Tool Geometry for Friction Stir Welding—Optimum Shoulder Diameter

@article{Mehta2011ToolGF,
  title={Tool Geometry for Friction Stir Welding—Optimum Shoulder Diameter},
  author={M. Mehta and A. Arora and A. De and T. DebRoy},
  journal={Metallurgical and Materials Transactions A},
  year={2011},
  volume={42},
  pages={2716-2722}
}
The most important geometric parameter in the friction stir welding (FSW) tool design is the shoulder diameter, which is currently estimated by trial and error. Here, we report a combined experimental and theoretical investigation on the influence of shoulder diameter on thermal cycles, peak temperatures, power requirements, and torque during FSW of AA7075-T6. An optimum tool shoulder diameter is identified using a three-dimensional, heat transfer and materials flow model. First, the predictive… Expand

Figures and Tables from this paper

Load bearing capacity of tool pin during friction stir welding
Although friction stir welding (FSW) is now widely used for the welding of aluminum and other soft alloys, premature tool failure limits its application to hard alloys such as steels and titaniumExpand
Mechanistic models and experimental analysis for the torque in FSW considering the tool geometry and the process velocities
Abstract Friction Stir Welding (FSW) offers great advantages over conventional welding due to the absence of melting and a small energy requirement. Consequently, the quality of the welded join isExpand
Optimizing the tool pin with three flats in friction stir welding of aluminum alloy
The role of tool pin profile is crucial in friction stir welding (FSW) process, but its optimization design still requires sufficient quantitative data and a comprehensive understanding of theExpand
Shoulder Related Temperature Thresholds in FSSW of Aluminium Alloys
Friction Stir Spot Welding (FSSW) is assumed as an environment-friendly technique, suitable for the spot welding of several materials. Nevertheless, it is consensual that the temperature controlExpand
Prediction and optimization of the mechanical properties of dissimilar friction stir welding of aluminum alloys using design of experiments
Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central compositeExpand
Numerical Simulation for the Optimization of Polygonal Pin Profiles in Friction Stir Welding of Aluminum
The tool with polygonal pin profile has been widely employed in friction stir welding (FSW) of aluminum, but there is hardly an effective optimization methodology existed as the thermomechanicalExpand
Effects of tool shoulder size on the thermal process and material flow behaviors in ultrasonic vibration enhanced friction stir welding
Abstract To improve the joint quality and lower the welding loads, ultrasonic vibration enhanced friction stir welding (UVeFSW) had been developed and had shown several benefits. The most importantExpand
Influence of tool shoulder geometry on properties of friction stir welds in thin copper sheets
Abstract The aim of this work is to study the influence of the shoulder geometry on friction stir welding of 1 mm-thick copper-DHP plates. The welds were produced using three different shoulderExpand
Durability Maps for Friction Stir Welding of an Aluminum Alloy
Friction stir welding is not used for hard alloys because of premature tool failure. A scheme is created which exploits the physical three-dimensional heat and mass flow models, and implements themExpand
Scaling effects during friction stir welding of aluminum alloys with reduced tool aspect ratios
Friction stir welding (FSW) is a solid-state welding technique providing a number of unique advantages such as the weldability of various similar and dissimilar material combinations, the absence ofExpand
...
1
2
3
4
5
...

References

SHOWING 1-10 OF 60 REFERENCES
Toward optimum friction stir welding tool shoulder diameter
Currently friction stir welding tools are designed by trial and error. Here we propose and test a criterion for the design of a tool shoulder diameter based on the principle of maximum utilization ofExpand
Characterization of the influences of FSW tool geometry on welding forces and weld tensile strength using an instrumented tool
Abstract FSW process automation is essential to making consistent and reliable friction stir welds and this requires an understanding of how tool design can influence process parameters, which inExpand
Model for predicting heat generation and temperature in friction stir welding from the material properties
Abstract This paper describes a simple numerical model for predicting the heat generation in friction stir welding (FSW) from the material hot deformation and thermal properties, the processExpand
Design of the friction stir welding tool using the continuum based FEM model
In friction stir welding (FSW), the welding tool geometry plays a fundamental role in obtaining desirable microstructures in the weld and the heat-affected zones, and consequently improving strengthExpand
CFD modelling of friction stir welding of thick plate 7449 aluminium alloy
Abstract CFD modelling of friction stir welding has been conducted to understand and optimise the welding of thick, 7449 aluminium alloy for aerospace applications. The aim is to produce highExpand
Influences of tool pin profile and tool shoulder diameter on the formation of friction stir processing zone in AA6061 aluminium alloy
Abstract AA6061 aluminium alloy (Al–Mg–Si alloy) has gathered wide acceptance in the fabrication of light weight structures requiring a high strength-to-weight ratio and good corrosion resistance.Expand
Material flow in heterogeneous friction stir welding of thin aluminium sheets: Effect of shoulder geometry
The aim of this investigation was to study the influence of tool geometry on material flow during heterogeneous friction stir welding in 1 mm thick plates of AA 5182-H111 and AA 6016-T4 aluminiumExpand
Toward reliable calculations of heat and plastic flow during friction stir welding of Ti-6Al-4V alloy
Abstract Heat transfer and visco-plastic flow during friction stir welding of Ti-6Al-4V alloy have been modeled in three dimensions by numerically solving the equations of conservation of mass,Expand
Effect of shoulder size on the temperature rise and the material deformation in friction stir welding
A fully coupled thermo-mechanical model is adopted to study the effect of shoulder size on the temperature distributions and the material deformations in friction stir welding. Numerical resultsExpand
Development of Trivex friction stir welding tool Part 1 – two-dimensional flow modelling and experimental validation
Abstract This paper describes the application of the computational fluid dynamics (CFD) code, FLUENT, to modelling the metal flow in friction stir welding (FSW). Through the use of a novel slipExpand
...
1
2
3
4
5
...