Influences of Tool pin Profile and Tool Shoulder Curvature on the Formation of Friction Stir Welding Zone in AA6061 Aluminium Alloy

Abstract:

Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the weld quality. Friction stir tool plays a major role in friction stir welding process. In this investigation, it is tried to evaluate the effect of tool pin thread and tool shoulder curvature on FSW zone formation in AA6061 aluminium alloy. In this regard, six different tool pin geometries (threadless triangular pin with/without conical shoulder, threaded triangular pin with conical shoulder, threadless square pin with/without conical shoulder, threaded square pin with conical shoulder) are used to fabricate the joints. The formation of FSP zones are analyzed macroscopically. Tensile properties of the joints are evaluated and correlated with the FSP zone formation. Consequently, it is obtained that welding creates a higher quality compared to other tool pin profiles using the square tool with curved shoulder and having threaded pin.

• Periodical: Advanced Materials Research (Volume 445)
• Pages: 789-794
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.445.789
• Online since: January 2012
• Authors: Vahid Moosabeiki, Ghasem Azimi, Mostafa Ghayoor
• Keywords: AA6061 Aluminum Alloy, Friction Stir Welding (FSW), FSP Zone, Tensile Properties, Tool Pin Profile, Tool Shoulder Curvature

References

[1] Reddy, G. M. adhusudhana, Sammaiah, P., Murthy CVS, Mohandas, T., Influence of welding techniques on microstructure and mechanical properties of AA 6061 (Al–Mg–Si) gas tungsten arc welds,. Proceedings of national conference on processing of metals, Coim- batore. 2002. p.33.

[2] Thomas, WM, et al. Friction stir welding. International patent application No. PCT/GB92/02203 and GB Patent Application No. 9125978. 8, December 1991, US Patent No. 5, 460, 317, (1991).

[3] Threadgill, PL., Friction stir welding , The state of the art, Bulletin 678, TWI, UK, (1999).

[4] Peel, M., Steuwer, A., Preuss, M., Withers, PJ., Microstructure, mechanical properties and residual stresses as a function of welding speed in AA5083 friction stir welds,. Acta Mater 2003; 51: 4791–801.

DOI: 10.1016/s1359-6454(03)00319-7

[5] Yan, J., Sutton, M., Reynolds, A., Sci. Technol. Weld. Joining, Vol 10, 2005, 725-736.

[6] Fuller, C., Mahoney, M., Bingel, W., 5th FSW Conf., 2004 (Metz, France), TWI.

[7] Chang, W., Bang, H., Jung, S., Yeon, Y., Kim, H., Lee, W., Mater. Sci. Forum, Vol 426-432, 2003, 2953-2958.