microhardness testing, and tensile property characterization. The width of the weld zone varied from 183 µm to 297 µm, and the thermomechanical affected zone (TMAZ) area ranged from 4.48 mm² to 14.79 mm² across different process parameters. In the parent material, the volume fraction of the β-phase was as low as 20.2%, contrasting with the dominant α-phase at 79.8%. The average grain size of the lamellar and globular α-phase mixture was 26.4 µm. Notably, the weld zone exhibited extremely refined α-phase grains, with diameters less than 5 µm in all cases. The volume fraction of the β'-phase increased significantly with higher frequencies, from 15.299 % at 30 Hz to 26.98% at 50 Hz, peaking at 40.08% at 70 Hz, leading to varying k phases. This variation in microstructure had a substantial impact on mechanical properties. Tensile strength ranged from 503 MPa to 582 MPa, while ductility varied from 13.5% to 21.7%. Additionally, the hardness of the parent material increased from approximately 155 Hv to 260 Hv. This study demonstrates that controlling the oscillation frequency and amplitude in linear friction welding processes can yield consistent, high-quality welds in nickel aluminium bronze.

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Effect of tool traverse speed on high strength structural AA6092/17.5 SiCp-T6 AMC friction stir welding

Cited by 2 publications

References 27 publications

A comprehensive investigation on various welding facets for FSW of advanced structural AMC

A comprehensive investigation on various welding facets for FSW of advanced structural AMC

Role of oscillation frequency and amplitude on the microstructure and properties of linear friction welded nickel aluminium bronze joints

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