Beruflich Dokumente
Kultur Dokumente
MADAN PATNAMSETTY
KHASHAYAR KHANLARI
FRICTION
FRICTION is the force resisting the relative motion of solid surfaces, fluid layers, and material
elements sliding against each other
when surfaces in contact move relative to each other, the friction between the two surfaces
converts kinetic and heat energy
FRICTION WELDING
The process that use machines that are designed to convert mechanical
energy into heat at the joint to be welded.
This process accomplishes welding by bringing atoms of the materials
being joined to equilibrium spacing principally through plastic
deformation due to the application of pressure at temperatures below
the melting point of the base materials, without the addition of filler
that melts.
This process rely on friction to cause heating and bring atoms or
molecules together by microscopic plastic deformation to produce a
weld
INTRODUCTION
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ZONES AFFECTED
THE TOOL ROTATION DIRECTION HAS
SIMILAR SENSE TO THE TOOL
TRANSLATION DIRECTION, IS KNOWN
AS THE ADVANCING SIDE OF THE
WELD
THE TOOL ROTATION IS OPPOSITE TO
THE TOOL TRANSLATION DIRECTION,
IS KNOWN AS THE RETREATING SIDE
OF THE WELD
ZONE IN CONTACT WITH SHOULDER http://products.asminternational.org/hbk/content/V06A/D03/graphics/inli
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IS SHOULDER EFFECTED ZONE AND
ZONE IN CONTACT WITH PIN IS PIN-
AFFECTED ZONE
THERMAL ASPECTS
THE WELDING CYCLE IS SPLIT IN FOUR STAGES DURING WHICH THE HEAT FLOW AND THERMAL
PROFILE WILL BE VARIED.
1. DWELL: THE MATERIAL IS PREHEATED BY A STATIONARY, ROTATING TOOL TO ACHIEVE A SUFFICIENT TEMPERATURE
AHEAD OF THE TOOL TO ALLOW THE TRAVERSE. THIS PERIOD MAY ALSO INCLUDE THE PLUNGE OF THE TOOL INTO
THE WORK PIECE.
2. TRANSIENT HEATING: WHEN THE TOOL BEGINS TO MOVE THERE WILL BE A TRANSIENT PERIOD WHERE THE HEAT
PRODUCTION AND TEMPERATURE AROUND THE TOOL WILL ALTER IN A COMPLEX MANNER UNTIL AN ESSENTIALLY
STEADY-STATE IS REACHED.
3. PSEUDO STEADY-STATE: ALTHOUGH FLUCTUATIONS IN HEAT GENERATION WILL OCCUR THE THERMAL FIELD
AROUND THE TOOL REMAINS EFFECTIVELY CONSTANT, AT LEAST ON THE MACROSCOPIC SCALE.
4. POST STEADY-STATE: NEAR THE END OF THE WELD HEAT MAY "REFLECT" FROM THE END OF THE PLATE LEADING TO
ADDITIONAL HEATING AROUND THE TOOL.
Qtotal = Q1+Q2+Q3
is the inclination of conical surface of the shoulder
Image courtesy from P.S. De, N. Kumar, J.Q. Su, and R.S. Mishra, Fundamentals of
Friction Stir Welding
MATERIAL FLOW
With respect to all the thermal aspects in FSW, Plastic flow plays an important role in
heat generation.
The basic material flow characteristics from the above kind of experiments are
1. Near the shoulder the atoms from retreating side are diffused or dragged towards the
centre weld line and deposited on advanced side
2. Atoms from the line intersecting pin diffuses and deposit behind the tool through the
retreating side for not more than 1 pin diameter, exception with welds of lower
thickness for which the shoulder has its domination.
3. Flow pattern similar to shoulder area is visible at pin bottom but at very low scale(area).
4. Tool run out can vary material flow in addition to causing periodic variation in welding
MATERIAL FLOW
Distribution showing the position of AA5454-O markers
(white region) in AA2195-T8 alloy after the passage of
friction stir tool pin. The markers placed perpendicular to
the weld path moved backward by a distance equal to the
chord length intersecting the pin circle, and oriented
parallel to welding direction. The double arrow gives a
measure of the pin diameter
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Difference in grain size within the ring patterns
observed in the horizontal-section microstructure of a
bead-on-plate run of cast A356 alloy. The tool
advance per revolution (APR) was 0.1 mm (0.004 in)
Onion rings type of bands are formed alternating with
different grain size and particle size distribution in the
weld nugget.
Bands are separated by an equal distance or less than
tool advance per revolution.
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MATERIAL FLOW
Image courtesy P.S. De, N. Kumar, J.Q. Su, and R.S. Mishra,
Fundamentals of Friction Stir Welding
FRICTIONAL COEFFICIENT
According to Schmidt and Hattels simulation, during the pseudo- steady-state
period, the contribution of friction to generate heat is reduced by 25% of total
heat generated, Thus for an accurate FSW process simulation, a proper
assessment of frictional heat contribution is essential.
Frictional forces are classified into two types:
1. Coulombs frictional force: The frictional force may be expressed as
= P
And is Coulombs co-efficient of friction and p is pressure applied.
2. constant shear Force: The frictional stress for constant shear model is
= m(0/3)
m = ionic factor and 0 = flow stress of the material
FRICTIONAL COEFFICIENT
But after the modification of the same theory there are three conditions assumed to be
existed. They are sticking, sliding, and partial sliding/sticking
conditions.
For sliding condition m value is 0 and for sticking condition the m value is 1, at times the
co-efficient of friction is greater than 1 (1.3)
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DEFECTS
Defects mainly occur due to flow related or geometric.
There are various types pf defects which includes
1. wormhole or voids: is the tunnel of inadequately consolidated and forged
material running in the longitudinal direction which is formed due to
excessive heat input due to high rotational speed low transverse feed
2. Lack of penetration:
3. Lack of fusion:
4. Surface lack of fill: due to insufficient forge pressure
5. Root-flow defect :
6. Nugget collapse: A unique defect which is caused high welding speed and
excessive metal flow to stir zone and excessive hot weld.
7. Surface galling: sticking of material at the tip of the pin causes surface
galling which is tearing of metal on top surface of weld.
8. Ribbon flashing: excessive expulsion of material on the surface of welding
9. Scalloping: defect in which the series of small voids located in the
advancing side interleaving the stir zone along the weld
DEFECTS
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STRAIN AND STRAIN RATE
Since the plastic deformation its is obvious to experience the strain and strain rate
through the process.
There is a continuous rise in strain and strain rate as it approaches the shear zone with a
maximum strain of at the shear zone boundary
The deformation in FSW is similar to torsional which leads to an expression for strain rate.
= Rm.2re/Le C.I. CHANG, C.J. LEE, AND J.C. HUANG, SCR. MATER., VOL 51, 2004, P 509514
Where Rm is average material flow rate re is the radius of the dynamically recrystallized zone,
and le is the depth of the dynamically recrystallized zone.
The strain in shear zone is expressed as
= ln(l/APR)+|ln(APR/l)| T. LONG, W. TANG, AND A.P. REYNOLDS, SCI. TECHNOL. WELD. JOIN., VOL 12, 2007, P
311317
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MICROSTRUCTURAL FEATURES
The microstructure depends on alloy
composition, initial
material temperature, welding parameter,
tool geometry, and cooling rate
The asymmetric nature of FSW resulted in high
characteristic microstructure, the zone can be
broken up as, with different microstructures in
each zone
1. THE STIR ZONE (NUGGET): The zone which
experiences extreme deformation and is a
consequence of rotating tool. And under some
processing conditions, an onion ring structure
develops. The interface between the parent
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material is relatively diffusive and its a quite
0082764.jpg
Typical macrograph showing various microstructural sharp towards the advancing side.
zones in friction stir welded 7075Al-T651. 2. THERMO-MECHANICALLY AFFECTED
ZONE (TMAZ): A special zone in between nugget
and HAZ which experiences both temperature
MICROSTRUCTURAL FEATURES
MAGNESIUM ALLOYS
5xxx 3.56
2xxx 0.512
1xxx 0.520
NUGGET GRAIN SIZE:
Grain size in nugget zone is influenced by Al-Cu-Mg-Ag-T6 5
Mg-5.5Y-4.3Zn 1
NUGGET ZONE MICRO STRUCTURE
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Thickness
Alloy mm Tool materials
Aluminium alloys <12 Tool steel, WC-Co
MP159(nickel cobalt based
<26 multi phased alloy)
Manganese alloys <6 Tool steel, WC
Copper and
copper alloys <50 Nickel alloys, tungsten alloys
<11 Tool steel
Tool pin Cylindrical Tapered with Threaded, Tri-flute Inclined Tapered with
shape with threads threads tapered with with flute cylindrical threads
three flutes ends flared with threads
out
Ratio of pin 1 0.4 0.3 0.3 1 0.4 R.S. Mishra, Z.Y. Ma / Materials
volume to
cylindrical Science and Engineering R 50
pin volume (2005) 178
Swept 1.1 1.8 2.6 2.6 Depends on 1.8
volume to pin angle
pin volume
ratio
Rotary No No No No No Yes
reversal
Application Butt welding; Butt welding Butt welding Lap welding Lap welding When
fails in lap with lower with further with lower with lower minimum
welding welding lower thinning of thinning of asymmetry
ADVANTAGES AND LIMITATIONS
ADVANTAGES
Good mechanical properties in the as-welded condition
Improved safety due to the absence of toxic fumes or the spatter of molten material.
No consumables a threaded pin made of conventional tool steel, e.G., Hardened H13, can weld
over 1 km (0.62 mi) of aluminium, and no filler or gas shield is required for aluminium.
Easily automated on simple milling machines lower setup costs and less training.
Can operate in all positions (horizontal, vertical, etc.), As there is no weld pool.
Generally good weld appearance and minimal thickness under/over-matching, thus reducing the
need for expensive machining after welding.
Low environmental impact.
DISADVANTAGES
Exit hole left when tool is withdrawn.
Large down forces required with heavy-duty clamping necessary to hold the plates together.
Less flexible than manual and arc processes (difficulties with thickness variations and non-linear
welds).
Often slower traverse rate than some fusion welding techniques, although this may be offset if
fewer welding passes are required.
APPLICATIONS
https://www.youtube.com/watch?v=aNbQH8XBgxQ
REFERENCES
IMAGE COURTESY: HTTP://SEMINARLINKS.BLOGSPOT.FI/2014/04/FRICTION-STIR-WELDING-FSW-
SEMINAR.HTML
HTTPS://WWW.YOUTUBE.COM/WATCH?V=ANBQH8XBGXQ
HTTP://EN.WIKIPEDIA.ORG/WIKI/FRICTION_STIR_WELDING
HTTP://EN.WIKIPEDIA.ORG/WIKI/FRICTION_WELDING
P.S. DE, N. KUMAR, J.Q. SU, AND R.S. MISHRA, FUNDAMENTALS OF FRICTION STIR WELDING,