Experiments on Friction Stir Processing (FSP), with Tilted Parent Metal

Abstract:

Friction stir processing (FSP), with tilted parent metal is a new process, which consists in the use of an inclined base plate with an angle α = 1 - 3 º related to the table of the FSP processing machine, by mounting a calibrated part under one end of the base plate. Two clamping plates are fixed with screws on the base plate, and a sheet (parent metal, PM) or a workpiece is placed between the base plate and the clamping plates. The processing tool has the same tilt angle with respect to the sheet to be processed. Said parts are components of the jig for the process described. The processing tool performs a movement with the speed v(x), correlated with a simultaneous movement with the speed v(z) = v(x) tg α. The correlation is achieved by means of a program developed for the processing machine. Due to the tilt, during the FSP process, the leading edge of the rotating tool shoulder progressively enters the PM, continuously, at the point where the shoulder penetration depth in the PM is minimal. On the multifunctional friction processing machine, MMPF type, the processing by the described process of an aluminium alloy sheet, with the sizes 300 mm x 200 mm x 4 mm was performed. A hardened C45 steel tool was used, having the following technical characteristics: shoulder diameter 14 mm, smooth frusto-conical pin with a large diameter of 2.5 mm, a small diameter of 2.0 mm, and a height of 1.5 mm. The parameters had the following values: tilt angle α = 2° 6'; pin penetration depth h = 1.60 - 1.85 mm; tool speed n = 1500 - 2000 rpm; speed v(x) = 1 - 2 mm / s; speed (software correlated) v(z) = 0.03672181 * (1 - 2) mm / s; the temperature of the sheet behind the tool t = 240 - 420 °C. The appearance of the processed sheet is appropriate. No imperfections are observed. The results are appropriate. The tilted PM brings the following advantages of the process: the mechanical stress to produce burrs and / or chips on the surface of the PM decreases; the way the FSP process is carried out is improved, by reducing gap moving and vibrations; the appearance and mechanical characteristics of the processed areas are improved; the quality level of the executed products rises; wear of processing tools is reduced; energy efficiency increases; the electricity consumption of the machine decreases; productivity increases.

• Periodical: Key Engineering Materials (Volume 890)
• Pages: 95-104
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.890.95
• Online since: June 2021
• Authors: Victor Verbiţchi*, Horia Florin Daşcău, Lia-Nicoleta Botila, Radu Cojocaru
• Keywords: Aluminium Alloy Sheet, Coordinates Machine, Friction Stir Processing, Reduced Mechanical Stress, Speed Correlation Program, Tilted Parent Metal

References

[1] W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Temple-Smith and C.J. Dawes, Friction-stir butt welding, GB Patent No. 9125978.8, International patent application No. PCT/GB92/02203, (1991).

[2] C.B. Fuller, Friction Stir Tooling: Tool Materials and Designs, Friction Stir Welding and Processing, ASM Inter., (2007), pag.7-37.

[3] W. J. Arbegast, Friction Stir Welding: After a Decade of Development, Weld. J., vol. 85, March (2006), pag. 28-35.

[4] K. Kimapong and T. Watanabe, Lap Joint of A5083 Aluminum Alloy and SS400 Steel by Friction Stir Welding, Mat. Trans. 46 (4) (2005), pag. 835-841.

DOI: 10.2320/matertrans.46.835

[5] S. Chimbli; Dana Medlin and W. Arbegast: Minimizing Lack-of-Consolidation Defects in Friction Stir Welds. In the volume Friction Stir Welding and Processing IV, edited by R.S. Mishra, and others, pages 135-143. The Minerals, Metals & Materials Society, TMS. TMS Annual Meeting, Orlando, Florida, USA, 2007. P 978-0-87339-661-5.

DOI: 10.1002/9781118062302.ch2

[6] L.N. López de Lacalle1; G. Urbikain Pelayo1; I. Azkona2; J. M. Pérez3; V. Verbiţchi4*; R. Cojocaru4; L.N. Boţilă4; C. Ciucă4 and I.A. Perianu4 (1University of the Basque Country, Bilbao, Spain; 2Company Metal Estalki S.L., Basque Country, Spain; 3Centre for Industrial Technology Development - CDTI, Madrid, Spain; 4National Research & Development Institute for Welding and Material Testing - ISIM Timisoara, Romania); Making steel – aluminium joints by fast alternative processes. In the journal SUDURA (Welding), ISSN 1453-0384, Issue 1, April, (2017), year XXVII, pages 5-13. Conference - SUDURA 2017, Iasi, April 6th–7th (2017), organized by ASR / Romanian Welding Society.

DOI: 10.36315/2021end124

[7] Lia-Nicoleta Boțilă1 (1ISIM Timişoara); R. Cojocaru1 and C. Ciucă1; Friction stir processing in multiple passes of the cast aluminum alloy EN AW 4047 (AlSi12). BID-ISIM – Welding and Material Testing, nr. 2/2019, pag.13-17, ISSN 1453-0392.

[8] Lia-Nicoleta Boțilă1 (1ISIM Timişoara); R. Cojocaru1 and C. Ciucă1; Friction stir processing in multiple passes of the EN AW 5083(AlMg4,5Mn0,7) cast aluminum alloy. BID-ISIM – Welding and Material Testing, nr.3/2019, pag.3-7, ISSN 1453-0392.

[9] Lia-Nicoleta Boțilă1 (1ISIM Timişoara); R. Cojocaru1 and C. Ciucă1; New ecologic method for joining of titanium alloys. BID-ISIM – Welding and Material Testing, nr.3/2019, pag.19-26, ISSN 1453-0392.

[10] C. Ciucă1 (ISIM Timișoara), R. Cojocaru1; Lia-Nicoleta Boțilă1 and I.-A. Perianu1; General considerations regarding friction stir welding of some steels used in important industrial fields. The 10th International Conference - Innovative Technologies for Joining Advanced Materials. November 7th - 8th, 2019, Timisoara, Romania.

DOI: 10.4028/www.scientific.net/amr.1157.83

[11] R. Cojocaru1 (1ISIM Timişoara), C. Ciucă1, Lia-Nicoleta Boţilă1,V. Verbiţchi1 and I.-A. Perianu1; Program Partnerships in priority areas. Project 219/ (2014-2017). Innovative, ecological and efficient joining technologies of metallic and polymeric materials used in the automotive industry, using the friction stir welding technique, Acronym Inova-FSW.

[12] R. Cojocaru1 (1ISIM Timişoara); L.N. Boţilă1; C. Ciucă1; H. Daşcău1 and V. Verbiţchi1; Friction Stir Lap Welding of Light Alloy Sheets. The 10th International Conference - Structural Integrity of Welded Structures, July 11th-12th, (2013), Timisoara, Romania. Proceedings of the Conference. Published by TTP Trans Tech Publications Ltd., Pfaffikon, Switzerland, (2013). ISSN print 1022-6680. Pages187-193.

[13] Lia-Nicoleta Boţilă1 (1ISIM Timişoara); R. Cojocaru1; C. Ciucă1; Characteristics of friction stir welding tools for high hardness materials. TIMA 11. The 5th International Conference - Innovative technologies for joining advanced materials. Timisoara, Romania, 2011. Proceedings CD, pages 8.

[14] Lia-Nicoleta Botila; Radu Cojocaru; Victor Verbitchi; et al.; Project PN 19 36 01 01. Researches regarding the development of new innovative methods of applying the friction stir welding (FSW) process, in order to extend the possibilities of application in priority areas (within the Laboratory for Friction Stir Processing, FSP). Stage 3. Experimental verification of the application technique of FSW welding in inert gas environment. Referential finalization. ISIM Timisoara, 2019-2020.

DOI: 10.4028/p-wr0f72

[15] EN ISO 25239:2011 - Friction stir welding - Aluminium, Part 4 - Specification and qualification of the welding procedure. Part 5 - Quality requirements and inspection.

DOI: 10.3403/30421848u