Friction stir extrusion of aluminum AA6061 into isostatically molded graphite

Strawn, Connor; Strauss, Alvin M.

doi:10.1016/j.jmapro.2021.07.052

Cited by 7 publications

(5 citation statements)

References 21 publications

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“…To apply this criterion to the FSE process, the local pressure appearing in the numerators of Equations ( 6) and (7) were replaced by the σmean acting in the porous material. This choice was made because the Piwnik and Plata criterion is used to study the bonding Based on this finding, it can be concluded that as the tool rotational speed increases, there is an increased likelihood of achieving maximum temperatures equal to or greater than 400 • C, regardless of the tool descent speed.…”

Section: Methodsmentioning

confidence: 99%

“…To apply this criterion to the FSE process, the local pressure appearing in the numerators of Equations ( 6) and (7) were replaced by the σ mean acting in the porous material. This choice was made because the Piwnik and Plata criterion is used to study the bonding conditions in a traditional extrusion process, considering the pressure generated between the parts of material that come into contact, for example after passing through the matrix holes.…”

Section: Methodsmentioning

confidence: 99%

“…For this reason, in 1993, the Welding Institute developed a new process for recycling metal waste, known as Friction Stir Extrusion (FSE), especially used for the low melting metals, i.e., aluminum and magnesium [ 4 , 5 , 6 ], but also nowadays used for other materials, such as graphite, to built aluminum-graphite joining [ 7 ], copper [ 8 ], and copper-carbon composites [ 9 ]. With this process, it is possible to extrude new pieces just starting directly from the scraps, limiting the necessary phases of the recycle process.…”

Section: Introductionmentioning

confidence: 99%

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Numerical Modeling of a Sustainable Solid-State Recycling of Aluminum Scraps by Means of Friction Stir Extrusion Process

2023

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One of the most important purposes of the modern industry is a sustainable production, considering the minimization of the energy and of the raw materials used, together with the reduction of polluting emissions. In this context, Friction Stir Extrusion stands out, since it allows to obtain extrusions starting from metal scraps deriving from traditional mechanical machining processes (e.g., chips deriving from cutting operations), heated only by the friction generated between the scraps and the tool, so avoiding the material melting phase. Given the complexity of this new kind of process, the objective of this research is the study of the bonding conditions considering both the heat and the stresses generated during the process under different working parameters, namely tool rotational and descent speeds. As a result, the combined approach involving the Finite Element Analysis and the Piwnik and Plata criterion proves to be a valid tool for forecasting if bonding phenomenon occurs and how it is influenced by the process parameters. The results have also demonstrated that it is possible to achieve completely massive pieces between 500 rpm and 1200 rpm, but at different tool descent speeds. Specifically, up to 1.2 mm/s for 500 rpm and just over 2 mm/s for 1200 rpm.

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Section: Methodsmentioning

confidence: 99%

“…To apply this criterion to the FSE process, the local pressure appearing in the numerators of Equations ( 6) and (7) were replaced by the σ mean acting in the porous material. This choice was made because the Piwnik and Plata criterion is used to study the bonding conditions in a traditional extrusion process, considering the pressure generated between the parts of material that come into contact, for example after passing through the matrix holes.…”

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Numerical Modeling of a Sustainable Solid-State Recycling of Aluminum Scraps by Means of Friction Stir Extrusion Process

2023

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“…These forming processes mainly use aluminum alloys, including AA5083, 15 AA6022, 14 and AA6061. 16 Butt welding and friction stir forming are well-documented processes; however, no published examples of butt welds combined with a forming process exist. Combining these two methods allows for a joint of three separate workpieces with a single operation.…”

Section: Introductionmentioning

confidence: 99%

Butted friction stir forming of AA6061-T6 to low carbon steel

Strawn

Strauss

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Friction stir welding (FSW) is a popular method for creating dissimilar material joints in the aerospace and automotive industries. This work proposes a new FSW derivative process: butted friction stir forming (BFSF). BFSF has the distinction of joining two abutting workpieces to a lapped third workpiece. Additionally, the process does not require modification to traditional FSW equipment and tooling. In this study, BFSF combines two workpieces of aluminum alloy 6061-T6 in a butt weld configuration throughout the process. As the FSW tool traverses, it travels over preformed, threaded holes in low carbon ASTM A36 hot rolled steel at regular spacing. Downward force combined with the stirring action of the tool displaces material into the hole, filling the threads and forming a mechanical interlock. Testing of various screw sizes and thread pitches allowed the determination of the optimal joint configuration. Aluminum die-cut bolts of each size established a point of comparison for base material strength. Of the sizes tested, the ANSI metric M profile M9-1.25 screw had the highest mechanical strength. In cross-tensile testing, the average failure load was 3915 N. Shear testing produced a failure load of 5749 N. The M9-1.25 formed screws had a 33.6% decrease in strength compared to the die-cut bolts. While this strength reduction is higher than is often experienced in traditional FSW, the results of this study are a valid proof of concept for further development in BFSF methods.

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“…Figure 1. Diagram of friction stir extrusion process with labelled axial, lateral, and traverse force directions 32. …”

mentioning

confidence: 99%

Friction stir extrusion of thin AA 7075-T6 into low-carbon steel: Effects of low weld pitch value

Shelton,

Strauss

2024

Science and Technology of Welding and Joining

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Friction stir extrusion, a derivative process of friction stir welding, forms a mechanical joint between workpieces by forging one into a prefabricated geometry within the other. Thin sheet AA7075-T651 extrusion joints were made into an O-ring dovetail channel within a low-carbon steel workpiece. The effects of low weld pitch process parameters on joint characteristics between the extruded thin sheet AA7075-T651 and low-carbon steel were observed. The weld pitch was varied from 0.02 to 0.05 mm rev−1. No material mixing was observed. Tensile-shear test results were normalised by sample width. The 0.04 mm rev−1 weld pitch group yielded the highest average joint strength at 493 N mm−1. The weld pitch parameters reduced machine in-process forces without a large decrease in joint strength.

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Friction stir extrusion of aluminum AA6061 into isostatically molded graphite

Cited by 7 publications

References 21 publications

Numerical Modeling of a Sustainable Solid-State Recycling of Aluminum Scraps by Means of Friction Stir Extrusion Process

Numerical Modeling of a Sustainable Solid-State Recycling of Aluminum Scraps by Means of Friction Stir Extrusion Process

Butted friction stir forming of AA6061-T6 to low carbon steel

Friction stir extrusion of thin AA 7075-T6 into low-carbon steel: Effects of low weld pitch value

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