Fundamentals of Friction Stir Welding, Its Application, and Advancements

Choudhary, Atul; Jain, Rahul

doi:10.1007/978-3-030-63986-0_2

Cited by 12 publications

(6 citation statements)

References 151 publications

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“…In FSW, kissing bonds are de ned as areas with separation of the materials or absence of metallic bonding and are caused by insu cient material stirring and low heat input [25,26]. Meanwhile, ash is characterised as excess material extrusion as a ribbon-type structure and is induced in FSW by low tool traverse speed and high tool rotation speed, leading to material overheating, softening, and expulsion [27,28]. Tunnel defects, also known as wormhole defects, are an internal cavity formed along the tool traverse direction caused by improper plasticisation of the material and de cient material movement around the tool pin [29,30].…”

Section: Introductionmentioning

confidence: 99%

Characterisation of materials properties and defects in structure fabricated via additive friction stir deposition

Paradowska,

Yakubov,

Ostergaard

et al. 2024

Preprint

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Additive friction stir deposition (AFSD) is an emerging solid-state non-fusion additive manufacturing (AM) technology, which produces parts with wrought-like material properties, high deposition rates, and low residual stresses. However, impact of process interruption on defect formation and mechanical properties has not yet been well-addressed in literature. In this study, Al6061 aluminium structure with two final heights and deposition interruption is successfully manufactured via AFSD and characterised. Defect analysis conducted via optical microscopy, electron microscopy, and X-ray computed tomography reveals >99% relative density with minimal defects in centre of the parts. However, tunnel defects at interface between substrate and deposit as well as kissing bonds are present. Edge of deposit contains tunnel defects due to preference for greater material deposition on advancing side of rotating tool. Virtual machining highlights the ability to remove defects via post processing, avoiding mechanical performance impact of stress concentrating pores. Electron back scatter diffraction revealed regions with localised shear bands contain 1-5 µm equivalent circular diameter grains. Kissing bonds exhibit in areas separated by large grain size difference. Meanwhile, Vickers hardness testing reveals hardness variation with deposit height. This work advances the understanding of complex microstructure development, material flow, and mechanical behaviour of AFSD Al6061 alloy.

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Section: Introductionmentioning

confidence: 99%

Characterisation of materials properties and defects in structure fabricated via additive friction stir deposition

Paradowska,

Yakubov,

Ostergaard

et al. 2024

Preprint

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show abstract

“…The dimensions of the pin and shoulder, as well as their shape and surface profile, determine the amount of heat generated, the mixing efficiency, and material flow intensity, and, consequently, also determine the microstructural effects of the processing and the resulting properties of the surface layer, including the material hardness and wear resistance. When designing and constructing a tool, it should be remembered that as much as 80-90% of the heat generated when the tool rubs against the material surface is generated by the shoulder, and only 10-20% of this heat is generated as a result of the friction of the remaining surfaces of the tool against the material [18]. During processing, the melting point of the modified material is not exceeded, and all changes in the microstructure and properties of the material occur during one short technological operation, which makes the FSP method a unique technology in many respects.…”

Section: Introductionmentioning

confidence: 99%

The Use of Ashes in Surface Metal Matrix Composites Produced by Friction Stir Processing

Iwaszko,

Kudła,

Sajdak

2024

Applied Sciences

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The article presents an assessment of the possibility of using ashes from the combustion of coal and biomass as a reinforcing phase in metal matrix composites. The composite surface layer was produced by means of the FSP (friction stir processing) method, using an original hole solution with a shifted working zone of the pin. The composite matrix was AA7075 alloy. The obtained composite was subjected to microscopic observations, tribological tests, and hardness measurements. The microscopic examinations revealed favorable changes in the microstructure, in particular, strong refinement of the grains, uniform distribution of the reinforcing phase, and good bonding of the particles of this phase with the matrix material. Changes in the microstructure resulted in a significant increase in the hardness (from 36 to 41% depending on the type of reinforcing phase) and wear resistance (from 24.1 to 32.9%), despite partial dissolution of the intermetallic phases. It was found that the effect of strengthening the matrix and the uniformity of the distribution of the reinforcing phase depend on the physicochemical properties of the used powders, especially on the shape and size of the particles. The research shows that the use of ashes as a reinforcing phase in composites is fully justified.

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“…Friction stir welding (FSW) has become a relatively new welding method that was developed by Wayne Thomas in 1991 at the Welding Institute (TWI) of the United Kingdom as a solid-state welding technique [1][2][3][4]. This innovation is a huge success for joining materials with low melting temperatures and aluminum alloys [5][6][7].…”

Section: Introductionmentioning

confidence: 99%

A Review on Tool Pin Geometry of Friction Stir Welding

Ahmed,

Kadhum,

Salleh

2024

alkej

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Friction stir welding (FSW) is an innovative solid joining operation that has recently been intensively adopted in welding various similar and dissimilar metallic materials, including aluminum, steel, titanium alloys, and others. The success of FSW relies on a set of parameters like rotational speed, travel speed, axial force, tool geometry, etc. The role of tool geometry (involving both pin and shoulder design) is highly important in producing sound and high-strength weld joints. Therefore, this research aims to review the latest published works regarding the performance of different tool geometries. The discussion of the findings of the cited works revealed that each tool pin design has shown different behavior due to the various stirring efficiencies of the materials being welded. All in all, the square threaded pin had the best geometry in terms of its mechanical properties compared to other pin designs. The threaded cylinders and threaded taper are most commonly utilized and offer good joints, while the maximum joint efficiency was achieved by the square pin profile and it reached 94% in some investigations.

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Fundamentals of Friction Stir Welding, Its Application, and Advancements

Cited by 12 publications

References 151 publications

Characterisation of materials properties and defects in structure fabricated via additive friction stir deposition

Characterisation of materials properties and defects in structure fabricated via additive friction stir deposition

The Use of Ashes in Surface Metal Matrix Composites Produced by Friction Stir Processing

A Review on Tool Pin Geometry of Friction Stir Welding

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