INFLUENCE OF TOOL SHAPE GEOMETRY ON THE FRICTION
STIR WELDING OF Al – Cu ALLOYS AT DIFFERENT PARAMETER
Harsh Patel, Laurentian University, Bharti School of Engineering.
Conclusion
Thus by this project, we verify the different input
parameters for friction stir welding and tool geometry to
get optimum welded joint property for maximum tensile
strength . At the tool rpm of 1400 and tool feed of
15 mm/min we got the maximum strengths for all three
different profiles . Comparing the joint strength at different
profiles we found that maximum weld Strength 61 .
324
MPa with Cylindrical Tool Profile and after that with
Tapered Cylindrical Tool Profile 79 .095 MPa comparing the
hardness strength at different profiles we found that
maximum hardness of welding point 40 . The sample value
of weld point hardness value is HR 30 T
Contact Information
Harsh Patel
Mechanical Engineering Graduate Student
Laurentian University,
935, Ramsay Lake Road,
Sudbury, Ontario P3E2C6 CANADA
Tel: +1(705) 918 2701
Email: [email protected]
Procedure
Objective
Friction Stir Welding (FSW) is a solid -state welding
process used for welding similar and dissimilar materials .
FSW is especially suitable to join sheet Al alloys, and this
technique allows different material couples to be welded
continuously . In this study, Al alloys and commercially
pure Cu will be produced at three different tool rotation
speeds( 620 ,930 ,1400 rpm) and Two different tool
traverse speeds( 12 ,15 mm/min) with One tool
position( 2 mm) by friction stir welding . The project aim
is to weld two plates of Al alloys & pure Cu using
different tool profiles and to optimize the parameters
like tool rotational speed, tool profile, depth of cut, feed
etc . And analyse the influence of the microstructures
and mechanical properties of friction stir Welding .
Tensile and Hardness tests will be used to determine the
mechanical properties .
1 . Firstly clamp the work -piece in a heavy duty setup, so
that it does not move or shake at the time of welding .
Workpiece should be abutting i.e . both parts should be kept
side to side at a particular distance from each other .
2 . Now insert a blunt or probe tool till the whole pin gets
inserted in the abutting edges . Now the shoulder gets in
touch with the abutting edges .
3 . The tool starts rotating with in contact with the job . Due
to contact of work -piece, friction is applied and as a result
of it heat is generated . This heat makes the metal plastically
melt .
4 . When the metal gets plasticized the high downward
forces or pressure makes a strong, clean and solid state
weld .
Tool Profile
We selected different tool geometries like Cylindrical
and Tapered Cylindrical to analyse their effect on joint
properties . We have designed these tools using Creo
software .
These tool profiles are made up of Material HSS D 2 .
These profiles gives different properties of welded
joints . Circular pin profile can be considered as multi
edge cutting tool .
Figure 3: Microstructures at Different Stair Zone Areas
Result Summary
.
References
Figure 1:working Process
Experimental work
First We selected Cylindrical Tool Profile Which pin
diameter, shoulder diameter, shoulder length and
height of the pin were 6 mm, 20 mm, 30 mm and 3 .6
mm, respectively . Depth of Cut and Offset of the pin
were 3 .6 mm and 2 mm Al side is same .
INPUT PARAMETERS WELDING IMAGES
Rotational speed(rpm) 620
Feed(mm/min) 12
Rotational speed(rpm) 620
Feed(mm/min) 15
Rotational speed(rpm) 930
Feed(mm/min) 12
Rotational speed(rpm) 930
Feed(mm/min) 15
Rotational speed(rpm) 1400
Feed(mm/min) 12
Rotational speed(rpm) 1400
Feed(mm/min) 15
Table: 2 Tensile Strength Test
Tool profile Speed
(rpm)
Feed
(mm/min)
Tensile strength
(MPa)
Cylindrical 620 12 8.393
Cylindrical 620 15 28.929
Cylindrical 930 12 35.674
Cylindrical 930 15 28.666
Cylindrical 1400 12 32.127
Cylindrical 1400 15 61.324
Tapered 620 12 20.952
Tapered 620 15 39.408
Tapered 930 12 42.719
Tapered 930 15 16.825
Tapered 1400 12 41.749
Tapered 1400 15 79.095
1 . TENSILE STRENGTH TEST
2 . HARDNESS TEST :-
Hardness test has been conducted on Rockwell hardness
Tester . Here we are calculating the hardness of weld spot . the
Hardness Of Welding Point 25 -40 . the sample value of weld
point hardness value is HR 30 T
3 . MICROSTRUCTURES AT DIFFERENT STIR ZONE AREAS :-
Figure 2: Tool Profile
Table: 1 Cylindrical Tool Profile Experimental Images