NDLI: Internal defect and process parameter analysis during friction stir welding of Al 6061 sheets

Content Provider	Springer Nature Link
Author	Ramulu, P. Janaki Narayanan, R. Ganesh Kailas, Satish V. Reddy, Jayachandra
Copyright Year	2012
Abstract	Welding parameters like welding speed, rotation speed, plunge depth, shoulder diameter etc., influence the weld zone properties, microstructure of friction stir welds, and forming behavior of welded sheets in a synergistic fashion. The main aims of the present work are to (1) analyze the effect of welding speed, rotation speed, plunge depth, and shoulder diameter on the formation of internal defects during friction stir welding (FSW), (2) study the effect on axial force and torque during welding, (c) optimize the welding parameters for producing internal defect-free welds, and (d) propose and validate a simple criterion to identify defect-free weld formation. The base material used for FSW throughout the work is Al 6061T6 having a thickness value of 2.1 mm. Only butt welding of sheets is aimed in the present work. It is observed from the present analysis that higher welding speed, higher rotation speed, and higher plunge depth are preferred for producing a weld without internal defects. All the shoulder diameters used for FSW in the present work produced defect-free welds. The axial force and torque are not constant and a large variation is seen with respect to FSW parameters that produced defective welds. In the case of defect-free weld formation, the axial force and torque are relatively constant. A simple criterion, (∂τ/∂p)defective > (∂τ/∂p)defect free and (∂F/∂p)defective > (∂F/∂p)defect free, is proposed with this observation for identifying the onset of defect-free weld formation. Here F is axial force, τ is torque, and p is welding speed or tool rotation speed or plunge depth. The same criterion is validated with respect to Al 5xxx base material. Even in this case, the axial force and torque remained constant while producing defect-free welds.
Starting Page	1515
Ending Page	1528
Page Count	14
File Format	PDF
ISSN	02683768
Journal	The International Journal of Advanced Manufacturing Technology
Volume Number	65
Issue Number	9-12
e-ISSN	14333015
Language	English
Publisher	Springer-Verlag
Publisher Date	2012-06-14
Publisher Place	London
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	Friction stir welding Defects Welding speed Rotational speed Plunge depth Shoulder diameter Industrial and Production Engineering Production/Logistics/Supply Chain Mechanical Engineering Computer-Aided Engineering (CAD, CAE) and Design
Content Type	Text
Resource Type	Article
Subject	Industrial and Manufacturing Engineering Control and Systems Engineering Mechanical Engineering Computer Science Applications Software

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