A simplified design of clamping system and fixtures for friction stir welding of aluminium alloys
DOI:
https://doi.org/10.15282/jmes.9.2015.10.0158Keywords:
Aluminum alloys; backing plate; clamping system; friction stir welding.Abstract
Sound friction stir welds could be attained by using an active design of backing/clamping system with a proper selection of the welding parameters. This work presented a simplified design of fixtures and backing plates to be used for friction stir welding of aluminum alloys. The test-rig was constructed to prevent dispersal or lifting of the specimens throughout the joining process and to ensure uniform distribution of temperature along the plates. The workpieces were subjected to uniform lateral and vertical pressures by means of bolts and nuts. Compound backing plates and pressure bars with additional side plates were included to increase the heat sink. Several coupons of dissimilar aluminum alloys AA7075 and AA6061 were joined to inspect the validity of this design. The tests showed promising results with defects-free welds, good strength and smooth surface finish without geometric imperfection and gap creation between the welded specimens. Efficiency of the joint reached its maximum value of about 82% with respect to the ultimate strength of the AA6061 alloy at 1100 rpm rotation speed and 300 mm/min feed. These results encourage using and improving the present design for future studies of friction stir welding.
References
Parida B, Vishwakarma SD, Pal S. Design and development of fixture and force measuring system for friction stir welding process using strain gauges. Journal of Mechanical Science and Technology. 2015;29:739-49.
Upadhyay P, Reynolds AP. Effects of forge axis force and backing plate thermal diffusivity on FSW of AA6056. Materials Science and Engineering: A. 2012;558:394-402.
Imam M, Racherla V, Biswas K. Effect of backing plate material in friction stir butt and lap welding of 6063-T4 aluminium alloy. International Journal of Advanced Manufacturing Technology. 2015;77(9):2181-95.
Colligan KJ. The friction stir welding process: an overview. In: Lohwasser D, Chen Z, editors. Friction Stir Welding: Woodhead Publishing; 2010. p. 15-41.
Zappia T, Smith C, Colligan K, Ostersehlte H, Kallee SW. 4 - Friction stir welding equipment. In: Lohwasser D, Chen Z, editors. Friction Stir Welding: Woodhead Publishing; 2010. p. 73-117.
Sathari NAA, Shah LH, Razali AR. Investigation of Single-Pass/Double-Pass Techniques on Friction Stir Welding of Aluminium. Journal of Mechanical Engineering and Sciences. 2014;7:1053-61.
Abd Razak NA, Ng SS. Investigation of Effects of MIG Welding on Corrosion Behaviour of AISI 1010 Carbon Steel. Journal of Mechanical Engineering and Sciences. 2014;7:1168-78.
Mishra RS, Mahoney MW. Friction stir welding and processing: ASM International; 2007.
Smith CB, Hinrichs JF, Crusan WA, Leverett J. FSW Stirs Up Welding Process Competition. Forming and Fabricating. 2003:25–31.
Zain-Ul-Abdein M, Nélias D, Jullien JF, Deloison D. Thermo-mechanical analysis of laser beam welding of thin plate with complex boundary conditions. International Journal of Material Forming. 2008;1:1063-6.
Liu C, Zhang JX. Numerical simulation of transient welding angular distortion with external restraints. Science and Technology of Welding and Joining. 2009;14:26-31.
Liu QS, Mahdavian SM, Aswin D, Ding S. Experimental study of temperature and clamping force during Nd:YAG laser butt welding. Optics & Laser Technology. 2009;41:794-9.
Zain-ul-abdein M, Nélias D, Jullien J-F, Deloison D. Experimental investigation and finite element simulation of laser beam welding induced residual stresses and distortions in thin sheets of AA 6056-T4. Materials Science and Engineering: A. 2010;527:3025-39.
Sathari NAA, Razali AR, Ishak M, Shah LH. Mechanical Strength of Dissimilar Aa7075 and Aa6061 Aluminum Alloys Using Friction Stir Welding. International Journal of Automotive and Mechanical Engineering. 2015;11:2713-21.
Ishak M, Noordin NFM, Razali ASK, Shah LHA, Romlay FRM. Effect of filler on weld metal structure of AA6061 aluminum alloy by tungsten inert gas welding. International Journal of Automotive and Mechanical Engineering. 2015;11:2438- 46.
Ahmad R, Asmael MBA. Effect of aging time on microstructure and mechanical properties of AA6061 friction stir welding joints. International Journal of Automotive and Mechanical Engineering. 2015;11:2364-72.
Christner B, Sylva G. Friction stir welding development for aerospace applications. ICAWT. Columbus, OH, USA.1996, p. 359-68.
Leonard A, Lockyer S. Flaws in friction stir welds. 4th International Symposium on Friction Stir Welding: Park City, Utah, USA; 2003.
Richter-Trummer V, Suzano E, Beltrão M, Roos A, dos Santos JF, de Castro PMST. Influence of the FSW clamping force on the final distortion and residual stress field. Materials Science and Engineering: A. 2012;538:81-8.
Fratini L, Micari F, Buffa G, Ruisi VF. A new fixture for FSW processes of titanium alloys. CIRP Annals - Manufacturing Technology. 2010;59:271-4.
Upadhyay P, Reynolds A. Effect of Backing Plate Thermal Property on Friction Stir Welding of 25-mm-Thick AA6061. Metallurgical and Materials Transactions
A. 2014;45:2091-100.
Khodir SA, Shibayanagi T, Naka M. Control of hardness distribution in friction stir welded AA2024-T3 aluminum alloy. Materials Transactions. 2006;47:1560- 7.
Hatifi MM, Firdaus MH, Razlan AY. Modal Analysis of Dissimilar Plate Metal Joining with Different Thicknesses using MIG Welding. International Journal of Automotive and Mechanical Engineering. 2014;9:1723-33.
Hariri A, Azreen P N, Abdull N, Leman AM, Yusof MZM. Determination of customer requirement for welding fumes index development in automotive industries by using quality function deployment approach. International Journal of Automotive and Mechanical Engineering. 2014;9:1609-19.
Chaki S, Ghosal S. A GA–ANN hybrid model for prediction and optimization of CO2 laser-mig hybrid welding process. International Journal of Automotive and Mechanical Engineering. 2015;11:2458-70.
Murphy A, Ekmekyapar T, Quinn D, Özakça M, Poston K, Moore G, et al. The influence of assembly friction stir weld location on wing panel static strength. Thin-Walled Structures. 2014;76:56-64.
Mishra RS, De PS, Kumar N. FSW of aluminum alloys. Friction stir welding and processing: Springer; 2014. p. 109-48.
Charde N. Effects of electrode deformation of resistance spot welding on 304 austenitic stainless steel weld geometry. Journal of Mechanical Engineering and Sciences. 2012;3:261-70.
Dursun T, Soutis C. Recent developments in advanced aircraft aluminium alloys. Materials & Design. 2014;56:862-71.
Bayazid SM, Farhangi H, Asgharzadeh H, Radan L, Ghahramani A, Mirhaji A. Effect of cyclic solution treatment on microstructure and mechanical properties of friction stir welded 7075 Al alloy. Materials Science and Engineering: A. 2016;649:293-300.
Abd Razak NA, Ng SS. Investigation of effects of MIG welding on corrosion behaviour of AISI 1010 carbon steel. Journal of Mechanical Engineering and Sciences. 2014;7:1168-78.
Shah L, Akhtar Z, Ishak M. Investigation of aluminum-stainless steel dissimilar weld quality using different filler metals. International Journal of Automotive and Mechanical Engineering. 2013;8:1121-31.
Kumar N, Mishra RS, Yuan W. Friction Stir welding of dissimilar alloys and materials: A Volume in the Friction Stir Welding and Processing Book Series: Butterworth-Heinemann; 2015.
Çam G, Mistikoglu S. Recent developments in friction stir welding of Al-alloys. Journal of Materials Engineering and Performance. 2014;23:1936-53.
NAA S, AR R. Investigation of single-pass double-pass techniques on friction stir welding of aluminium. Journal of Mechanical Engineering and Sciences. 2014;7:1053-61.
Fu MJ, Li XH, Han XQ, Xu HY. Research on work hardening type superplastic deformation behavior of FSW titanium alloy. Materials Science Forum, 2016; 838-839; 506-11.
El-Batahgy A-M, Miura T, Ueji R, Fujii H. Investigation into feasibility of FSW process for welding 1600MPa quenched and tempered steel. Materials Science and Engineering: A. 2016;651:904-13.
Gao Y, Nakata K, Nagatsuka K, Matsuyama T, Shibata Y, Amano M. Microstructures and mechanical properties of friction stir welded brass/steel dissimilar lap joints at various welding speeds. Materials and Design. 2016;90:1018-25.
Murr LE. A Review of FSW Research on dissimilar metal and alloy systems. Journal of Materials Engineering and Performance. 2010;19:1071-89.
Guo JF, Chen HC, Sun CN, Bi G, Sun Z, Wei J. Friction stir welding of dissimilar materials between AA6061 and AA7075 Al alloys effects of process parameters. Materials & Design. 2014;56:185-92.
İpekoğlu G, Çam G. Effects of initial temper condition and postweld heat treatment on the properties of dissimilar friction-stir-welded joints between AA7075 and AA6061 aluminum alloys. Metallurgical and Materials Transactions
A. 2014;45:3074-87.
Cole EG, Fehrenbacher A, Duffie NA, Zinn MR, Pfefferkorn FE, Ferrier NJ. Weld temperature effects during friction stir welding of dissimilar aluminum alloys 6061-t6 and 7075-t6. International Journal of Advanced Manufacturing Technology. 2013;71:643-52.
Shah LH, Zainal Ariffin NF, Razali AR. Parameter optimization of AA6061- AA7075 dissimilar friction stir welding using the Taguchi method. Applied Mechanics and Materials. 2014;695:20-3.
Ishak M, Shah LH, Aisha ISR, Hafizi W, Islam MR. Study of resistance spot welding between AISI 301 stainless steel and AISI 1020 carbon steel dissimilar alloys. Journal of Mechanical Engineering and Sciences. 2014;6:793-806.
Metals ASf, Davis JR. ASM handbook. 2. Properties and selection: nonferrous alloys and special-purpose materials: ASM international; 2009.
Rai R, De A, Bhadeshia HKDH, DebRoy T. Review: friction stir welding tools. Science and Technology of Welding and Joining. 2011;16:325-42.
Thomas W, Norris I, Staines D, Watts E. Friction stir welding-process developments and variant techniques. The SME Summit. 2005;1:1-21.
Peel M, Steuwer A, Preuss M, Withers PJ. Microstructure, mechanical properties and residual stresses as a function of welding speed in aluminium AA5083 friction stir welds. Acta Materialia. 2003;51:4791-801.
Williams SW, Steuwer A. 8 - Residual stresses in friction stir welding. In: Lohwasser D, Chen Z, editors. Friction Stir Welding: Woodhead Publishing; 2010. p. 215-44.
Zettler R. 3 - Material deformation and joint formation in friction stir welding. In: Lohwasser D, Chen Z, editors. Friction Stir Welding: Woodhead Publishing; 2010. p. 42-72.
Cavaliere P, Nobile R, Panella FW, Squillace A. Mechanical and microstructural behaviour of 2024–7075 aluminium alloy sheets joined by friction stir welding. International Journal of Machine Tools and Manufacture. 2006;46:588-94.
Cavaliere P, Cerri E, Squillace A. Mechanical response of 2024-7075 aluminium alloys joined by Friction Stir Welding. Journal of Materials Science. 2005;40:3669-76.
Firouzdor V, Kou S. Formation of liquid and intermetallics in Al-to-Mg friction stir welding. Metallurgical and Materials Transactions A. 2010;41:3238-51.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2015 The Author(s)
This work is licensed under a Creative Commons Attribution 4.0 International License.
