friction stir welding of aluminium alloy
-
Upload
manishmitm -
Category
Documents
-
view
1.993 -
download
5
Transcript of friction stir welding of aluminium alloy
A Presentation on
Effect of Friction Stir Welding on mechanical properties and formability of thin commercial Al blanks
Submitted byManish Singh (2011MEP3270)
Under the guidance of
Dr. S. Aravindan and Dr. D. Ravi Kumar
Department of Mechanical Engineering Indian Institute of Technology, Delhi
Contents
1. Introduction
2. Experimental setup
3. Experimental procedure
4. Results and discussion
5. Conclusion
6. Gantt chart
7. References
Friction stir welding : FSW is a solid–state, hot–shear joining process in which a rotating tool with a shoulder moves along the butting surfaces of two rigidly clamped plates placed on a backing plate as shown in Fig.
Schematic illustration of the Friction Stir Welding process[1].
Friction Stir Welding Set up:
1. Vertical Milling machine2. Fixture 3. Backing Plate4. Tool 5. Specimen
Fixture:
Backing Plate
Backing plate (200X100X8 mm) used in FSW process.
Tool dimensions Values
Shoulder length (mm) 10
Shank diameter (mm) 19.95
Shank length (mm) 57
FSW Tools
Table 1- Tools Used for Welding
Tool Tool 1 Tool 2 Tool 3
Tool
Figure
Tool pin
Diameter8 mm 12 mm 16 mm
Specimen:
Specimen (170X50X1.7 mm).
Yes
No
Experimental procedure
Welding Run
No.
Rotational
speed (rpm)
Welding speed
(mm/min)
Tool diameter
(mm)
Depth of
plunging (mm)
1 450 80 8 0.2
2 450 160 12 0.2
3 450 250 16 0.2
4 560 160 8 0.2
5 560 250 12 0.2
6 560 80 16 0.2
7 710 250 8 0.2
8 710 80 12 0.2
9 710 160 16 0.2
Process parameterThe welding was carried out by using the selected variations of parameters as shown in Table1 which is obtained by Taguchi’s orthogonal array method for minimizing the number of experiments.
Distance from Centre
Line
Sample no.Welding Run 1 Welding Run 4 Welding Run 7
-7 44.9 44.4 45.6
-6 43.4 44.6 43.6
-5 43.32 42.4 42.6
-4 40.7 41.7 41.5
-3 42.5 40.1 40.6
-2 39.8 40.8 37.6
-1 37.9 39.3 37.5
0 41.8 38.1 36.3
1 38.6 36.9 38.3
2 41.2 36.8 40.0
3 42.4 39.5 41.3
4 42.6 41.5 41.6
5 42.8 41.1 41.9
6 43.8 40.6 42.1
7 44.2 44.6 43.8
Table 4- Vickers Hardness values of all samples with respect to weld region
Microhardness profile of welded samples
Weld Run No.Welding
parametersLDH Test Samples LDH (mm) Remarks
Run No. 1
Rotational
Speed = 450
rpm
Welding
Speed = 80
mm/min
Shoulder
Diameter = 8
mm
11.04
Failure
occurs from
weld centre
line
13.76
Failure
occurs from
TMAZ/HA
Z
Limiting Dome Height Test of FS Welded Samples
Run No. 4
Rotational
Speed = 560
rpm
Welding
Speed = 160
mm/min
Shoulder
Diameter =
8 mm
Welding
parameters
12.72
Failure
occurs from
TMAZ/HAZ
11.32
Failure
occurs from
Weld centre
line
Weld Run No.Welding
parametersLDH Test Samples LDH (mm) Remarks
Run No. 7
Rotational
Speed = 710
rpm
Welding
Speed = 250
mm/min
Shoulder
Diameter = 8
mm
12.04
Failure
occurs in
Weld centre
line
14.28
Failure
occurs from
Weld centre
line
Weld Run No.Welding
parametersLDH Test Samples
LDH
(mm)Remarks
Tensile Sample along the Weld
Tensile Sample Transverse to
the Weld
Hardness Sample Transverse to the Weld
Weld Centre Line
Weld Nugget
Tensile test
Conclusion:
1. Hardness in advancing side is more than the retreating side in HAZ and TMAZ because the grain refinment is more in advancing side than retreating side.
2. From the LDH tests, it is observed that LDH in run 7(710 rpm, 250 mm/min, 8mm) is higher than the LDH in run 1(450 rpm, 160 mm/min, 8mm) and run 4(560 rpm, 160 mm/min, 8mm). As formability strongly depends on mechanical properties of the welded blank, further tests (tensile tests and LDH tests) have to be carried out to draw the conclusions.
3. In LDH tests the failure occurred in the weld region in some samples and in HAZ/TMAZ in other samples.
Work done till now Time
1. To study the literature and see the various aspect of project 25thJuly - 15th February
2. Weld specimen preparation by friction stir welding process. 10th January- 25th January
3. To study the micro-structure of weld specimen 25th January- 5th February
4. Performance of micro hardness test and LDH test. 5th February - 18th February
5. Report writing. 15th February -20th
February
Work to be done 1. Weld specimen for remaining runs is going to be prepared.2. LDH tests and microhardness tests will be performed after that.
Time
Activity
June Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar. Apr. May
Literature
review
Setup
preparation
TWBs
preparation by
FSWSample preparation & Mechanical testing
Forming test
Report
writing
Gantt chart
References
1. R. Nandan ,T. DebRoy ,H.K.D.H. Bhadeshia, Recent advances in friction-stir welding – Process, weldment structure and properties, Progress in Materials Science 53 (2008) 980–1023.
2. J. Jeswiet, M. Geiger, U. Engel, M. Kleiner, M. Schikorra, J. Duflou, R. Neugebauer, P. Bariani, S. Bruschi, Metal forming progress since 2000, CIRP Journal of Manufacturing Science and Technology 1 (2008) 2–17.
3. Amir Abbas Zadpoor, Jos Sinke, Rinze Benedictus, Raph Pieters, Mechanical properties and microstructure of friction stir welded tailor-made blanks, Materials Science and Engineering A 494 (2008) 281290.
4. Sushanta Kumar Panda, D. Ravi Kumar, Improvement in formability of tailor welded blanks by application of counter pressure in biaxial stretch forming, journal of materials processing technology 2 0 4 ( 2 0 0 8 ) 70–79.
5. R Ganesh Narayanan1 and K Narasimhan, Predicting the forming limit strains of tailor-welded blanks, The manuscript was received on 17 April 2008 and was accepted after revision for publication on 20 June 2008.
6. M.Sivashanmugam, S.Ravikumar, T.Kumar, V.Seshagiri Rao, D.MuruganandamA Review on Friction Stir Welding for Aluminium Alloys, 978-1-4244-9082-0/10/$26.00 ©2010 IEEE
7. D.M. Rodrigues, A. Loureiro, C. Leitao, R.M. Leal, B.M. Chaparro, P. Vilaça, Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds, Materials and Design 30 (2009) 1913–1921.
8. Wonoh Lee, Kyung-Hwan Chung, Daeyong Ki, Junehyung Kim, Chongmin Kim, Kazutaka Okamoto, R.H. Wagoner, Kwansoo Chung, Experimental and numerical study on formability of friction stir welded TWB sheets based on hemispherical dome stretch tests, International Journal of Plasticity 25 (2009) 1626–1654.
9. Daeyong Kim, WonohLee, JunehyungKim, ChongminKim, KwansooChung, Formability evaluation of friction stir welded 6111-T4 sheet with respect to joining material direction, International Journal of Mechanical Sciences 52 (2010) 612–625.
10. Kwansoo Chung, Wonoh Lee, Daeyong Kim, Junehyung Kim, Kyung-Hwan Chung, Chongmin Kim, Kazutaka Okamoto, R.H. Wagoner, Macro-performance evaluation of friction stir welded automotive tailor-welded blank sheets: Part I – Material properties, International Journal of Solids and Structures 47 (2010) 1048–1062.