Characteristics of Potential Sources - Vertical Force, Torque  and Current on Penetration Depth for Quality Assessment  in Friction Stir Welding of AA 6061 Pipes

El-Kassas, Ahmed M.; Sabry, Ibrahim; Mourad, Abdel‐Hamid I.; Thekkuden, Dinu Thomas

doi:10.15866/irease.v12i4.16362

Cited by 15 publications

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“…Novel techniques are suggested in such cases to join using the friction stir welding process [21][22][23]. Parameters play a crucial role in the case of friction stir welding [24]. Weld porosity and slag inclusion defects are formed due to the rapid oxidation during the fusion welding [25].…”

Section: Introductionmentioning

confidence: 99%

Optimization of metal inert gas-welded aluminium 6061 pipe parameters using analysis of variance and grey relational analysis

2020

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It is an underlying fact for the case of the joining process especially welding to have optimized parameters in order to achieve joints with outstanding mechanical characteristics. In the current work, aluminium 6061 pipes were welded using gas metal arc welding process with appropriate ER 4043 electrode and argon shielding gas. Optimum welding parameters (namely, current, voltage and travel speed) are investigated using analysis of variance ANOVA and grey relational analysis GRA statistical approaches. High tensile strength and low corrosion rate were set as required characteristics of quality welds. Since there are two responses and two objectives, multiple-criteria decision-making approach-GRA, and ANOVA are performed. Optimal parameters from these statistical approaches are converged to 110 A, 19 V and 3 cm/ min, respectively. It is deduced from this study that the optimal parameters are convergent irrespective of the two used techniques for the investigated experimental data.

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Section: Introductionmentioning

confidence: 99%

Optimization of metal inert gas-welded aluminium 6061 pipe parameters using analysis of variance and grey relational analysis

2020

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“…It is shown that from traditional FSW to UFSW, grain size is decreased. It has been It's been deliberate The complex recrystallization and recovery of aluminum alloys plays an important role in the grain size of the welded region in FS [26], [27]; hus, at the same time, the application of vibration and cooling results in high angle grain boundaries because higher dislocation density and dynamic recovery and finally fine grain size. This implied the need to examine the mechanical characteristics of the joint because of the unusual apportionment of the material in the WZ.…”

Section: Microstructural Characterizationmentioning

confidence: 99%

Investigation of microstructure and mechanical characteristic of underwater friction stir welding for Aluminum 6061 alloy – Silicon carbide (SiC) metal matrix composite

Sabry

2021

JMES

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Demand for metal matrix composites (MMCs) is expected to increase in these applications, such as ‎in the aerospace and automotive sectors. Adequate joining techniques, which are important for ‎structural materials, have not yet been developed for Metal Matrix Composite (MMCs), however. ‎This work aimed to demonstrate the feasibility of ‎friction stir welding (FSW) and ‎underwater friction stir welding (UFSW) for joining Al 6061/5, Al 6061/10, and Al ‎‎6061/18 wt. %SiC composites have been produced by utilizing reinforce stir casting technique. Two ‎rotational ‎speeds,1000and 1800 rpm, and traverse speed 10mm \ min were examined. Specimen ‎composite plates 10 mm thick have been successfully welded by FSW. For FSW and UFSW, a tool ‎made of high-speed steel (HSS) with a conical pin shape was used. The result revealed that the ‎ultimate tensile strength of the welded joint by FSW and UFSW at rotation speed 1800 rpm for (Al ‎‎6061/18 wt. ‎‎% SiC composites) was 195 MPa and 230 MPa respectively. The ultimate ‎tensile ‎strength of the welded joint by FSW and UFSW (Al 6061/18 wt.% SiCe composites) was 165 MPa ‎and 180 MPa at rotation speed ‎‎1000 rpm respectively. The microstructural assessment showed that due ‎to larger grain sizes at FSW and UFSW, most of the fractures are located in the thermal ‎mechanically affected zone (TMAZ) adjacent to the weld nugget zone (WNZ). It is observed that in ‎failure, most of the joints show ductile features. As the volume fraction of SiC (18 wt.%) increases, ‎the friction stir welded and underwater friction stir welded efficiency decreases.

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“…In order to reduce the defects of the FSW joint and increase the mechanical strength, a study was conducted on TRS, WS, plunge speed, dwell time, PD, and TPD, which are non-tool process parameters. Process parameters have been shown to affect the mechanical performance and microstructure [ 26 , 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 ]. The joint strength has been shown to increase with increasing TPD [ 31 , 32 , 33 , 34 ].…”

Section: Introductionmentioning

confidence: 99%

“…Process parameters have been shown to affect the mechanical performance and microstructure [ 26 , 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 ]. The joint strength has been shown to increase with increasing TPD [ 31 , 32 , 33 , 34 ]. In addition, research on various bonding methods between various materials is in progress.…”

Section: Introductionmentioning

confidence: 99%

Effect of Microstructure and Tensile Shear Load Characteristics Evaluated by Process Parameters in Friction Stir Lap Welding of Aluminum-Steel with Pipe Shapes

2022

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In recent years, friction stir welding (FSW) of dissimilar materials has become an important issue in lightweight and eco-friendly bonding technology. Although weight reduction of low-rigidity parts has been achieved, the weight reduction has been minimal because high-rigidity parts such as chassis require the use of iron. Considering the difficulty of welding a pipe shape, it is necessary to understand the effect of process parameters on mechanical performance. As a result of the study by various process parameters affecting the joint between aluminum and steel in the shape of a pipe, it can be seen that the tool penetration depth (TPD) has the most important effect on the tensile shear load (TSL). However, the effect of TPD on intermetallic compound (IMC), which has the most important influence on fracture, has not been well established. In this study, the effect of process parameters on IMC thickness and TSL in FSW of A357 cast aluminum and FB590 high tensile steel was investigated to reduce the weight of the torsion beam shaft of an automobile chassis. After the FSWed experiment, measurements were performed using an optical microscope and scanning electron microscopy (SEM) to investigate the microstructure of the weld. The formation of an IMC layer was observed at the interlayer between aluminum and steel. TPD is a major factor in IMC thickness variation, and there is a direct relationship between IMC thickness reduction and TSL increase, except for certain sections where the welding speed (WS) effect is large. Therefore, in order to improve mechanical properties in friction stir lap welding of aluminum and steel for high-rigidity parts, it is necessary to deepen the TPD at a level where flow is dominant rather than heat input.

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Characteristics of Potential Sources - Vertical Force, Torque and Current on Penetration Depth for Quality Assessment in Friction Stir Welding of AA 6061 Pipes

Cited by 15 publications

References 0 publications

Optimization of metal inert gas-welded aluminium 6061 pipe parameters using analysis of variance and grey relational analysis

Optimization of metal inert gas-welded aluminium 6061 pipe parameters using analysis of variance and grey relational analysis

Investigation of microstructure and mechanical characteristic of underwater friction stir welding for Aluminum 6061 alloy – Silicon carbide (SiC) metal matrix composite

Effect of Microstructure and Tensile Shear Load Characteristics Evaluated by Process Parameters in Friction Stir Lap Welding of Aluminum-Steel with Pipe Shapes

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