A Review of Force Control Techniques in Friction Stir Process

Busu, Nur'Amirah; Jaffarullah, M. Shamil; Low, Cheng Yee; Shaari, Mohd Saiful Bahari; Armansyah, Armansyah; Jaffar, Ahmed

doi:10.1016/j.procs.2015.12.331

Cited by 22 publications

(13 citation statements)

References 14 publications

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“…The FSW parameters that largely affect the flow stresses and traverse force evolution are the tool traverse speed, tool rotational speed, and shoulder diameter, which all significantly affect the heat input during processing. 36 The traverse force data were analyzed and the results of the analysis of variance are given in Table 4, which reveal that the effects of all the individual factors (A, B, and C) and interactions of A × B and A × C significantly affect the traverse force during FSW. Among all the parameters and interactions, factor C found to have the largest contribution affecting the traverse force followed by B, A × C, A × B, A , and B × C .…”

Section: Resultsmentioning

confidence: 99%

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

Siddiquee

Pandey

Abidi

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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Welding AISI 304 stainless steel is challenging, especially as fusion-based welding processes (such as arc welding) severely undermine the material's corrosion resistance due to sensitization. Solid-state friction stir welding is one of the most suitable alternatives. Friction stir welding of high-strength high-softening materials such as AISI 304 is difficult mainly because of the non-availability of affordable tools and tool life. In this study, AISI 304 stainless steel was successfully butt-welded by friction stir welding. The experiments were performed using Taguchi's L27 orthogonal array. Shoulder diameter, tool r/min, and traverse speed were selected as the most influential welding parameters. A Tungsten Carbide (WC) tool was employed with a tapered pin profile. Defect-free joints were fabricated successfully for all the welding conditions. Microstructural examinations using optical microscopy and scanning electron microscopy revealed significant grain refinement in the stir zone and the presence of distinct structural features such as stepped, dual, and ditch in various characteristics zones. The presence of precipitates was also observed in samples and was confirmed via energy-dispersive X-ray spectroscopy analysis. The in-process traverse force was measured by a special arrangement of force measuring units attached to the work fixture. The traverse force data were analyzed and optimized. The results of an analysis of variance reveal that the traverse speed was the most important parameter, followed by tool r/min, interaction between the tool shoulder diameter and traverse speed, interaction between the tool shoulder diameter and tool r/min, and, finally, the tool r/min.

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Section: Resultsmentioning

confidence: 99%

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

Siddiquee

Pandey

Abidi

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…In this study, control of the axial force, travel force and torque were studied. The drawbacks of the control strategies were mentioned and techniques to improve the weld quality were suggested (Busu et al , 2015).…”

Section: Discussion On Control Schemes Adopted For Friction Stir Weldingmentioning

confidence: 99%

Fundamentals and review on material science, control theory and parametric inter-dependencies during friction stir welding of aluminium metal matrix composites

Rahul

Sharmila

2019

WJE

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Purpose The purpose of this study is to present a comprehensive review of the fundamental concepts and terminologies pertaining to different types of aluminium metal matrix composites, their joining techniques and challenges, friction stir welding (FSW) process, post-welding characterizations and basic control theory of FSW, followed by the discussions on the research reports in these areas. Design/methodology/approach Joining of aluminium metal matrix composites (Al-MMC) poses many challenges. These materials have their demanding applications in versatile domains, and hence it is essential to understand their weldability and material characteristics. FSW is a feasible choice for joining of Al-MMC over the fusion welding because of the formation of narrow heat affected zone and minimizing the formation of intermetallic compounds at weld interface. The goal in FSW is to generate enough thermal energy by friction between the workpiece and rotating tool. Heat energy is generated by mechanical interaction because of the difference in velocity between the workpiece and rotating tool. In the present work, a detailed survey is done on the above topics and an organised conceptual context is presented. A complete discussion on significance of FSW process parameters, control schemes, parameter optimization and weld quality monitoring are presented, along with the analysis on relation between the interdependent parameters. Findings Results from the study present the research gaps in the FSW studies for joining of the aluminium-based metal matrix composites, and they highlight further scope of studies pertaining to this domain. Originality/value It is observed that the survey done on FSW of Al-MMCs and their control theory give an insight into the fundamental concepts pertaining to this research area to enhance interdisciplinary technology exploration.

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“…Beside friction generated heat, heat is also created by severe plastic deformation of the material [3]. It is proven that axial force increases heat generation, reduces isotherms density and expands Heat Affected Zone (HAZ) [27].…”

Section: Fsp Process Parametersmentioning

confidence: 99%

“…Increasing axial force directly affects the surface qualityimproving hardness and increased mechanical properties at stirred zone [26]. Important factor regarding axial force is its consistency in order to produce good microstructure quality, therefore force control is of the utmost importance [27].…”

Section: Axial Forcementioning

confidence: 99%

Review of Friction Stir Processing (FSP) Parameters and Materials for Surface Composites

Milenković¹,

Živić²,

Jovanovic³

et al. 2021

Tribol. Ind.

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This paper presents a review of important aspects related to the Friction StirWelding and Friction Stir Processing (FSW/FSP) concepts. The FSP, as a variation of the FSW, uses the same principle, but instead of the material joining, the FSP focuses on a surface modification aiming at improving surface properties of the substrate material. Thin surface composites can be made either by using grooves or drilled holes. FSP process parameters have been elaborated: axial force, rotational and traverse speed, tilt angle, insertion depth and tool geometry, as well as number of passes. Review of the used materials in fabrication of composites by using FSP is shortly presented. Effects of the FSP on mechanical properties have been discussed: effects on the microstructure, hardness and wear properties, tensile strength, and fracture and defects formation. FSP has evolved as an efficient method to modify surface structures, especially important for metallic materials that exposed to different harsh conditions, and further research will enable its wider use in industry.

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A Review of Force Control Techniques in Friction Stir Process

Cited by 22 publications

References 14 publications

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

Fundamentals and review on material science, control theory and parametric inter-dependencies during friction stir welding of aluminium metal matrix composites

Review of Friction Stir Processing (FSP) Parameters and Materials for Surface Composites

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