Generation of force and torque during joining of AZ91C plates by FSW under distinctive tool tilt angle and their impact on mechanical strength and micro-structure

Yaknesh, S.; Sampathkumar, K.; Sevvel, P.; Solomon, I. John

doi:10.1080/01694243.2022.2057763

Cited by 11 publications

(8 citation statements)

References 47 publications

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“…The top view of the spot welds plunged by the tool shoulder was comprised of circular friction stirring onion rings on the upper aluminium weld samples as remarked in friction stir welded AZ91C Mg alloy 51 (Figure 13). There was tool pin assisted cylindrical hole also noticed as the revolving tool withdrawn just after welding.…”

Section: Resultsmentioning

confidence: 99%

Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Pattanaik,

Nayak,

Bisoyi

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Friction stir processing procedures are often found to be an alternative choice for the joining of thermoplastic polymers without melting the base materials. In recent years, dissimilar metallic to thermoplastic assemblies are highly used in aerospace and automotive industries as mechanical fastener or fusion welding techniques are rather inadequate for extreme discrepancy in thermal properties. The present work addresses the feasibility of friction stirred spot welding for non-ferrous aluminium (Al 6061) to polycarbonate using taper cylindrical tool of hardened H13 steel along with machine integrated axial thrust and stirring torque signals. The real-time positional and axial velocity of the rotating tool has been acquired to distinguish between plunging and dwelling stage. The process stability that is, the deviation of thrust-torque in respective phases was processed. The interaction of plunge depth and dwell time on tool pin assisted keyhole with associated material expulsion for different tool revolving speed was established. The weld mechanical behaviour has been scanned using load versus elongation diagram with associated weld pair interface. Lastly, sensors’ based process monitoring extended to weld quality prediction have been made using various significant features of thrust-torque-velocity based approaches. The tool spinning speed followed by dwell time was found to be important on weld quality index. The joint efficiency was significantly upgraded (more than 60%) at intermediate dwell time (40 s) with low tool plunging (0.3 mm) or reversed parametric setting at high tool revolving speed (2500 rpm) due to substantial reduction in axial thrust with higher stirring torque. The local deviation in thrust-torque during plunging was equally responsible with global mean thrust-torque in dwelling to dictate the joint strength and the weld ductility. The material stirring torque was better indicator of weld shear strength while pin assisted slot size highly correlated with tool thrust though tool plunging speed was highly crucial.

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Section: Resultsmentioning

confidence: 99%

Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Pattanaik,

Nayak,

Bisoyi

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…Except for the zone of agitation of the joint manufactured at 0 °angle of tilt, the rest of the 2 weldments made using the TPNT tool don't show onion ring characteristics. At the very instant, this onion kind of circle had been seen very commonly within the tool stir region produced by the TPNT tool [41]. Te onion ring shape comes from the way through the softened metal fow.…”

Section: Force and Torque Generationmentioning

confidence: 95%

Mechanical and Microstructural Investigation on AZ91B Mg Alloys with Tool Tilt Variation by Friction Stir Welding

Yaknesh

Tharwan

Rajasekaran

et al. 2022

Advances in Materials Science and Engineering

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By modifying the angle of tilt of 2 distinct tool pin shapes, both tapered with and without threaded structures, TPT tool pin with threads and TPNT tool pin with no threads, the mechanical behaviour and microstructural attributes were examined for the joints of AZ91B alloy formed by friction stir welding. Spindle torque and unique forces operating laterally and axially (referred to as Y-force and X-force, respectively) were created at the junction of the tool and plate, which were monitored and assessed in order to know the influence of degrees of tilt. When the tool’s angle of tilt advances, torque and forces of the spindle also show an increasing trend that is important to friction stir welding. The spindle torque and Y-force produced by the TPT tool are higher than those of the TPNT tool, whereas the X-force associated with the TPT tool is less. Discrepancies in forces grow along the concurrent increase in the angle of tilt for the TPNT as well as TPT tools, exhibiting opposite behaviour. The onion ring-type structure was visualized in the threaded tool pin structure TPT due to the high flow of plasticized metal compared to TPNT tool joints, for which the onion ring shape is not visible. With the TPT tool, the joint made at a 0° angle of tilt had a peak tensile strength of 232 MPa.

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“…Based on the literature survey [26][27][28], the most dominant parameters which were proven to play a vital role in impacting the properties of the AZ80A Mg alloy joints to be attained by employing the FSW process are listed out in table 2, along with their respective distinctive levels, notation and units. Due to the broad spectrum of the dominating parameters of the FSW process, it was proposed to choose a central composite category response surface based matrix of design possessing 4 dominant factors (parameters of FSW process), 5 distinct levels having 31 runs.…”

Section: Parameters Of Fsw Processmentioning

confidence: 99%

“…Moreover, it does not analyze all the possible combinations of variables that impact the outcomes of the process, particularly when the process is complex, non-linear or dynamic [21,22]. As a result, in the recent years, several researchers have preferred response surface based design methodology for their experimental works with respect to the FSW process and have proved that the employment of this RSM ( i.e., response surface methodology) is effective in formulating the empirical relationship amidst several parameters of the FSW process and in anticipating the responses [23][24][25][26]. As a result, in this experimental investigation, an attempt was put forward to attain AZ80A Mg alloy joints possessing highest value of tensile strength through the employment of central composite based design technique of RSM.…”

Section: Introductionmentioning

confidence: 99%

Parametric based optimization of friction stir welded wrought AZ80A Mg alloy employing response surface methodology

et al. 2023

Mater. Res. Express

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An endeavour was put forward to friction stir weld flat plates of AZ80A Mg alloy by employing the central composite based design technique of response surface methodology, taking into consideration the parameters namely tool rotational speed, traverse speed, tool’s tilt angle, and pin geometry of the employed tool. Numerical model was formulated to correlate the relationship amidst the employed parameters of FSW process and the responses, namely tensile strength and elongation percentage of the AZ80A Mg alloy joints. The formulated model was also optimized to attain AZ80A Mg alloy joints possessing highest value of tensile strength. Competency of the formulated numerical model was validated employing the analysis of variance and the observations of the affirmation experiments plotted in the form of scatter diagrams revealed an appreciable agreement with the values of the anticipated models. Response and contour plots generated from the established numerical model was employed to understand the interactive impacts of the parameters of FSW process on the variables of the response. AZ80A mg alloy joints fabricated during the employment of tool possessing straight cylindrical geometry at atilt angle of 0.630, rotational speed of 962.077 rpm, tool traverse speed of 2.105 mm sec−1 possessed the highest tensile strength of 195.299 MPa and was proven to be free from flaws.

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Generation of force and torque during joining of AZ91C plates by FSW under distinctive tool tilt angle and their impact on mechanical strength and micro-structure

Cited by 11 publications

References 47 publications

Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Mechanical and Microstructural Investigation on AZ91B Mg Alloys with Tool Tilt Variation by Friction Stir Welding

Parametric based optimization of friction stir welded wrought AZ80A Mg alloy employing response surface methodology

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