China
Africa
Explore chapters and articles related to this topic
Development of Friction-Assisted Processes
Published in B. Ratna Sunil, Surface Engineering by Friction-Assisted Processes, 2019
Development of friction stir spot welding (FSSW) has offered several advantages to join sheets and plates without melting the base materials. FSSW is completed in three steps including plunging, stirring and retreating [14]. In the initial step, the rotating non-consumable tool is plunged into the stack of the plates and penetrated until the tool shoulder is touched the surface of the top plate. In the second step, the rotating tool is allowed to stir for sufficient time to facilitate appropriate mixing of the material from both the sheets. In the third step, the rotating tool is retreated by leaving a region of spot welded which contains a sound metallurgical joint. However, after retreating, the tool leaves an unfilled hole in the center of the stir zone that may decrease the mechanical strength. Later on, several variations were proposed by different authors to close the cavity produced during the third step by modifying the tool design [15–18]. Development of FSSW addressed several issues such as joining non-ferrous metals which usually results in brittle phases in fusion-based welding processes. The technology has been already transferred and commercially used in automobile and aerospace applications.
Hybrid Joining Processes
Published in R. Ganesh Narayanan, Jay S. Gunasekera, Sustainable Material Forming and Joining, 2019
V. Satheeshkumar, R. Ganesh Narayanan
Like fusion welding, solid-state welding methods can also be combined either with one of the fusion welding or solid-state welding methods for joining. Use of solid-state welding methods minimizes the use of harmful consumables and fluxes, thus improving the sustainability of the process and product. The hybrid variety helps in enhancing the joint quality. In this context, friction stir-based methods like friction stir welding, friction welding, friction stir spot welding, friction riveting, diffusion bonding, and other methods like magnetic pulse welding are used in various industrial applications (Martinsen et al., 2015). Some of the hybrid varieties and benefits toward sustainable manufacturing are discussed in this section.
Effect of Fe particles on the microstructural evolution and mechanical properties of friction welded Al-Cu components
Published in Australian Journal of Mechanical Engineering, 2022
Abin Joe Alex, Vaira Vignesh R., R. Padmanaban, M. Govindaraju
Siddharth, Senthilkumar, and Chandrasekar (2017) studied the effect of welding parameters (tool rotation speed, plunge depth, dwell time) on friction stir spot welded non-heat treatable Al alloy (AA5052) with a Cu alloy (C27200). The study utilised a response surface methodology to optimise the welding for obtaining a maximum tensile shear failure load and minimum hardness value. The result indicated that the optimum parameters for friction stir spot welding of AA5052-C27200 were 1350 rpm with a plunge depth of 1.95 mm and a dwell time of 13.5 seconds. Besides, the study concluded that friction stir spot welding of such alloys with desirable properties is not practicable at a low tool rotation speed. Sahin (2010) friction welded pure Cu with Al-Zn alloy and optimised welding parameters such as friction pressure, upset pressure, and dwell time using regression analysis. The investigation revealed that the formation of a grey layer due to uneven dissipation of heat, and the presence of Al-Cu phases (Al2Cu, AlCu, and Al4Cu9) reduced the tensile strength of the joint.
Tribiological investigation and optimization of friction stir spot welding of dissimilar metals by LSSM-ANN method
Published in Mechanics Based Design of Structures and Machines, 2022
Ajit Kumar Pattanaik, Kamal Pal, Debadutta Mishra
Friction stir spot welding is one of the most relevant friction-based joining technologies developed in parallel to the Friction Stir Welding process, it can be utilized for the joining of two dissimilar metals. Gerlich et al. (Gerlich, Su, and North 2005) investigated the mechanism of tool penetration during friction stir spot welding of aluminum alloy and magnesium sheet materials and explained the progression of wear events, from mild wear to severe wear and melt wear is created at the base of the rotating pin. The study about the weld parameters and constraints are necessary for the formation of effective weld quality. Paoletti et al. (Paoletti, Lambiase, and Di Ilio 2016) studied the variation of dwell time, tool plunge rate and rotational speed. Mechanical characterization and dimensional analysis of the joints were performed to assess the influence of the process parameters of the joint quality under-considered processing conditions. According to the achieved results, using low values of the plunging speed has beneficial effects on both the process (reduction in the force and torque) and the mechanical behavior of the joints. Increasing the tool rotational speed results in reduced processing forces, higher material mixing, and temperature. The dwell time has a negligible effect on developing forces while it highly influences the material temperature, the dimension of the welded region and consequently the mechanical behavior of the joint.
Processes for environmentally friendly and/or cost-effective manufacturing
Published in Materials and Manufacturing Processes, 2021
The recent advances of USW for Mg alloys have been reviewed by Rubino et al. USW is suitable for dissimilar and similar joining of magnesium alloys. Magnesium alloys are recently joined with novel processes including friction stir spot welding (FSSW), USW and friction stir welding. USW is an effective approach for the joining of thin metal components, and has the significant advantage of low-energy input over FSSW and conventional resistance spot welding processes. USW is especially attractive to the automotive industry for dissimilar welding. Compared to the conventional resistance spot welding, ultrasonic-assisted friction stir spot welding has significant benefits including enhanced physical and mechanical properties, and decreased energy requirements.[239]