Tilt Angle Effect on Friction Stir Welding Conditions

Abstract:

In this paper, the effect of tool tilt angle on heat generation and forging force for 1050 aluminum plates, welded by friction stir butt welding, were investigated. Usage of the welding tool with and without pin made it possible to elucidate the particularly reactions of the pin and shoulder on tilt angle variation. For this purpose, tool tilt angle was varied from 0⁰ to 3⁰ under other constant parameters, such as tool geometry and of tool traverse-rotation speed ratio. For the estimation shoulder work pieces interaction the Reynolds lubricant film theory equations were used. The results indicate that the tilt angle is an effective factor on material forging and heat generation behind the pin in the Advancing Side (AS). Recorded peak temperatures were varied from 312 °C to 442 °C in the weld centre.

• Periodical: Key Engineering Materials (Volume 910)
• Pages: 115-122
• DOI: https://doi.org/10.4028/p-4rlc0e
• Online since: February 2022
• Authors: Andrey Tsarkov*, Konstantin Trukhanov, Igor Zybin, Alexei Vichniakov
• Keywords: Aluminum Alloy, Friction Force, Friction Stir Welding, Hydrodynamic Theory, Lubricant Film, Tool Tilt Angle

References

[1] A.K. Lakshminarayanan, S. Malarvizhi, and V. Balasubramanian, Developing friction stir welding window for AA2219 aluminium alloy. Trans. Nonferrous Met. Soc. China, (2011), 21(11), 2339-2347.

DOI: 10.1016/s1003-6326(11)61018-2

[2] G. Rambabu, D.B. Naik, C.V. Rao, K.S. Rao, and G.M. Reddy, Optimization of friction stir welding parameters for improved corrosion resistance of AA2219 aluminum alloy joints. Defense Technology, (2015), 11(4), 330-337.

DOI: 10.1016/j.dt.2015.05.003

[3] K.S. Arora, S. Pandey, M. Schaper, and K. Kumar, Microstructure evolution during friction stir welding of aluminum alloy AA2219. J. Mater. Sci. Technol., (2010), 26(8), 747-743.

DOI: 10.1016/s1005-0302(10)60118-1

[4] H. Chen, K. Yan, T. Lin, S. Chen, C. Jiang, and Y. Zhao, The Investigation of Typical Welding Defects for 5456 Aluminum Alloy Friction Stir Welds, Materials Science and Engineering, (2006), 433(1-2), 64-69.

DOI: 10.1016/j.msea.2006.06.056

[5] E.F. Shultz, E.G. Cole, C.B. Smith, M.R. Zinn, N.J. Ferrier, and F.E. Pfefferkorn, Effect of Compliance and Travel Angle on Friction Stir Welding With Gaps, Journal of Manufacturing Science and Engineering, (2010), Vol. 132.

DOI: 10.1115/1.4001581

[6] A.H. Derazkola and A. Simchi, Experimental and thermomechanical analysis of friction stir welding of poly (methy methacrylate) sheets. Sci. Technol. Weld. Join., (2018), 23(3), 209-218.

DOI: 10.1080/13621718.2017.1364896

[7] R. Arash and M. Amir, Influence of machine parameters on material flow behavior during channeling in modified friction stir channelling, Int. J. Mater. Form., (2016), 9(1), 1-8.

DOI: 10.1007/s12289-014-1193-8

[8] M. Elyasi, D.H. Aghajani, and M. Hosseinzadeh, Investigations of tool tilt angle on properties friction stir welding of A441 AISI to AA1100 aluminium, Proceedings of the Institution of Mechanical Engineers, Part B: J. Eng. Manuf., (2016), 230(7), 1234-1241.

DOI: 10.1177/0954405416645986

[9] A. Banik, B.S. Roy, J.D. Barma, and S.C. Saha, An experimental investigation of torque and force generation for varying tool tilt angles and their effects on microstructure and mechanical properties: Friction stir welding of AA 6061-T6., J. Manuf. Process., (2018), 31, 395-404.

DOI: 10.1016/j.jmapro.2017.11.030

[10] L. Long, G. Chen, S. Zhang, T. Liu, and Q. Shi, Finite element analysis of the tool tilt angle effect on the formation of friction stir welds, J. Manuf. Process., (2017), 30, 562-569.

DOI: 10.1016/j.jmapro.2017.10.023

[11] S.D. Meshram and G.M. Reddy, Influence of Tool Tilt Angle on Material Flow and Defect Generation in Friction Stir Welding of AA2219, (2018), Defense Science Journal, Vol. 68, No. 5, pp.512-518.

DOI: 10.14429/dsj.68.12027

[12] P.H. Shah and V.J. Badheka An Experimental Insight on the Selection of the Tool Tilt Angle for Friction Stir Welding of 7075 T651 Aluminum Alloys, Indian Journal of Science and Technology, (2016),Vol 9(S1).

DOI: 10.17485/ijst/2016/v9is1/102976

[13] K. Reshad Seighalani, M.K Besharati Givi, A.M. Nasiri, P. Bahemmat, Investigations on the Effects of the Tool Material, Geometry, and Tilt Angle on Friction Stir Welding of Pure Titanium, (2010), J. Mater. Eng. Perform. 19, 955.

DOI: 10.1007/s11665-009-9582-8

[14] H.A.D. Hamid, A.A. Roslee, Study the Role of Friction Stir Welding Tilt Angle on Microstructure and Hardness, (2015), Appl. Mech. Mater., 799–800, 434–438.

DOI: 10.4028/www.scientific.net/amm.799-800.434

[15] C. Hamilton, S. Dymek, M. Kopyscianski, A. Weglowska, A. Pietras, Numerically Based Phase Transformation Maps for Dissimilar Aluminum Alloys Joined by Friction Stir-Welding. Metals, (2018), 8, 324.

DOI: 10.3390/met8050324

[16] N.A. Slezkin Dynamics of a viscous incompressible fluid, Publishing house of Tekhniko-teoreticheskoi literatury - Moscow, (1955).