Open Access Open Access  Restricted Access Subscription or Fee Access

Characteristics of Potential Sources - Vertical Force, Torque and Current on Penetration Depth for Quality Assessment in Friction Stir Welding of AA 6061 Pipes


(*) Corresponding author


Authors' affiliations


DOI: https://doi.org/10.15866/irease.v12i4.16362

Abstract


Friction stir welding of the pipes or curved bodies in aerospace components is tedious due to complex geometry, and hence, research articles related to it are rare. Primarily, this research has investigated the nature of vertical welding force, torque and current on the weld quality during the friction stir welding of Aluminium 6061 (AA 6061) pipe at different penetration depths – 1.4 mm, 1.54 mm, 1.66 mm, 1.7 mm, 1.9 mm and 2 mm. The feed rate and rotational speed have been set at 1 mm/s and 1800 rpm respectively. The weld quality has been evaluated using visual inspection and tensile test. From the results, penetration depths from 1.7 mm to 2 mm have been suitable for producing quality welds on a specimen with 2 mm thickness, which resulted in fewer shoulder marks, and percentage reduction of strength lower than 25.61% compared to the base metal. Friction stir welding using penetration depth of 1.4 mm has resulted in a weld, with excess shoulder marks and 43.84% of reduction in strength, which is not acceptable. In addition, the range of penetration depths (1.7 mm to 2 mm) for which the force remains constant is recommended for producing quality welds. While torque and power have increased linearly with the penetration depth, the distribution of the current has remained the same for different penetration depths. However, the current consumption has varied significantly in each one of the friction stir welding stages clearly distinguishing the tool penetration, the dwell time, the traverse tool movement and the tool pull out. The experimentation has been successful in laying the foundation for the process parameters signifying the importance of penetration depth.
Copyright © 2019 Praise Worthy Prize - All rights reserved.

Keywords


Friction Stir Welding (FSW); AA 6061 Pipe; Penetration Depth; Vertical Force; Torque; Current Consumption

Full Text:

PDF


References


Mourad, AH I., M. Allam, and A. El Domiaty, Study on the mechanical behavior of aluminum alloy 5083 friction stir welded joint, ASME 2014 Pressure Vessels and Piping Conference, American Society of Mechanical Engineers, 2014.
https://doi.org/10.1115/pvp2014-28556

Mourad, Abdel-Hamid I., Khalifa H. Harib, and Aly El-Domiaty, Fracture Behavior of Friction Stir Spot Welded Joint, ASME 2010 Pressure Vessels and Piping Division/K-PVP Conference, American Society of Mechanical Engineers, 2010.
https://doi.org/10.1115/pvp2010-25986

S. Ahmed and P. Saha, Development and testing of fixtures for friction stir welding of thin aluminium sheets, J. Mater. Process. Technol., Vol. 252, pp. 242–248, 2018.
https://doi.org/10.1016/j.jmatprotec.2017.09.034

T. Mira-Aguiar, D. Verdera, C. Leitão, and D. M. Rodrigues, Tool assisted friction welding: A FSW related technique for the linear lap welding of very thin steel plates, J. Mater. Process. Technol., Vol. 238, pp. 73-80, 2016.
https://doi.org/10.1016/j.jmatprotec.2016.07.006

A. H. I. Mourad, A. Khourshid, and T. Sharef, Gas tungsten arc and laser beam welding processes effects on duplex stainless steel 2205 properties, Mater. Sci. Eng. A, Vol. 549, pp. 105-113, 2012.
https://doi.org/10.1016/j.msea.2012.04.012

M. Maeda, H. Liu, H. Fujii, and T. Shibayanagi, Temperature field in the vicinity of FSW-tool during friction stir welding of aluminium alloys, Weld. World, Vol. 49, n. 3-4, pp. 69–75, 2005.
https://doi.org/10.1007/bf03266478

Y. M. Hwang, Z. W. Kang, Y. C. Chiou, and H. H. Hsu, Experimental study on temperature distributions within the workpiece during friction stir welding of aluminum alloys, Int. J. Mach. Tools Manuf., Vol. 48, n. 7-8, pp. 778-787, 2008.
https://doi.org/10.1016/j.ijmachtools.2007.12.003

M. Imam, K. Biswas, and V. Racherla, On use of weld zone temperatures for online monitoring of weld quality in friction stir welding of naturally aged aluminium alloys, Mater. Des., Vol. 52, pp. 730–739, 2013.
https://doi.org/10.1016/j.matdes.2013.06.014

S. Amini and M. R. Amiri, Pin axis effects on forces in friction stir welding process, Int. J. Adv. Manuf. Technol., Vol. 78, n. 9–12, pp. 1795–1801, 2015.
https://doi.org/10.1007/s00170-015-6785-z

R. Jain, S. K. Pal, and S. B. Singh, Finite element simulation of pin shape influence on material flow, forces in friction stir welding, Int. J. Adv. Manuf. Technol., Vol. 94, n. 5-8, pp. 1-17, 2017.
https://doi.org/10.1007/s00170-017-0215-3

A. Forcellese, M. Martarelli, and M. Simoncini, Effect of process parameters on vertical forces and temperatures developed during friction stir welding of magnesium alloys, Int. J. Adv. Manuf. Technol., Vol. 85, n. 1–4, pp. 595–604, 2016.
https://doi.org/10.1007/s00170-015-7957-6

R. Beygi, M. Kazeminezhad, M. Z. Mehrizi, G. Eisaabadi B, and A. Loureiro, Friction stir butt welding of Al-Cu bilayer laminated composites: analysis of force, torque, and temperature, Int. J. Adv. Manuf. Technol., Vol. 88, n. 1–4, pp. 393–400, 2017.
https://doi.org/10.1007/s00170-016-8778-y

B. Das, S. Pal, and S. Bag, Design and development of force and torque measurement setup for real time monitoring of friction stir welding process, Meas. J. Int. Meas. Confed., Vol. 103, pp. 186–198, 2017.
https://doi.org/10.1016/j.measurement.2017.02.034

H. F. Wang, J. L. Wang, D. W. Zuo, and W. W. Song, Application of Stir Tool Force Measuring Dynamometer for Friction Stir Welding of Aluminum Alloys, Strength Mater., Vol. 49, n. 1, pp. 162–170, 2017.
https://doi.org/10.1007/s11223-017-9854-8

H. Su, C. S. Wu, A. Pittner, and M. Rethmeier, Simultaneous measurement of tool torque, traverse force and axial force in friction stir welding, J. Manuf. Process., Vol. 15, n. 4, pp. 495–500, 2013.
https://doi.org/10.1016/j.jmapro.2013.09.001

B. Das, S. Pal, and S. Bag, Torque based defect detection and weld quality modelling in friction stir welding process, J. Manuf. Process., Vol. 27, pp. 8–17, 2017.
https://doi.org/10.1016/j.jmapro.2017.03.012

U. Kumar, I. Yadav, S. Kumari, K. Kumari, N. Ranjan, R. K. Kesharwani, R. Jain, S. Kumar, S. Pal, D. Chakravarty, and S. K. Pal, Defect identification in friction stir welding using discrete wavelet analysis, Adv. Eng. Softw., Vol. 85, pp. 43–50, 2015.
https://doi.org/10.1016/j.advengsoft.2015.02.001

R. Ranjan, A. R. Khan, C. Parikh, R. Jain, R. P. Mahto, S. Pal, S. K. Pal, and D. Chakravarty, Classification and identification of surface defects in friction stir welding: An image processing approach, J. Manuf. Process., Vol. 22, pp. 237–253, 2016.
https://doi.org/10.1016/j.jmapro.2016.03.009

P. Sinha, S. Muthukumaran, R. Sivakumar, and S. K. Mukherjee, Condition monitoring of first mode of metal transfer in friction stir welding by image processing techniques, Int. J. Adv. Manuf. Technol., Vol. 36, n. 5–6, pp. 484–489, 2008.
https://doi.org/10.1007/s00170-006-0854-2

R. Rajashekar and B. M. Rajaprakash, Development of a model for friction stir weld quality assessment using machine vision and acoustic emission techniques, J. Mater. Process. Technol., Vol. 229, pp. 265–274, 2016.
https://doi.org/10.1016/j.jmatprotec.2015.09.030

A. Sumesh, D. T. Thekkuden, B. B. Nair, K. Rameshkumar, and K. Mohandas, Acoustic signature based weld quality monitoring for SMAW process using data mining algorithms, Applied Mechanics and Materials, Vol. 813, pp. 1104–1113, 2015.
https://doi.org/10.4028/www.scientific.net/amm.813-814.1104

D. T. Thekkuden, A.-H. I. Mourad, J. V. Christy, and A. H. Idrisi, Assessment of weld quality using control chart and frequency domain analysis, ASME 2018 Pressure Vessels and Piping Conference, pp. V06BT06A004-V06BT06A004, 2018.
https://doi.org/10.1115/pvp2018-85091

C. Chen, R. Kovacevic, and D. Jandgric, Wavelet transform analysis of acoustic emission in monitoring friction stir welding of 6061 aluminum, Int. J. Mach. Tools Manuf., Vol. 43, n. 13, pp. 1383–1390, 2003.
https://doi.org/10.1016/s0890-6955(03)00130-5

B. Das, S. Pal, and S. Bag, Monitoring of Friction Stir Welding Process using Main Spindle Motor Current, J. Inst. Eng. Ser. C, pp. 1–6, 2017.
https://doi.org/10.1007/s40032-017-0371-0

D. T. Thekkuden, A. Santhakumari, A. Sumesh, A.-H. I. Mourad, and K. Rameshkumar, Instant detection of porosity in gas metal arc welding by using probability density distribution and control chart, Int. J. Adv. Manuf. Technol., Vol. 95, n. 9-12, pp. 4583–4606, 2018.
https://doi.org/10.1007/s00170-017-1484-6

H. J. Liu, H. Fujii, M. Maeda, and K. Nogi, Tensile properties and fracture locations of friction-stir-welded joints of 6061-T6 aluminum alloy, J. Mater. Sci. Lett., Vol. 22, pp. 1061–1063, 2003.
https://doi.org/10.1023/A:1024970421082

G. M. Reddy, P. Mastanaiah, K. S. Prasad, and T. Mohandas, Microstructure and mechanical property correlations in AA 6061 aluminium alloy friction stir welds, Trans. Indian Inst. Met., Vol. 62, n. 1, pp. 49–58, 2009.
https://doi.org/10.1007/s12666-009-0007-z

S. Rajakumar, C. Muralidharan, and V. Balasubramanian, Statistical analysis to predict grain size and hardness of the weld nugget of friction-stir-welded AA6061-T6 aluminium alloy joints, Int. J. Adv. Manuf. Technol., Vol. 57, n. 1–4, pp. 151–165, 2011.
https://doi.org/10.1007/s00170-011-3279-5

S. Rengarajan and V. S. Rao, Characteristics of AA7075-T6 and AA6061-T6 friction welded joints, Trans. Can. Soc. Mech. Eng., Vol. 39, n. 4, pp. 845–854, 2015.
https://doi.org/10.1139/tcsme-2015-0067

J. Teimurnezhad, H. Pashazadeh, and A. Masumi, Effect of shoulder plunge depth on the weld morphology, macrograph and microstructure of copper FSW joints, J. Manuf. Process., Vol. 22, pp. 254–259, 2016.
https://doi.org/10.1016/j.jmapro.2016.04.001

N. Z. Khan, A. N. Siddiquee, Z. A. Khan, and S. K. Shihab, Investigations on tunneling and kissing bond defects in FSW joints for dissimilar aluminum alloys, J. Alloys Compd., Vol. 648, pp. 360–367, 2015.
https://doi.org/10.1016/j.jallcom.2015.06.246

W. M. S. Wan Sulong, M. A. Rojan, and M. N. Mazlee, Influence of tool plunge depth on the joint strength and hardness of friction stir welded AA6061 and mild steel, Adv. Struct. Mater., Vol. 85, pp. 373–383, 2018.
https://doi.org/10.1007/978-3-319-72697-7_30

N. Z. Khan, Z. A. Khan, and A. N. Siddiquee, Effect of Shoulder Diameter to Pin Diameter (D/d) Ratio on Tensile Strength of Friction Stir Welded 6063 Aluminium Alloy, Mater. Today Proc., Vol. 2, n. 4–5, pp. 1450–1457, 2015.
https://doi.org/10.1016/j.matpr.2015.07.068

S. Eslami, L. Mourao, N. Viriato, P. J. Tavares, and P. M. G. P. Moreira, Multi-axis force measurements of polymer friction stir welding, J. Mater. Process. Technol., Vol. 256, pp. 51–56, 2018.
https://doi.org/10.1016/j.jmatprotec.2018.01.044

M. Mehta, K. Chatterjee, and A. De, Monitoring torque and traverse force in friction stir welding from input electrical signatures of driving motors, Sci. Technol. Weld. Join., Vol. 18, n. 3, pp. 191–197, 2013.
https://doi.org/10.1179/1362171812y.0000000084

M. S. Węglowski and S. Dymek, Relationship between friction stir processing parameters and torque, temperature and the penetration depth of the tool, Arch. Civ. Mech. Eng., Vol. 13, n. 2, pp. 186–191, 2013.
https://doi.org/10.1016/j.acme.2013.01.003

W. R. Longhurst, I. C. Wilbur, B. E. Osborne, and B. W. Gaither, Process monitoring of friction stir welding via the frequency of the spindle motor current, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., Vol. 232, n. 4, pp. 720–730, 2018.
https://doi.org/10.1177/0954405416654089

G. Swaminathan & S. Sathiyamurthy, Experimental Study of Mechanical and Metallurgical Properties of Friction Stir Welded Dissimilar Aluminum Alloys, Int. J. Mech. Prod. Eng. Res. Dev., Vol. 8, n. 1, pp. 1049–1058, 2018.
https://doi.org/10.24247/ijmperdfeb2018125

S. S. Kumar, S. D. Ashok, and S. Narayanan, Investigation of friction stir butt welded aluminium alloy flat plates using spindle motor current monitoring method, Procedia Eng., Vol. 64, pp. 915–925, 2013.
https://doi.org/10.1016/j.proeng.2013.09.168


Refbacks

  • There are currently no refbacks.



Please send any question about this web site to info@praiseworthyprize.com
Copyright © 2005-2024 Praise Worthy Prize