Heat transfer and material flow in friction stir welding

Bag, Swarup; Yaduwanshi, Deepak Kumar; Pal, Surjya K.

doi:10.1533/9780857094551.21

Cited by 9 publications

(4 citation statements)

References 36 publications

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“…Several studies have shown that frictional heat from the tool shoulder surface comprises 80-90% of the total process heat [18], [19]. Therefore, the experimental results obtained were supported by previous studies [20], [21], [22], [23], [24], [25], [26]. To try to understand the nature of the heat produced by shoulder friction, the parameters that may Succeed Fail be influencing the success ratio of FSW welds with respect to the design of each tool have been briefly analysed at a mathematical level.…”

Section: Resultssupporting

confidence: 83%

Wire-based Direct Energy Deposition (DED-wire) used as additive manufacturing technology for industrial Inconel 718 tools for Robotic Friction Stir Welding (R-FSW)

ALVAREZ,

Leal,

Pastor-Cintas

et al. 2024

Preprint

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The Inconel 718 nickel-base superalloy (IN718) is a high-strength and highly corrosion-resistant material used in several industrial applications. Its high mechanical and chemical properties make this material a focus of interest for additive manufacturing because IN718 is expensive, and a heat treatment post-manufacturing is typically needed. This greatly increases costs and production time, with a loss of material due to machining of the material blocks that can be avoided with additive manufacturing by providing material only where needed. For the Robotic Friction Stir Welding (R-FSW) a tool with high performance is demanded. It is because the tool is inserted and moved forward between the two work pieces to join. Frictional heat is generated between the wear-resistant tool and the two workpieces. This means that the tool material is subjected to high temperature, normal oxygen conditions and high mechanical stress. Furthermore, the tool's design usually has to change very often depending on the type of material to be welded and the thickness. In this work, IN718 tools for the R-FSW process have been additively manufactured with optimized parameters under high manufacturing speed conditions and with the advantages of using metal wire. As built and heat-treated conditions heat have been microstructural and mechanically analyzed. Finally, different tool designs of the same IN718 DED-wire manufactured material have been tested in several friction stir welds, analyzing their behavior and the relation with the successful welds. The optimal thermal status and design for the IN718 FSW tools has been determined.

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Section: Resultssupporting

confidence: 83%

Wire-based Direct Energy Deposition (DED-wire) used as additive manufacturing technology for industrial Inconel 718 tools for Robotic Friction Stir Welding (R-FSW)

ALVAREZ,

Leal,

Pastor-Cintas

et al. 2024

Preprint

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“…The stir tool affects the frictional heat generation and plastic material flow. Compared to similar FSW, the stir tool plays a more important role in the dissimilar FSW process [34,73]. The stir tool consists of two parts, namely the shoulder and the pin.…”

Section: Effect Of Stir Toolmentioning

confidence: 99%

Friction stir welding of aluminium to magnesium: A critical review

Mao

et al. 2022

Materials Science and Technology

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Aluminium/magnesium hybrid structure has been paid increasing attention recently due to its excellent lightweight. However, aluminium/magnesium is easy to form pores, cracks, and massive intermetallic compounds when fusion welding is used. Friction stir welding is as solid-state method, which avoids the above-mentioned problems caused by fusion welding. This article systematically reviews recent progress in friction stir welding of aluminium/magnesium from temperature field, metal flow and weld composition. Moreover, the effects of control parameters on the temperature field, metal flow and weld composition are discussed objectively, respectively. Finally, this work puts forward some problems that need to be solved urgently in the future based on summarising the recent progress of friction stir welding of aluminium/magnesium.

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“…[18][19][20] Besides, other researchers studied the joint design, which significantly affects the material flow pattern, temperature distribution, and the microstructure evolution of material. [21][22][23] FSW of materials having low thermal conductivity, such as titanium alloys, is a challenge. 16,[24][25][26][27] One of the unique techniques used to meet this challenge and give the ability to weld different joint configurations is SSFSW.…”

Section: Introductionmentioning

confidence: 99%

An investigation on mechanical and microstructural evolution of stationary shoulder friction stir welded aluminum alloy AA7075-T651

Hammad

Ahmed

Lü³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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The stationary shoulder friction stir welding (SSFSW) technique promotes new opportunities for welding material. In the current work, a special setup of SSFSW was designed and manufactured in only three parts according to the homemade friction stir welding (FSW) machine dimensions and specifications. This setup with minimum parts is easily adjustable beside it facilitates fast control of the tool pin length. This gives the design more advantages than the previous designs published for the same purpose. Two different parameters were used with the SSFSW setup to butt weld samples of AA7075-T6 of 5 mm thick. Various welding travel speeds of 25, 50 mm/min to 75 mm/min and different values of Z-force of 20, 25 KN, and 50 KN were used to evaluate the effect of the SSFSW parameters on the joints quality and properties. The results confirmed that sound joints were produced without internal or surface defects. In addition, the joints are characterized with a smooth surface finish compared to the conventional FSW joints. A narrow heat affected zone around the nugget due to the elimination of heat generation by the shoulder. The tensile strength of welded samples increases with increasing the vertical force with the maximum tensile strength of 418.7 MPa at a rotational speed of 600 rpm, a welding speed of 50 mm/min, and 50 KN Z-force. This implies that the vertically applied force upon SSFSW is an important parameter in controlling the joint properties. Analysis of the hardness distribution across the weld cross-section shows a slight reduction in the heat-affected zone.

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Heat transfer and material flow in friction stir welding

Cited by 9 publications

References 36 publications

Wire-based Direct Energy Deposition (DED-wire) used as additive manufacturing technology for industrial Inconel 718 tools for Robotic Friction Stir Welding (R-FSW)

Wire-based Direct Energy Deposition (DED-wire) used as additive manufacturing technology for industrial Inconel 718 tools for Robotic Friction Stir Welding (R-FSW)

Friction stir welding of aluminium to magnesium: A critical review

An investigation on mechanical and microstructural evolution of stationary shoulder friction stir welded aluminum alloy AA7075-T651

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