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Since its inception no one has done analysis and design of FSW tool. Initial dimensions of FSW tool are decided by educated guess. Optimum stresses on tool pin have been determined at optimized parameters for bead on plate welding on AZ31B–O Mg alloy plate. Fatigue analysis showed that the chosen FSW tool for the welding experiment has not ∞ life a...
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This paper investigates the effect of different tool pin morphologies on the inter-mixing capability, microstructure, mechanical properties, corrosion, fracture, and wear behaviors of the dissimilar friction stir welded AA6061-T6 alloy--Al 20wt% Mg2Si composite. Grooved shoulder tools with varying pin profiles such as tapered cylindrical, threaded...
Citations
... The experimental data was gathered from published sources [20] . The tool's proportions are determined based on previous experience. ...
Friction stir welding is a solid-state joining process used to weld various materials. Tool life is an important consideration when welding strong metals with the Friction stir welding technique (FSW). The current research aims to calculate tool life by mathematical derivation and simulation using ANSYS transient structural analysis. There are two tool materials and five-pin profiles to consider. The calculated tool life using mathematical formulation is within 15% of the simulation outcome. Further changes are made to the simulation to make the tool life estimate more realistic under FSW’s operation. PcBN tool has superior mechanical properties over the tungsten carbide tool, so the procedure started with the tungsten carbide tool. The conical pin profile is giving 31466 cycles of tool life, which is 70 min run time while working at 450 rpm rotational speed. As a result, for high-strength materials joining, the tool must be chosen based on tool life parameters. The addition of a 1.5 mm fillet at the pin-to-shoulder junction has improved the tool life by 1147 cycles. The PcBN tool is simulated with a conical tool with new pin profiles of conical with grooves and cylindrical fillet with grooves. The maximum tool life of 94018 cycles is obtained for the conical PcBN tool.
... The used vibrating tool head is made of titanium with (22 mm tip diameter and 100 mm length) and is used to generate ultrasonic vibration waves at a frequency of 24 kHz, a power of 85 watt and adjustable amplitude up to 100, and the ultrasonic processor (model up 400S) is used in these experiments to obtain the required ultrasonic vibration. The used FSW tool is shown in Fig. (1-a), with various quantities [29] and the operation of welding is shown in Figs,(1,b -c). From this figure, it can calculate all the resultant forces during welding as follow;; Fig. (1-a) The forces analysis at the FSW tool. ...
... From Fig. (1-a) (1-c) The operation of welding. Fig. (1) The FSW tool and the operation of welding, [29]. ...
In this century, innovation and technology are required to fabricate the hybrid joint of metal and polymers. Due to their lightweight and anti-corrosion properties, the mixed components are increasingly used to produce lightweight hybrid structures such as aerospace and automobiles. It is essential to develop welding techniques for joining dissimilar materials and instead use them in engineering structures. The bonding mechanism of the weld joint has varied depending upon the welding process. In the present review, the bonding mechanism of various hybrid joints like Friction stir welding (FSW), Friction stir spot joining, Friction riveting, laser welding, ultrasonic welding and induction welding is discussed in detail. The defects observed in the different welding process is discussed in details. The mechanical properties and microstructure analysis of different hybrid joints are reviewed in detail for a different combination of hybrid joints.
Friction stir processing tool is designed based on the torque capacity of the CNC milling motor by analytical models. The tool shoulder of diameter 20 mm and taper pin of average diameter 4 mm are obtained from yield strength and shear strength of the material respectively. The structural and fatigue analysis of tool resulted in negligible deformation, low stress and high fatigue life. The simulation resulted in no deformation of the tool and it is also shown that there is sufficient plastic deformation at the stir zone, and hence the designed tool can be used to process Mg alloys experimentally to fabricate the surface composites successfully.
Even though friction stir welding was invented long back (1991) by TWI England, till now there has no method or procedure or approach developed, which helps to obtain quickly optimum or exact parameters yielding good or sound weld. An approach has developed in which an equation has been derived, by which approximate rpm can be obtained and by setting range of rpm ±100 or 50 rpm over approximate rpm and by setting welding speed equal to 60 mm/min or 50 mm/min one can conduct FSW experiment to reach optimum parameters; one can reach quickly to optimum parameters, i.e. desired rpm, and welding speed, which yield sound weld by the approach. This approach can be effectively used to obtain sound welds for all similar and dissimilar combinations of materials such as Steel, Al, Mg, Ti, etc.
