Role of Various Tool Pin Profiles in Friction Stir Welding of AA2024 Alloys

Singh, Bharat; Saxena, Kuldeep K.; Singhal, Piyush; Joshi, Tilak C.

doi:10.1007/s11665-021-06017-3

Cited by 14 publications

(5 citation statements)

References 41 publications

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“…Te Y-force has surpassed the X-force in dominance and is continuously expanding. Because the tool pin and shoulder interacted, the metal fowed in a way that caused a deviation in the pin-generated plasticized metal fow [24]. Tis meant that onion ring-like features didn't form in the nugget zone.…”

Section: Microstructure and Macrostructure Tablementioning

confidence: 99%

“…Tere are extremely less works of literature. References [23][24][25] have made reviews on the FSW regarding the efect of tool tilt angle. For instance, Zhai et al [23] the outcome of angle of tilt on production of heat, metal fow behaviour, and feld temperature during friction stir with regard to tool pin shape impact on FSW, it is clear from the literature that FSW is produced by changing the speed of the tool, and the tool tilt angle is either fxed or not considered [20][21][22].…”

Section: Introductionmentioning

confidence: 99%

“…For instance, Zhai et al [23] the outcome of angle of tilt on production of heat, metal fow behaviour, and feld temperature during friction stir with regard to tool pin shape impact on FSW, it is clear from the literature that FSW is produced by changing the speed of the tool, and the tool tilt angle is either fxed or not considered [20][21][22]. Tere is extremely little literature that has reviewed the FSW regarding the efect of tool tilt angle [23][24][25]. For instance, Zhai et al [23] the outcome of the angle of tilt on the production of heat, metal fow behaviour, and feld temperature during friction stir welding was explored both experimentally and numerically.…”

Section: Introductionmentioning

confidence: 99%

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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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Section: Microstructure and Macrostructure Tablementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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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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“…Joints manufactured with the following specifications had the highest load carrying capacity such as pin length 1.5 mm, welding speed 200 mm/min and tool rotational speed 1,200 rpm. Singh et al (2021a) investigated the major impact of tool pin profile on mechanical and microstructural characteristics of friction stir welded AA2024 joints. The pin profiles used to make the AA2024 joints includes conical, pedal, cylindrical with thread, triangular, square and pentagonal pins.…”

Section: Introductionmentioning

confidence: 99%

Impact of ultrasonic vibration power and tool pin profile on mechanical and microstructural behaviour of friction stir welded dissimilar aluminium alloy joints

K.P.¹,

J.²,

Shanmugam³

2023

AEAT

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Purpose The purpose of this paper is to investigate the impact of ultrasonic vibration (UV) and tool pin profile on mechanical properties and microstructural behaviour of AA7075-T651 and AA6061-T6 joints was analysed. Design/methodology/approach The joints were fabricated using three different tool pin profiles such as cylindrical, square and triangle. For each tool pin profile, two different UV powers of 1.5 kW and 2 kW were used. Findings On both the advancing and retreating sides of the weld, the thermo-mechanically affected zone has the lowest microhardness. In all joints, the tensile fracture locations match to the minimum hardness values. Field emission scanning electron microscope fractography of tensile tested specimens reveals heterogeneous modes of brittle, shear and ductile fracture. Three-point bending analysis was performed to determine the ductility and soundness of the weld joint. The acoustic softening effect of UV, as well as the static and dynamic ratio of tool pin profile, plays an important role in determining the material flow and mechanical behaviour of the joint. Practical implications Dissimilar aluminium joining fascinates many applications like aircraft, aerospace, automobiles, ship building and electronics, where fusion welding is a very intricate process because of the deviation in its physical and chemical properties. Originality/value From this study investigation, it is found that the square pin profiled tool with 2 kW UV power produces metallurgical defect-free and mechanically sound weld with maximum tensile strength, hardness and bending load of 297 MPa, 151HV and 3.82 kN, respectively.

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“…FSW procedure includes heating the ends of two parts of the joint to a temperature below the minimum melting point of the base metals [5,6]. This feature gave FSW an advantage over fusion techniques for welding many metals, such as welding aluminium, copper, and titanium alloys [7][8][9]. Welding different metals, such as aluminium and copper, are highly important for reducing weight by replacing copper with aluminium, saving welding costs, and considering the safety factor of welded joints [10,11].…”

Section: Introductionmentioning

confidence: 99%

Effect of Friction Stir-Welding Tool Pin Geometry on the Characteristics of Al-Cu Joints

Elmetwally¹,

Abdelhafiz²,

El-Sheikh³

et al. 2023

Applied Engineering Letters

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Friction stir welding (FSW) is considered to be a solid-state welding technique that is suitable well for joining copper and aluminium sheets. The current experimental study focused on the influence of pin geometry on the micro-structural and mechanical characteristics of such joints. An aluminium sheet was welded to a copper sheet at a constant rotational speed of 1280 rpm and a traverse speed of 16 mm/min. The welding tool was made from W302 steel with four different pin profiles: straight cylindrical, tapered, triangular, and squared. When the squared pin was utilized, the optimum joint was produced as the specimen prepared from this joint had a defectfree structure and a tensile strength of 107.2 MPa (80% of the aluminium strength). On the other hand, the pin with a triangular profile was utilized to determine the minimum characteristics, and the specimens' structures revealed dislocations, separations, and cracking in copper particles inside the aluminium matrix. The microhardness trend is consistent across all specimens. Moreover, specimens welded using squared and cylindrical pin tools have the maximum hardness values obtained at the stir zone of the copper side. The inspection of fractured surfaces showed well mixing between aluminium and copper as well as ductile fracture when a squared pin tool was used while it showed a combination of ductile fracture and brittle fracture for the specimen welded with a triangular pin tool. Based on this study, the use of the squared pin tool gives the most favourable results compared with other pin profiles.

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Role of Various Tool Pin Profiles in Friction Stir Welding of AA2024 Alloys

Cited by 14 publications

References 41 publications

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

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

Impact of ultrasonic vibration power and tool pin profile on mechanical and microstructural behaviour of friction stir welded dissimilar aluminium alloy joints

Effect of Friction Stir-Welding Tool Pin Geometry on the Characteristics of Al-Cu Joints

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