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A Presentation for Free! Friction Stir Welding Mechanical Properties & Microstructure

The American University in Cairo Mechanical Engineering Department MENG 433: Welding/Casting Design & Inspection. A Presentation for Free! Friction Stir Welding Mechanical Properties & Microstructure. Presented to Dr. Hanadi Salem MENG 433 Class. Presented by Moataz M. Attallah. Outline.

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A Presentation for Free! Friction Stir Welding Mechanical Properties & Microstructure

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  1. The American University in CairoMechanical Engineering DepartmentMENG 433: Welding/Casting Design & Inspection A Presentation for Free! Friction Stir Welding Mechanical Properties & Microstructure Presented to Dr. Hanadi Salem MENG 433 Class Presented by Moataz M. Attallah

  2. Outline • Welding: Definition, types, nomenclature • Aluminum Welding: types, problems associated with • Friction Stir Welding: Definition, applications, parameters, welding quality

  3. Welding Definition A localized coalescence of metals or non-metals produced either by heating the materials to the welding temperature, with or without the application of pressure, or by the application of pressure alone, with or without the use of a filler material. (Davies, 1990)

  4. Laser welding Oxyacetylene Electric arc welding Welding Categories(1) Fusion welding • The heat for fusion/melting is supplied by an electric/chemical/other energy sources. • Filler material may/may not be used. www.twi.co.uk

  5. Seam welding Spot welding Friction welding Welding Categories(2) Solid state welding • Pressure and heat (supplied from friction or electric resistance) are involved. • No filler material. • Full melting is not required (softening). www.twi.co.uk

  6. Evaluation of Welds Weldability: • Preservation of mechanical properties. • Absence of inclusions. • Produce crack free welds. • Undesirable-post weld microstructure. • Minimal reactivity with the atmosphere in service.

  7. Aluminum Alloys Welding • Al-Cu (2xxx) series is extensively used in aerospace and transportation applications • High risk of cracking/oxidation during welding www.twi.co.uk

  8. Existing Technologies TIG/MIG/MAG Metal/TungstenInert/Active Gas Welding www.twi.co.uk

  9. Porosity Cracks Liquation cracking Series 2xxxWeld Defects www.twi.co.uk

  10. New TechnologyFriction Stir Welding (FSW) • Invented by the Welding Institute (TWI) UK in late 1991. • Solid-state welding technique suitable for difficult-to-weld materials. • No filler (electrode) required. • Showed success with variety of alloys. • Suitability for Al 2xxx series is under investigation.

  11. FSW Process Description www.frictionstirlinks.com

  12. FSW Process www.rockwell.com

  13. Tool Steel Whorl TM Tool Welding Tool www.twi.co.uk

  14. Various joint geometries Large Thickness Long sheets High weld quality Process Capabilities www.twi.co.uk

  15. Process Advantages • Low distortion/shrinkage, even in long welds • Excellent mechanical properties as proven by fatigue, tensile and bend tests • No fume • No porosity • Energy efficient • Non-consumable tool (no filler wire) • No gas shielding for welding aluminum • Used in transportation industry www.twi.co.uk

  16. www.fpe.co.uk Process Limitations • Not enough data has been published for process control and quality for 2xxx Al • Feasible for welding of plates and sheets (no other possible sections)

  17. Process Parameters Vertical Force (N) Feed rate mm/sec Speed (RPM) www.frictionstirlinks.com

  18. Weld Nugget (Cross-section) FS Weld A. Unaffected material (base metal) B. Heat affected zone (HAZ) C. Thermo-mechanically affected zone (TMAZ) D. Weld nugget/Stirred zone Weld Quality www.twi.co.uk

  19. Initial Results

  20. Conclusions • FSW is a novel welding technique, yet without enough experimental data. • The process can be considered promising in welding Al 2xxx alloys. • More data will be available (hopefully) by the end of the current study.

  21. Thank youQuestions? Your feedback is important!

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