Experimental defect analysis and force prediction simulation of high weld pitch friction stir welding

Crawford, Reginald; Cook, Gerald; Strauss, Alvin M.; Hartman, Daniel A.; Stremler, Mark A.

doi:10.1179/174329306x147742

Cited by 84 publications

(57 citation statements)

References 19 publications

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“…At a constant rotational speed, an increase in the travel speed leads to wormhole initiation near the bottom of the weld. Furthermore, the size of the wormholes increases with the travel speed [117] because of inadequate material flow towards the bottom of the weld. There are indications that the travel speed to rotational speed ratio is an important variable in the formation of the wormhole defect [118].…”

Section: Defectsmentioning

confidence: 99%

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Recent advances in friction-stir welding – Process, weldment structure and properties

Nandan

DebRoy

Bhadeshia

2008

Progress in Materials Science

1,823

911

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Friction stir welding is a refreshing approach to the joining of metals. Although originally intended for aluminium alloys, reach of FSW has now extended to a variety of materials including steels and polymers. This review deals with the fundamental understanding of the process and its metallurgical consequences. The focus is on heat generation, heat transfer and plastic flow during welding, elements of tool design, understanding defect formation and the structure and properties of the welded materials.

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Section: Defectsmentioning

confidence: 99%

“…Significant heterogeneity in heat generation at that interface can lead to defect formation in the form of excess flash due to surface overheating [117,120].…”

Section: Defectsmentioning

confidence: 99%

Recent advances in friction-stir welding – Process, weldment structure and properties

Nandan

DebRoy

Bhadeshia

2008

Progress in Materials Science

1,823

911

View full text Add to dashboard Cite

show abstract

“…Hence, attention should be paid to ensure suitable processing conditions, in order to avoid potential defects in the weld nugget zone (WNZ), the TMAZ or sometimes at the WNZ/TMAZ interface (Crawford et al 2006). For example, an 'onionring' characteristic of the central nugget region, where the most severe deformation occurs, is a result of the way in which the material is deposited, from the front to the back, by the threaded tool.…”

Section: Process Variablesmentioning

confidence: 99%

Investigation of weld defects in friction-stir welding and fusion welding of aluminium alloys

Kah

Rajan

Martikainen

et al. 2015

Int J Mech Mater Eng

174

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Transportation industries are obliged to address concerns arising from greater emphasis on energy saving and ecologically sustainable products. Engineers, therefore, have a responsibility to deliver innovative solutions that will support environmental preservation and yet meet industries' requirements for greater productivity and minimised operational costs. Aluminium alloys have successfully contributed to meeting the rising demand for lightweight structures. Notable developments in aluminium welding techniques have resolved many welding related problems, although some issues remain to be addressed. The present study attempts to give an overview of the key factors related to the formation of defects in welding methods commonly used with aluminium alloys. First, a concise overview of defects found in friction-stir welding, laser beam welding and arc welding of aluminium alloys is presented. The review is used as a basis for analysis of the relationship between friction-stir welding process parameters and weld defects. Next, the formation and prevention of the main weld defects in laser beam welding, such as porosity and hot cracking, are discussed. Finally, metallurgical aspects influencing weld metal microstructure and contributing to defects are tabulated, as are defect prevention methods, for the most common flaws in arc welding of aluminium alloys.

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“…The severity of defects was noted to increase concomitantly with weld pitch. The occurrence of the wormhole running along the weld length on the advancing side of the weld nugget is a consequence of insufficient material transport around the tool pin to the advancing side that results in insufficient consolidation of the plasticized material (Crawford et al, 2006). Figure 3 illustrates the effect of the weld pitch on the microhardness profile across the welded joints.…”

Section: Fsw Process Window Investigation For Butt-weld Configurationmentioning

confidence: 99%

Process operational windows and industrialization scenarios for assembly of large aluminium structures by robotic friction stir welding

Wanjara¹,

Monsarrat²,

Larose³

2015

Can. Aeronaut. Space J.

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Abstract. In this work, friction stir welding (FSW) of 3.18 mm thick AA6061-T6 sheets in the butt-and lap-joint configuration was investigated with the objective of industrializing the process using low-cost serial industrial robots. The influence of weld pitch on the welding defects, microstructure, hardness, and bend performance of butt and lap welds was examined to identify process operational windows for both joint types. In parallel with these trials, a methodology based on kinetostatic analysis was developed to identify and evaluate viable robotized scenarios for FSW. On the basis of the experimental FSW process development results, this methodology was then applied to identify optimized FSW scenarios for the fabrication of large integrated AA6061 structural components with stringer-to-skin and skin-to-skin joints. Candidate workcell layouts are also presented.Résumé. Dans ce travail, le soudage par friction malaxage (mieux connu sous l'acronyme FSW pour Friction Stir Welding) de feuilles d'aluminium 6061-T6 d'une épaisseur de 3.18 mm dans les configurations bout-à-bout et par recouvrement a été étudié dans l'optique d'industrialiser le procédé via l'utilisation de robots sériels industriels à bas coû t. L'influence du pas de soudage (weld pitch) sur les défauts de soudage, la microstructure, la dureté et la performance en flexion a été examinée afin d'établir les fenêtres opératoires du procédé pour les deux types de soudure. En parallèle de ces essais expérimentaux, une méthodologie basée sur l'analyse cinétostatique a été développée afin d'identifier et d'évaluer des scénarios viables d'implantation du soudage par friction malaxage robotisé. Cette méthodologie a par la suite été appliquée en utilisant les résultats des tests expérimentaux de soudage afin d'identifier des scénarios d'implantation optimisés pour l'assemblage de composants structurels intégrés de grande dimension en AA60601 comprenant à la fois des joints lisse sur revêtement et revêtement sur revêtement. Des scénarios d'implantation potentiels ont été identifiés et sont présentés.

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Experimental defect analysis and force prediction simulation of high weld pitch friction stir welding

Cited by 84 publications

References 19 publications

Recent advances in friction-stir welding – Process, weldment structure and properties

Recent advances in friction-stir welding – Process, weldment structure and properties

Investigation of weld defects in friction-stir welding and fusion welding of aluminium alloys

Process operational windows and industrialization scenarios for assembly of large aluminium structures by robotic friction stir welding

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