Influences of tool pin profile and tool shoulder diameter on the formation of friction stir processing zone in AA6061 aluminium alloy

Elangovan, K.; Balasubramanian, V.

doi:10.1016/j.matdes.2007.01.030

Cited by 376 publications

(160 citation statements)

References 7 publications

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“…The influence of precipitate distribution on microhardness profile has been reported by several authors in recent years [11,14,15]. The influence has been related to the amount of heat introduced locally in the WN during FSW.…”

Section: Microhardness Evolutionmentioning

confidence: 87%

“…Other studies, carried out on a wide variety of precipitation hardened aluminum alloys, the influence of FSW process parameters on the characteristics of the precipitates and their impact on hardness profile has been investigated and mostly related to the local amount of heat generated by the rotating tool [11][12][13][14][15]. Therefore tool geometry plays a critical role in obtaining defect free FSW joints and its selection have a direct impact in optimizing of the other process parameters such as tool rotation speed, tool advance, etc.…”

Section: Introductionmentioning

confidence: 99%

“…An extensive review of the literature indicates that tool geometry has a determining effect on the flow of the material beneath the shoulder and hence the elimination of the kissing bonds. However, due to the highly dynamic nature of the process and the difficulty in mathematically formulating and predicting material flow, the tool geometry optimization has been mostly based on experience [3,5,9,[11][12][13][14][15]. Specifically, Zhao et al [2] found optimum joint properties in a 2014 aluminum alloy using a screw pitched taper stirrer pin.…”

Section: Introductionmentioning

confidence: 99%

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Friction stir lap welding of 5456 aluminum alloy with different sheet thickness: process optimization and microstructure evolution

Salari

Jahazi

Khodabandeh

et al. 2015

Int J Adv Manuf Technol

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The influences of friction stir welding process parameters on microstructure evolution and mechanical properties of lap welded 5456 aluminum alloy plates with different thickness and temper conditions were investigated. The upper plate was 5mm thick, cold rolled aluminum alloy 5456-T321 and the lower plate was 2.5mm annealed sheet (5456-O). Four different pin geometries (conical thread pin, cylindrical-conical thread pin, stepped conical thread pin, and Flared Triflute pin tool) and two rotational speeds (600 and 800rpm) were used to produce the joints. Microstructures and microhardness values in the weld nugget (WN), thermomechanically affected zone (TMAZ), and the heat affected zone (HAZ) were examined and correlated with selected processing conditions. Specifically, the influence of tool geometry on the flow of the plasticized material in the nugget zone, extent of hooking defect, and mechanical properties (microhardness) of the FSW joints were documented and quantified.It was found that weld joints made by using the stepped conical thread pin tool produced a homogeneous microstructure with finer grain size (5.4 µm) and higher microhardness levels than the other tools. The optimum processing conditions resulting in sound and defect free joints with highest mechanical properties were obtained with the stepped conical thread pin and 600rpm rotational speed.The evolution of the microhardness in each region is characterized and related to processing conditions.

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Section: Microhardness Evolutionmentioning

confidence: 87%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Friction stir lap welding of 5456 aluminum alloy with different sheet thickness: process optimization and microstructure evolution

Salari

Jahazi

Khodabandeh

et al. 2015

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…As a result, the pin length should be chosen accurately. To do so, it is better to choose the pin length 0.2 mm to 0.3 mm shorter than the sum of the thickness of the two pieces [19]. The surface appearance of welds produced by the four different tools is shown in Figure 7.…”

Section: Effect Of Tool Pin Profile On Surface Appearancementioning

confidence: 99%

Influence of Pin Profile on Quality of Friction Stir Lap Welds in Carbon Fiber Reinforced Polypropylene Composite

Ahmadi¹,

Arab²,

Ghasemi³

et al. 2012

MECHANICS

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In recent years, interest on friction stir welding has grown more since such a joining technique allows welding of light weight alloys like aluminum and its alloys which are difficult to weld or even unweldable with the traditional fusion welding processes. This process can also be one of the joining processes considered for welding polymer matrix composites such as polypropylene composites which find a number of applications in different industries. This paper presents the effect of tool pin profile on surface appearance and tensile shear strength of friction stir lap welds in carbon fiber reinforced polypropylene composites with 4 mm thickness. Four high speed steel tools with different pinprofiles of threaded cylindrical, threaded cylindrical-conical, simple cylindrical-conical and threaded conical were employed for this study. Using these tools, lap welds were made under similar conditions of tool rotational speed, welding speed and tilt angle. Specimens were prepared for tensile shear testing. The tensile shear test results showed that the threaded cylindrical-conical tool produced a weld with better surface appearance and higher tensile shear strength.

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“…Examinations were made on the development of FSP zones on five distinctive tool pin profile and three different shoulder diameters in FSW of AA6061 aluminum alloy (Al-Mg-Si alloy) with a dimension of 300 × 150 × 6 mm 3 . Elangovan and Balasubramanian [9] concluded that the FSP zones were mechanically upgraded and metallurgically enhanced by a square pin tool with 18 mm shoulder diameter.…”

Section: Introductionmentioning

confidence: 99%

Friction Stir Welding of Dissimilar Butt Joints with Novel Joint Geometry

Jayabalakrishnan¹,

Balasubramanian²

2018

Acta Phys. Pol. A

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In this study, 1 mm thin sheets of AA 6061 and steel were welded by friction stir, with new joint geometry. Conventional friction stir welding develops high distortion to the specimen, particularly when the thickness is very small. In this process, friction stir welding is carried out by a tool without probe and with new joint geometry. Contrary to the conventional friction stir welding, where various tool profiles are used to obtain successful joints, the present study of investigation focused on developing a profile in the sheet metal edges to be joined. The aluminium sheet was positioned on the contoured steel sheet. Rotating tool with tilt angle was made to progress into the top sheet. Frictional heat plasticized the upper blank and the edges of the aluminium sheet were forged and extruded into the steel contour. The welding between steel and aluminium was due to a coalescence of the two materials and clamping effect was provided by the contour in the steel sheet. Tensile test was conducted to evaluate the quality of the welding along with macro and micro metallographic investigations. Further to this, scanning electron microscopy with energy dispersive X-ray and X-ray diffraction analysis have been done to understand the presence of intermetallics at the weld nugget. Tensile strength of 122.22 MPa was achieved. Intermetallics of Mg2Si, MnAl6 and FeAl6, Al5Fe2 was found as dominant compound at the interface. Welding of thin sheets is enhanced by form clamping and chemical diffusion bonding.

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Influences of tool pin profile and tool shoulder diameter on the formation of friction stir processing zone in AA6061 aluminium alloy

Cited by 376 publications

References 7 publications

Friction stir lap welding of 5456 aluminum alloy with different sheet thickness: process optimization and microstructure evolution

Friction stir lap welding of 5456 aluminum alloy with different sheet thickness: process optimization and microstructure evolution

Influence of Pin Profile on Quality of Friction Stir Lap Welds in Carbon Fiber Reinforced Polypropylene Composite

Friction Stir Welding of Dissimilar Butt Joints with Novel Joint Geometry

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