Skip to main content
SpringerLink
Log in

Experimental and numerical investigation of process force evolution in Ultra-High Rotational Speed Micro FSW

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

A variant of Friction Stir Welding (FSW) called Ultra-high rotational speed micro friction stir welding (UHRSμFSW) is proposed for welding thin sheets. Experimental and numerical investigations are carried out to study the effect of ultra-high tool rotational speed on the process force. Studies conducted on softer AA1100 and stronger AA5052 alloys show that the axial force is reduced by 62.7% on increasing the tool rotational speed from 3,000 rpm to 24,000 rpm in AA5052 alloy, whereas the decrease is 52.8% in AA1100 alloy. It is discovered that the plunge depth is the most important process parameter – after tool rotational speed − influencing the process force. Results from the current study prove that UHRSμFSW is an effective method for joining thin metal sheets. Due to the low process force, the proposed variant can help to develop cost-effective FSW welding robots and portable FSW machines.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35

Similar content being viewed by others

References

  1. Ahmed S, Verma M, Saha P (2021) Process responses during μFSW of AA6061-T6 under the influence of triple-spiral micro-grooves on shoulder end-surface. J Mater Process Technol 290:116984. https://doi.org/10.1016/j.jmatprotec.2020.116984

    Article  Google Scholar 

  2. Lone NF, Alam MM, Ashraf A et al (2021) Evolution in Micro-friction Stir Welding BT - Advances in Manufacturing and Industrial Engineering. In: Mathiyazhagan K, Kumar H (eds) Singari RM. Springer Singapore, Singapore, pp 649–656

    Google Scholar 

  3. Teh NJ, Goddin H, Whitaker A (2011) Developments in micro applications of friction stir welding. In: TWI. https://www.twi-global.com/technical-knowledge/published-papers/developments-in-micro-applications-of-friction-stir-welding

  4. Sen M, Shankar S, Chattopadhyaya S (2020) Micro-friction stir welding (μFSW) – A review. Mater Today Proc 27:2469–2473. https://doi.org/10.1016/j.matpr.2019.09.220

    Article  Google Scholar 

  5. Verma M, Ahmed S, Saha P (2021) Challenges, process requisites/inputs, mechanics and weld performance of dissimilar micro-friction stir welding (dissimilar μFSW): A comprehensive review. J Manuf Process 68:249–276. https://doi.org/10.1016/j.jmapro.2021.05.045

    Article  Google Scholar 

  6. Zhang HJ, Wang M, Qi RL et al (2017) Effect of rotation speed on nugget structure and property of high rotation speed friction stir welded Al-Mn aluminum alloy. Int J Adv Manuf Technol 92:2401–2410. https://doi.org/10.1007/s00170-017-0295-0

    Article  Google Scholar 

  7. Chen S, Zhou Y, Xue J et al (2017) High Rotation Speed Friction Stir Welding for 2014 Aluminum Alloy Thin Sheets. J Mater Eng Perform 26:1337–1345. https://doi.org/10.1007/s11665-017-2524-y

    Article  Google Scholar 

  8. Baskoro AS, Hadisiswojo S, Kiswanto G et al (2020) Influence of welding parameters on macrostructural and thermomechanical properties in micro friction stir spot welded under high-speed tool rotation. Int J Adv Manuf Technol 106:163–175. https://doi.org/10.1007/s00170-019-04490-8

    Article  Google Scholar 

  9. Liu FJ, Fu L, Chen HY (2018) Microstructure evolution and fracture behaviour of friction stir welded 6061–T6 thin plate joints under high rotational speed. Sci Technol Weld Join 23:333–343. https://doi.org/10.1080/13621718.2017.1389837

    Article  Google Scholar 

  10. Zhang HJ, Wang M, Zhu Z et al (2017) Nugget Structure Evolution with Rotation Speed for High- Rotation-Speed Friction-Stir-Welded 6061 Aluminum Alloy. J Mater Eng Perform 27:1378–1386. https://doi.org/10.1007/s11665-018-3228-7

    Article  Google Scholar 

  11. Li Z, Chen S, Meng L, et al (2021) On the effects of high and ultra-high rotational speeds on the strength, corrosion resistance, and microstructure during friction stir welding of Al 6061-T6 and 316L SS Alloys. Coatings 11:https://doi.org/10.3390/coatings11121550

  12. Liu FJ, Fu L, Chen HY (2018) Effect of high rotational speed on temperature distribution, microstructure evolution, and mechanical properties of friction stir welded 6061–T6 thin plate joints. Int J Adv Manuf Technol 96:1823–1833. https://doi.org/10.1007/s00170-018-1736-0

    Article  Google Scholar 

  13. Zhang H, Chen S, Zhang Y, et al (2021) Effect of high rotational‐speed friction‐stir welding on microstructure and properties of welded joints of 6061‐T6 Al alloy ultrathin plate. Materials (Basel) 14:https://doi.org/10.3390/ma14206012

  14. Baskoro AS, Suwarsono KG, Winarto, (2014) Effects of high speed tool rotation in micro friction stir spot welding of Aluminum A1100. Appl Mech Mater 493:739–742. https://doi.org/10.4028/www.scientific.net/AMM.493.739

    Article  Google Scholar 

  15. Ni Y, Fu L, Shen Z, Liu XC (2019) Role of tool design on thermal cycling and mechanical properties of a high-speed micro friction stir welded 7075–T6 aluminum alloy. J Manuf Process 48:145–153. https://doi.org/10.1016/j.jmapro.2019.10.025

    Article  Google Scholar 

  16. Huang Y, Meng X, Zhang Y et al (2017) Micro friction stir welding of ultra-thin Al-6061 sheets. J Mater Process Technol 250:313–319. https://doi.org/10.1016/j.jmatprotec.2017.07.031

    Article  Google Scholar 

  17. Jain R, Pal SK, Singh SB (2017) Numerical modeling methodologies for friction stir welding process. In: Computational Methods and Production Engineering: Research and Development. Woodhead Publishing, pp 125–169

  18. Malik V, Sanjeev N, Hebbar HS, Kailas SV (2014) Time Efficient Simulations of Plunge and Dwell Phase of FSW and its Significance in FSSW. Procedia Mater Sci 5:630–639. https://doi.org/10.1016/J.MSPRO.2014.07.309

    Article  Google Scholar 

  19. Chauhan P, Jain R, Pal SK, Singh SB (2018) Modeling of defects in friction stir welding using coupled Eulerian and Lagrangian method. J Manuf Process 34:158–166. https://doi.org/10.1016/j.jmapro.2018.05.022

    Article  Google Scholar 

  20. Chen K, Liu X, Ni J (2017) Thermal-mechanical modeling on friction stir spot welding of dissimilar materials based on Coupled Eulerian-Lagrangian approach. Int J Adv Manuf Technol 91:1697–1707. https://doi.org/10.1007/s00170-016-9884-6

    Article  Google Scholar 

  21. Geng P, Morimura M, Wu S et al (2022) Prediction of residual stresses within dissimilar Al/steel friction stir lap welds using an Eulerian-based modeling approach. J Manuf Process 79:340–355. https://doi.org/10.1016/j.jmapro.2022.05.001

    Article  Google Scholar 

  22. Ansari MA, Samanta A, Behnagh RA, Ding H (2018) An efficient coupled Eulerian-Lagrangian finite element model for friction stir processing. Int J Adv Manuf Technol 101:1495–1508. https://doi.org/10.1007/s00170-018-3000-z

    Article  Google Scholar 

  23. Türkan M, Karakaş Ö (2022) Numerical modeling of defect formation in friction stir welding. Mater Today Commun 31:https://doi.org/10.1016/j.mtcomm.2022.103539

  24. Hou Z, Sheikh-Ahmad J, Jarrar F, Ozturk F (2018) Residual Stresses in Dissimilar Friction Stir Welding of AA2024 and AZ31: Experimental and Numerical Study. J Manuf Sci Eng Trans ASME 140:https://doi.org/10.1115/1.4039074

  25. Salloomi KN, Al-Sumaidae S (2021) Coupled Eulerian-Lagrangian prediction of thermal and residual stress environments in dissimilar friction stir welding of aluminum alloys. J Adv Join Process 3:100052. https://doi.org/10.1016/j.jajp.2021.100052

    Article  Google Scholar 

  26. Mohan R, Jayadeep UB, Manu R (2021) CFD modelling of ultra-high rotational speed micro friction stir welding. J Manuf Process 64:1377–1386. https://doi.org/10.1016/j.jmapro.2021.02.060

    Article  Google Scholar 

  27. Song P, Li W, Wang X, Xu W (2019) Study on mechanical properties and constitutive model of 5052 aluminium alloy. Mater Sci Technol 35:916–924. https://doi.org/10.1080/02670836.2019.1596611

    Article  Google Scholar 

  28. Aghdami AM, Davoodi B (2020) An inverse analysis to identify the Johnson-Cook constitutive model parameters for cold wire drawing process. Mech Ind 21:https://doi.org/10.1051/meca/2020070

  29. Rana PK, Narayanan RG, Kailas SV (2021) Assessing the dwell time effect during friction stir spot welding of aluminum polyethylene multilayer sheets by experiments and numerical simulations. Int J Adv Manuf Technol 114:1953–1973. https://doi.org/10.1007/s00170-021-06910-0

    Article  Google Scholar 

  30. Biswas P, Mandal NR (2011) Effect of Tool Geometries on Thermal History of FSW of AA1100. Weld J 90:129–135

    Google Scholar 

  31. Aziz SB, Dewan MW, Huggett DJ, et al (2018) A fully coupled thermomechanical model of friction stir welding (FSW) and numerical studies on process parameters of lightweight aluminum alloy joints. Acta Metall Sin (English Lett 31:1–18. https://doi.org/10.1007/s40195-017-0658-4

  32. Ni Y, Fu L, Chen HY (2019) Effects of travel speed on mechanical properties of AA7075-T6 ultra-thin sheet joints fabricated by high rotational speed micro pinless friction stir welding. J Mater Process Technol 265:63–70. https://doi.org/10.1016/j.jmatprotec.2018.10.006

    Article  Google Scholar 

  33. Al-Badour F, Merah N, Shuaib A, Bazoune A (2013) Coupled Eulerian Lagrangian finite element modeling of friction stir welding processes. J Mater Process Technol 213:1433–1439. https://doi.org/10.1016/j.jmatprotec.2013.02.014

    Article  Google Scholar 

  34. Quintana KJ, Silveira JLL (2018) Analysis for the forces in FSW for aluminum alloy considering tool geometry and process velocities. J Brazilian Soc Mech Sci Eng 40:1–11. https://doi.org/10.1007/s40430-018-1162-0

    Article  Google Scholar 

  35. Shahi P, Barmouz M, Modares T (2014) Force and torque in friction stir welding. In: Mohammad Kazem Besharati Givi PA (ed) Advances in Friction-Stir Welding and Processing. Woodhead Publishing, pp 459–498

Download references

Funding

The authors declare that no funds, grants, or other support were received during the preparation of this manuscript.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology Calicut, Kozhikode, 673601, Kerala, India

    Renju Mohan, Ullissery Balan Jayadeep & Manu Rajankutty

Authors
  1. Renju Mohan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ullissery Balan Jayadeep
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Manu Rajankutty
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Renju Mohan: Conceptualization, Methodology, Software, Validation, Formal analysis, Investigation, Visualization, Writing – original draft.

Ullissery Balan Jayadeep: Resources, Review & editing, Supervision.

Manu Rajankutty: Interpretation of results, Review & editing, Supervision and guidance.

Corresponding author

Correspondence to Renju Mohan.

Ethics declarations

Conflict of interests

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Mohan, R., Jayadeep, U.B. & Rajankutty, M. Experimental and numerical investigation of process force evolution in Ultra-High Rotational Speed Micro FSW. Int J Adv Manuf Technol 130, 2523–2545 (2024). https://doi.org/10.1007/s00170-023-12871-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12871-3

Keywords

Search

Navigation