Experimental and numerical investigation of the generated heat in polypropylene sheet joints using friction stir welding (FSW)

Mirabzadeh, Reza; Parvaneh, Vali; Ehsani, Amir

doi:10.1007/s12289-021-01622-y

Cited by 12 publications

(6 citation statements)

References 41 publications

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“…The TTA in FSW significantly impact the material's surface flow during welding [20]. The tool tilt angle refers to the angle between the rotating tool axis and the normal axis on the workpiece surface [21]. This angle determines the direction and amount of material flow during the FSW process, which affects the weld quality and microstructure [22].…”

Section: Thermal Cyclesmentioning

confidence: 99%

Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

et al. 2023

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This study aims to investigate the impact of partial-contact tool tilt angle (TTA) on the mechanical and microstructure properties of the AA1050 alloy friction stir weld (FSW). Three levels of partial-contact TTA were tested, 0°, 1.5°, and 3°, compared to previous studies on total-contact TTA. The weldments were evaluated using surface roughness, tensile tests, microhardness, microstructure, and fracture analysis. The results show that in partial-contact conditions, increasing TTA decreases the generated heat in the joint line and increases the possibility of FSW tool wear. This trend was the opposite of joints that were friction stir welded via total-contact TTA. The microstructure of the FSW sample was finer at higher partial-contact TTA, while the possibility of defect formation at the root of the stir zone in higher TTA was more than in lower TTA. The robust sample prepared at 0° TTA had 45% of AA1050 alloy strength. The maximum recorded heat in 0° TTA was 336 °C and the ultimate tensile strength of this sample was 33 MPa. The elongation of the 0° TTA welded sample was 75% base metal, and the average hardness of the stir zone was 25 Hv. The fracture surface analysis of the 0° TTA welded sample consisted of a small dimple, indicating the brittle fracture mode.

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Section: Thermal Cyclesmentioning

confidence: 99%

Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

et al. 2023

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“…to estimate the generated and distributed heat for polypropylene sheet joints [23]. It indicated that if the heat transfer in weld tool is well predicted, the number of experiment tests may be reduced.…”

Section: Mirabzadeh Et Al Developed a 3-d Symmetric Finite Element (F...mentioning

confidence: 99%

Heat transfer in aluminum-steel joint and weld tool during the friction stir welding: Simulation and experimental validation

Guo

Cui

et al. 2023

Int J Adv Manuf Technol

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The heat transfer behaviors are important to control the performance of Aluminum-Steel joint. However, because the models with weld tool are majorly tested for the same material joints, the heat transfer behaviors with weld tool for aluminum-steel joint are not fully understood.In this paper, a novel CFD model with weld tool is developed and tested to investigate the effects of weld tool on the aluminum-steel joint. The calculated temperature and thermal cycles for various traverse speed agreed well with the corresponding IR experimental results. It is found that the model with weld tool can decrease the temperature gradient and inhomogeneity of temperature field for aluminum-steel joint. The model with weld tool can provide calculated viscosity based on the validated temperature field to analysis the insufficient stirring defect of aluminumsteel joint.

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“…Chakradhar and Narendranath [28] designed an experiment using the RSM method for joining an AA6061 aluminum alloy using the FSW process to determine the optimal parameters for tensile strength and weld hardness. Mirabzadeh et al [29] examined heat generated by FSW welding on polypropylene sheets through process factor analysis using the RSM method with Box Behnken design. Ahmadnia et al [30] studied the effects of FSW welding parameters on the tensile strength, hardness, and elongation of AA6061 and AA5051 aluminum alloy welds using the RSM method.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the optimal parameters for butt joints in a friction stir welding (FSW) process with dissimilar aluminium alloys

Harachai¹,

Prasomthong

2023

Mater. Res. Express

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Aluminum alloys are used in the modern automotive industry because they are lightweight. However, it is establised that conventional fusion welding processes affect weld performance. In this study, friction stir welding (FSW), also known as solid-state welding, was used to weld dissimilar aluminum alloys, AA6061-T6 and AA5083plates. Response surface methodology based on Box-Behnken design (BBD) was used to investigate the appropriate process parameters. In this study, the effects of rotation speed (S), welding feed rate (f), and work angle (θ) were investigated. These three factors were examined at three levels over 17 experimental runs. The design was used to conduct experiments and develop mathematical regression models. Variance analysis was performed to examine the adequacy of the developed models. Finally, the effects of the process parameters on the mechanical properties of welded alloyes were investigated using mathematical models based on the macrostructure, microstructure, chemical composition, and fracture characteristics of the joints using SEM. The investigation found that the optimum welding parameters are a rotational speed of 777 rpm, welding speed of 44 mm/min, and a work angle of 0.75o. Furthermore, the results confirm that the mathematical models and experiments are consistent.

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Experimental and numerical investigation of the generated heat in polypropylene sheet joints using friction stir welding (FSW)

Cited by 12 publications

References 41 publications

Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

Heat transfer in aluminum-steel joint and weld tool during the friction stir welding: Simulation and experimental validation

Investigation of the optimal parameters for butt joints in a friction stir welding (FSW) process with dissimilar aluminium alloys

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