Papers by Author: Rui Louro

Abstract: The task of obtaining suitable welding parameters for the friction stir welding process is often a difficult one, due to the lack of published data and the fact that the exact mechanism by which the process operates has not yet been fully determined. Therefore, suitable welding parameters often need to be obtained by using extensive, time consuming and expensive experimental methods. The work detailed in this paper pertains to the use of the Taguchi method as a mean to reduce the disadvantages of these experimental methods, more specifically, their cost. The Taguchi method accomplishes this task by substantially reducing the number of welding trials that are needed to obtain suitable welding parameters. This reduction leads to the parameters being obtained more rapidly and at a substantially smaller cost. In this paper a procedure for applying the Taguchi method to the friction stir welding process is presented as well as its application to the welding of a specific component. The method was applied to the welding of 4mm thick AA5083-H111 plates in a butt joint configuration, which constitutes one of the most common industrial welding scenarios. The purpose of the experimental tests was to maximize the welding speed whilst ensuring an acceptable welding quality. The quality of the welds was determined through visual inspection and tensile and bending tests. The application of the Taguchi method allowed, with a relatively small number of experimental welds, to provide some insight into the manner by which the parameters should be altered in order to optimize the process.

Abstract: Friction Stir Welding (FSW) is a relatively young technology in the field of welding. Its process parameters and their influence on weld quality are currently the topic of intense research. Present work focuses on the influence of the tool plunging force on the mechanical properties, microstructure and surface finish of friction stir welds. Three welds have been produced using the same tool rotation and traverse speed and different tool dimensions and plunging forces. Visual inspection, optical and scanning electron microscopy were undertaken to assess surface and dimensional features as well as to study microstructure. Bend, hardness and tensile tests were carried out to characterise the weld strength. Taken into account the plunging force values of the conducted welds, a relationship between weld properties and calculated welding pressures was created. Favourable welding pressure values are recommended.

Abstract: The Friction Stir Welding (FSW) process has a large industrial potential in the field of joining lightweight alloys. Due to the increasing industrial use of aluminium alloys the benefits provided by this technology are very appealing. However, this potential has not, until this time, become a reality due to the lack of relevant available information concerning the process. The lack of information is especially serious in regards to the welding tools. This component, whose importance in the FSW process cannot be overstated, has not been the subject of extensive published research due mainly to the difficulties related to the modelling of the FSW process, which means that all of the development in this field has to be conducted through a trial and error approach. This approach entails significant costs and success risks, thus reducing the capability of R&D institutions to carry out extensive research. The objective behind the work detailed in this paper is the assessment of the effects of the welding tool geometry and features in the weld quality and process productivity. The work was carried out via an experimental procedure, which consisted of carrying out several welds using different pin lengths, pin diameter, pin geometry and shoulder diameter. The geometries that were used are based on known geometries from literature and new concepts. Due to practical limitations the study was conducted using a 3mm thick AA 6082-T6 butt joint configuration. The quality of the welds was assessed through destructive and non destructive testing, namely a visual inspection, an x-ray and a macrographic examination. These results can then be used to correlate the effects of the different tool geometries with the weld quality and productivity. The process productivity can be, according to [1], directly related to the welding speed, this is due to the near absence of welding consumables in the FSW process, leading to the predominance of fixed costs. The results pertaining to this work enable a better comprehension of the manner by which the tool geometry influences the weld quality and the process productivity, thus providing a stepping stone in the ongoing task of optimizing and modelling of the FSW process. The results presented in this paper may also be useful when extrapolated to other materials and thicknesses.

Abstract: The Friction Stir Welding (FSW) process is a quite recent joining method whose particular characteristics yield to materials modifications not yet fully understood. This paper aims to present the research results of a study focused on the modifications induced in an aluminium alloy AA5083 – H111, when processed by FSW to build components for structural applications. The welded samples were firstly analysed by optical microscopy in order to define the different joined zones and to identify defects. Further tests included the measurement of the Vickers microhardness, grain and particle distribution and chemical analysis of the constituents, particularly of the intermetallic second phase particles, by Auger spectroscopy. Special attention has been given to the characterisation of several microstructural “non-homogeneities” like a laminated structure called onion ring and an identified anomaly (in the form of a line), whose presence was evaluated in order to determine its effects on the final joint properties. The results have shown important new details about the relationship between the microstructure and the final joint structural properties, contributing to improve the knowledge about the materials behaviour increasing the potential of utilization of the FSW process.