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A Study on Tooling and Its Effect on Heat Generation and Mechanical Properties of Welded Joints in Friction Stir Welding

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Abstract

Friction stir welding (FSW) has been the most attracting solid state welding process as it serves numerous advantages like good mechanical, metallurgical properties etc. Non weldable aluminium alloys like 5XXX, 7XXX series can be simply joined by this process. In this present study a mathematical model has been developed and experiments were successfully performed to evaluate mechanical properties of FSW on similar aluminium alloys i.e. AA1100 for different process parameters and mainly two kind of tool geometry (straight cylindrical and conical or cylindrical tapered shaped pin with flat shoulder). Tensile strength and micro hardness for different process parameters are reported of the welded plate sample. It was noticed that in FSW of similar alloy with tool made of SS-310 tool steel, friction is the major contributor for the heat generation. It was seen that tool geometry, tool rotational speed, plunging force by the tool and traverse speed have significant effect on tensile strength and hardness of friction stir welded joints.

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Abbreviations

AA :

Aluminium alloy

\(\left[ {C_{e}^{t} } \right]\) :

Element specific heat matrix

FSW:

Friction stir welding

HAZ:

Heat affected zone

H P :

Height of the probe

h 1 :

Indent height of shoulder

h f :

Convection coefficient

\(\left[ {K_{e}^{tb} } \right]\) :

Element diffusion conductivity matrix

\(\left[ {K_{e}^{tc} } \right]\) :

Element convection surface conductivity matrix

{L}:

Vector operator

\(\left\{ N \right\}\) :

Element shape function

\(\left\{ n \right\}\) :

Unit outward normal vector

P n :

Plunging force

Q Sp :

Heat generation due to vertical pressure in shoulder

Q Sm :

Heat generation in shoulder due to travelling of tool shoulder

Q S :

Total heat generation in shoulder

Q 1 :

Heat generation due to vertical pressure at probe tip

Q 2 :

Heat generation due to the rotational movement of the probe (side surface)

Q 3 :

Heat generation due to travelling of the probe (side surface)

Q P :

The total heat generation at the probe

\(\left\{ {Q_{e}^{f} } \right\}\) :

Element heat flow vector for surface S1

\(\left\{ {Q_{e}^{c} } \right\}\) :

Elemental convection surface heat flow vector

\(q_{sup}\) :

Heat supply

\(q^{\prime\prime\prime}\) :

Heat generation

{q}:

Heat flux vector

R S :

Shoulder radius

R Pb :

Radius of probe base

R Pt :

Radius of probe tip

S * ys :

The yield strength of the material at 80 % of the melting point temperature

T α :

Ambient temperature

\(\left\{ {T_{e} } \right\}\) :

Nodal temperature vector

V:

Tool velocity

ω :

Angular velocity of the tool

τ * :

The shear strength of the material at 80 % of its melting point temperature

μ :

Frictional co-efficient between the tool and workpiece

ρ :

Density of plate material

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Acknowledgmen

This paper is the expanded version of an article titled, “A Study on Tooling and Its Effect on Heat Generation and Mechanical Properties of Welded Joints in Friction Stir Welding” presented in 5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) during December 12–14, 2014 at Indian Institute of Technology Guwahati, India.

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Authors and Affiliations

  1. Indian Institute of Technology Guwahati, Guwahati, 781039, Assam, India

    Sujoy Tikader & Pankaj Biswas

  2. National Institute of Technology Durgapur, Durgapur, 713209, West Bengal, India

    Asit Baran Puri

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  1. Sujoy Tikader
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Correspondence to Sujoy Tikader.

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Tikader, S., Biswas, P. & Puri, A.B. A Study on Tooling and Its Effect on Heat Generation and Mechanical Properties of Welded Joints in Friction Stir Welding. J. Inst. Eng. India Ser. C 99, 139–150 (2018). https://doi.org/10.1007/s40032-016-0325-y

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