Review: Friction stir welding tools

Naresh, Ram; De, A.; Bhadeshia, H. K. D. H.; DebRoy, T.

doi:10.1179/1362171811y.0000000023

Cited by 655 publications

(331 citation statements)

References 147 publications

(265 reference statements)

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“…16). Strain rate contours also tend to be wider when tool rotational speed increases from 120 to 200 RPM due to more material has affected by the tool thermo-mechanical action, this result is in agreement with the findings found in [32] [33]. The strain rate also shows a decrease towards the workpiece bottom and its values tend to vanish at the probe end centre as shown in Fig.…”

Section: Cfd Resultssupporting

confidence: 82%

“…This paper is focus only on the PCBN tool wear as this is the tool which has been used to produce the samples under study. Other tool materials which have been used for high melting alloys are usually made of refractory materials based on tungsten such as WC, W-Re, W-Co and can be found in literatures [3][4][5][6][7]. Wear issues in PCBN FSW tool considered better than other refractory materials such as tungsten based tools.…”

Section: Introductionmentioning

confidence: 99%

“…The micro hardness of this tool HV (2600-3500) shows that the PCBN tool is the second hardest tool after diamond. It also has a low coefficient of friction which in turn helps in producing smooth surfaces after completing the FSW process [3]. However, a low coefficient of friction in a FSW tool necessitates the increase in tool rotational speed to produce the required heat for welding [4].…”

Section: Introductionmentioning

confidence: 99%

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Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

Al-moussawi

Smith

2018

Met. Mater. Int.

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Poly Crystalline Boron Nitride (PCBN) tool wear during the friction stir welding of high melting alloys is an obstacle to commercialize the process. This work simulates the friction stir welding process and tool wear during the plunge/dwell period of 14.8 mm EH46 thick plate steel. The Computational Fluid Dynamic (CFD) model was used for simulation and the wear of the tool is estimated from temperatures and shear stress profile on the tool surface. Two sets of tool rotational speeds were applied including 120 and 200 RPM. Seven plunge/dwell samples were prepared using PCBN FSW tool, six thermocouples were also embedded around each plunge/dwell case in order to record the temperatures during the welding process. Infinite focus microscopy technique was used to create macrographs for each case. The CFD result has been shown that a shear layer around the tool shoulder and probe-side denoted as thermo-mechanical affected zone (TMAZ) was formed and its size increase with tool rotational speed increase. Maximum peak temperature was also found to increase with tool rotational speed increase. PCBN tool wear under shoulder was found to increase with tool rotational speed increase as a result of tool's binder softening after reaching to a peak temperature exceeds 1250 °C. Tool wear also found to increase at probe-side bottom as a result of high shear stress associated with the decrease in the tool rotational speed. The amount of BN particles revealed by SEM in the TMAZ were compared with the CFD model.

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Section: Cfd Resultssupporting

confidence: 82%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

Al-moussawi

Smith

2018

Met. Mater. Int.

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“…Tool rotates and plunges to abutting edges of the plates that plastically deform the material and flow the material in onion ring form in welding direction. Tool geometry characterizes as tool shoulder, tool shoulder surfaces, tool shoulder angle, pin geometry with its shape and size [9].…”

Section: A Tool Geometrymentioning

confidence: 99%

Emerging Modeling and Simulation Techniques for Friction Stir Welding - A Review

2015

International Conference on Advancements and Recent Innovations in Mechanical, Production and Industrial Engineering

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Abstract-Friction stir welding is a relatively new solid-state joining technique which is widely acceptable in various industries (aerospace, automotive, railway, and shipbuilding) to join similar and dissimilar metallic alloys that are difficult to weld by conventional fusion welding process. In last decade, the friction stir welding processes developments have been active areas research due to dimensional stability of the welded structure, low residual stresses and most important eco-friendly wielding process. The welding mechanism is based on the frictional heat generation process through the interaction of a non-consumable tool to adjoining edges of the plates to be joined. There are a number of issues that affect the performance of friction stir welding such as heat generation, material flow, tool geometry, tool rotation, travel speed, axial force, and tilt angle. Several modeling and simulation techniques have been applied for the characterization of friction stir wielding process phenomenon that are empirical, analytical, numerical and artificial intelligence modeling techniques. The objective of this paper is to review the recent works on modeling and simulation techniques and to emphasize the future requirements for increased understanding of the modeling and simulation efforts in the field of friction stir welding.

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“…Concave, flat or convex shoulders with or without scrolls, ridges or knurling, grooves, or concentric circles and cylindrical, conical, oval, triangular pins or pins with more complex geometry, such as whorl or MX triflute pins, for instance, have been developed in recent years, as compiled by Rai et al (2011). Such complex geometries seek to increase the amount of local heat generated due to the greater interface area between the tool and the workpiece, increasing the flow of material in the stir zone, as mentioned by Mishra et al (2005).…”

Section: Introductionmentioning

confidence: 99%

Effect of tool geometry on friction stir processing and fatigue strength of MIG T welds on Al alloys

Jesús¹,

Loureiro²,

Costa³

et al. 2014

Journal of Materials Processing Technology

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Please cite this article as: de Jesus, J.S., Loureiro, A., Costa, J.M., Ferreira, J.M.,Effect of tool geometry on friction stir processing and fatigue strength of MIG T welds on al alloys, Journal of Materials Processing Technology (2014), http://dx.doi.org/10. 1016/j.jmatprotec.2014.05.012 This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain. Page 1 of 35A c c e p t e d M a n u s c r i p t EFFECT OF TOOL GEOMETRY ON FRICTION STIR PROCESSING AND FATIGUE STRENGTH OF MIG T WELDS ON AL ALLOYS HighlightsTool geometry has great influence on properties of FSP MIG welds; FSP removes defects in the MIG weld toe and increases its radius of curvature;Grain refinement in processed regions is affected by tool geometry Tool geometry influences the fatigue strength of FSP MIG T welds.

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Review: Friction stir welding tools

Cited by 655 publications

References 147 publications

Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

Thermo-Mechanical Effect on Poly Crystalline Boron Nitride Tool Life During Friction Stir Welding (Dwell Period)

Emerging Modeling and Simulation Techniques for Friction Stir Welding - A Review

Effect of tool geometry on friction stir processing and fatigue strength of MIG T welds on Al alloys

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