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Artificial Neural Networks (ANNs) for Prediction and Optimization in Friction Stir Welding Process
Published in Ganesh M. Kakandikar, Dinesh G. Thakur, Nature-Inspired Optimization in Advanced Manufacturing Processes and Systems, 2020
Mukuna Patrick Mubiayi, Veeredhi Vasudeva Rao
The base material is the part far from the welded zone that has not been deformed and whose microstructure and mechanical properties are not affected by the heat from the welding process. The heat-affected zone (HAZ) is the area closer to the centre of the joint where the material is affected by a thermal cycle, resulting in the modification of the microstructure and/or the mechanical properties. Furthermore, in the HAZ, there is no occurrence of plastic deformation (Mishra and Mohaney, 2007). On the other hand, the thermomechanically affected zone (TMAZ) is situated in the area where the tool has produced material plastic deformation and the generated heat from the welding has produced some influence on the material. In the stir zone (weld nugget), full recrystallization takes place in the area previously occupied by the tool pin (Mishra and Mohaney, 2007). Friction stir welding technique has been used to join a large variety of materials in similar and dissimilar joint configurations (aluminium, copper, magnesium, titanium, and steel). Furthermore, the prediction of joint properties and the optimization of process parameters will broaden the application of this joining technique.
An Overview of Viable Unconventional Processing Methods for Advanced Materials
Published in T. S. Srivatsan, T. S. Sudarshan, K. Manigandan, Manufacturing Techniques for Materials, 2018
Subramanian Jayalakshmi, Ramachandra Arvind Singh, Rajashekhara Shabadi, Jayamani Jayaraj, Sambasivam Seshan, Manoj Gupta
Friction stir processing was developed based on friction stir welding, which is a solid-state joining process. It is an emerging metalworking technique that can provide localized modification and control of microstructure at the near-surface region of metallic components. During friction stir processing, a rotating tool with a shoulder and a pin is plunged into the surface of a work piece (desired base matrix) and moved along the length and breadth of the surface to be processed (Figure 9.34) (Gan et al. 2010; Lee et al. 2006a; Mahoney and Lynch 2016; Nithin Viswanath et al. 2016; Weglowski and Pietras 2011). To produce a composite surface, the surfaces are grooved and filled with the reinforcement powder, which are then processed by the passing friction stir processing tool (Gan et al. 2010; Lee et al. 2006a; Mahoney and Lynch 2016; Nithin Viswanath et al. 2016; Weglowski and Pietras 2011). As the tool rotates, it moves forward to process the region of interest. Friction stir processing causes intense plastic deformation, material mixing, and thermal exposure, resulting in significant microstructural refinement, densification, and homogeneity in the processed zone. This technique has been successfully used (i) to produce fine-grained structures, (ii) to achieve phase modification, (iii) for surface alloying, and (iv) for the synthesis of surface micro/nanocomposites. In most friction stir processed surfaces, the surface grain structure is altered (either by friction stir processing alone or through the addition of reinforcements during friction stir process to produce surface composites). As a consequence, improvement in properties such as greater resistance to wear, fatigue, and corrosion can be realized.
Bridge Management Objectives and Methodologies
Published in J.E. Harding, G.E.R. Parke, M.J. Ryall, Bridge Management 3, 2014
Friction stir welding is a continuous hot shear process involving a non-consumable rotating probe of harder material than the substrate itself. The probe, a portion of a shaped tool, is entered between the abutting joints of the workpiece, rotary motion generates friction heat, which creates a plasticised region (a local active zone) around the immersed probe. The shouldered region provides additional friction treatment to the workpiece as well as preventing plasticised material from being expelled. The tool is then steadily moved along the joint line, with the plasticised zone coalescing behind the tool to form a solid-phase joint as the tool moves forward.
Evaluating the corrosion behaviour of AA6061-T6 alloy and its friction stir welded joints
Published in Canadian Metallurgical Quarterly, 2023
Navdeep Minhas, Lenka Sudheer, Varun Sharma, Shailendra Singh Bhadauria
Friction stir welding is a solid-state welding process, where, the rotating tool as shown in Figure 1(a1) transverses over the weld line to produce a weld without reaching the melting temperature of the material. In this study, a square butt joint configuration was adopted for joining the 6 mm thick plates of size (100 × 100) mm using the friction stir welding operation. The high carbon steel tool with scrolled shoulder and threaded frustum pins (Figure 1(b1)) were used to produce two numbers of Single-pass (SP-FSW) and two numbers of double-pass joints (DP-FSW) joints with varied tilt angles. For each weld, the tool traverse direction was maintained perpendicular to the rolling direction of the base material. The welding parameters used for fabricating the welded joints are given in Table 2 along with their corresponding nomenclature. The welded joints so obtained are shown in Figure 1(a2–a5).
Impact of pin tool designs on the mechanical properties and microstructure of aluminum alloys AA7075- AA6061
Published in Journal of the Chinese Institute of Engineers, 2021
Adeeba Batool, Nazeer Ahmad Anjum, Muhammad Yasir Khan
Friction Stir Welding (FSW) has been established by The Welding Institute (TWI) in the U.K. in 1991 (Topic, Höppel, and Göken 2009). Welding has always been a manufacturing or a carving method, by which materials, normally thermoplastics or metals, are joined together with fusion. The main aspect of the welding process is the tool design. Friction stir welding uses a tool, i.e. non-consumable, to join the parts without melting a workpiece material. Continuing scientific and technological commitment to decreasing vehicle weight in the aerospace sector and reducing emissions has led to the spread of the use of aluminum alloys as a metal substitute for steel in many formerly steel-dominated applications. Aluminum alloys and aluminum alloy composites have been widely accepted in the manufacturing, automotive, rail, aircraft, aerospace, and construction industries. The researchers have been varying the tool design, tool material, welding material, tool rotational speed, welding speed, and tool tilt angle to see the weld quality results. (Tehyo et al. 2012) used FSW to join the semi-solid metals, SSM356-T6 and AA6061-T651, and investigated the mechanical properties at rotational speeds of 1750 rpm and 2000 rpm at different feed rates with a 3° tilt angle. The results showed that a high rotation rate of 2000 rpm with a welding speed of 80 mm/min led to higher tensile strength.
Evaluation of mechanical properties of dissimilar aluminium alloys during friction stir welding using tapered tool
Published in Cogent Engineering, 2021
Benjamin I. Attah, Sunday A. Lawal, Esther T Akinlabi, Katsina C. Bala
Friction stir welding is a solid-state joining procedure that uses a non-consumable tool to connect two materials to the workpiece. This is a process that can be used to integrate titanium alloy, aluminium alloy, magnesium alloy, stainless and mild steels, in recent times, it has been used in joining polymer materials (Ikumapayi & Akinlabi, 2019; Ikumapayi, Akinlabi, Majumdar et al., 2019; Kum. et al., 2017). Different grades of aluminium alloys exist, some of which have not been welded using a friction stir welding process. Dissimilar welding requires different suitable process parameters which is the basis for which this work was done. In view of the importance of the two alloy pairs for aerospace and other industrial applications, a study was performed to establish a workable joining parameter. Good and sound welds depend on the mechanical properties which are used to ascertain the integrity of welded joints. Friction stir welding utilizes the heat generated from the friction between the rotating tool and a workpiece. The heat helps in putting the materials into plastic deformation state and upon completing the process the materials are allowed to cool and solidify to form a welded joint. Mechanical properties of the weldment are altered by the heat generated during friction stir welding leading to microstructural modifications of the alloys. The processing parameters employed influence these modifications (Abolusoro & Akinlabi, 2020; Bocchi et al., 2018; Cavaliere et al., 2009), making it important to understand the influence of these parameters on the weld quality.