Toward optimum friction stir welding tool shoulder diameter

Arora, Amit; De, A.; DebRoy, T.

doi:10.1016/j.scriptamat.2010.08.052

Cited by 228 publications

(118 citation statements)

References 15 publications

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“…Although the reason for this behavior is not well understood, we found that welds with best properties corresponded to maximum utilization of the supplied torque in overcoming sticking. [22] In short, the previous research has established the importance of shoulder geometry in both the operation of the FSW process and the resulting properties of the welded joints.…”

Section: Introductionmentioning

confidence: 99%

Tool Geometry for Friction Stir Welding—Optimum Shoulder Diameter

Mehta

Arora

et al. 2011

Metall Mater Trans A

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101

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The most important geometric parameter in the friction stir welding (FSW) tool design is the shoulder diameter, which is currently estimated by trial and error. Here, we report a combined experimental and theoretical investigation on the influence of shoulder diameter on thermal cycles, peak temperatures, power requirements, and torque during FSW of AA7075-T6. An optimum tool shoulder diameter is identified using a three-dimensional, heat transfer and materials flow model. First, the predictive capability of the model is tested by comparing the computed values of peak temperature, spindle power, and torque requirements for various shoulder diameters against the corresponding experimental data. The change in the values of these variables with shoulder diameter is correctly predicted by the model. The model is then used to identify the optimum tool shoulder diameter that facilitates maximal use of the supplied torque in overcoming interfacial sticking. The tool with optimum shoulder diameter is shown to result in acceptable yield strength (YS) and ductility.

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Section: Introductionmentioning

confidence: 99%

Tool Geometry for Friction Stir Welding—Optimum Shoulder Diameter

Mehta

Arora

et al. 2011

Metall Mater Trans A

Self Cite

101

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“…[27] The critical temperatures for the dynamic recrystallization, deformation temperature (T), and the strain rate ð_ eÞ are related by the ZenerHollomon parameter (Z) equation: [26] …”

Section: Figures 5(a) Through (C)mentioning

confidence: 99%

Establishing Mathematical Models to Predict Grain Size and Hardness of the Friction Stir-Welded AA 7020 Aluminum Alloy Joints

Ilkhichi

Soufi

Hussain

et al. 2014

Metall Mater Trans B

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In this study, response surface methodology in conjunction with a central composite design was applied to predict the grain size and hardness of friction stir-welded AA 7020 aluminum alloy joints. For this purpose, three welding parameters, including tool rotational speed, traverse speed, and tool axial force, at five levels and 20 runs were considered. In order to validate the predicted models, the analysis of variance was performed. Hardness and microstructural features of the joints were investigated using microhardness test and optical microscopy, respectively. In addition, the influences of friction stir welding parameters on grain size and hardness of the joints were examined thoroughly. The analysis of variance results revealed that the developed models were significant and accurate to predict the responses. Furthermore, with increasing the heat input, the hardness of the joints decreased, where the grain size increased continuously. In addition, the optimized condition for achieving the lowest grain size and highest hardness of the joints was reached as 800 rpm, 125 mm/min and 8 kN.

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“…These make the torque to be insensitive to the traverse speed. In addition, optimum rotating tool design influences torque produced through the effect of sum of contact areas and contact conditions at the interface where it plays major role in plastic deformation or strain work distribution, material transportation or flow and toward process loads and work material temperature [41,48,49,50]. As temperature increases, work material temperature dependent shear stress plump and no longer display full solid properties thus reduces the torque at the rotating tool to work material interface and further reducing power and energy required to produce heat within the process.…”

Section: Effect Of Welding Parameters On Joint Qualitymentioning

confidence: 99%