Crack resistance of aluminium alloy friction stir welded joint

Charpy testing is conducted on a high-speed data acquisition instrument, using instrumented pendulum to separate energies for crack initiation and propagation. The J-R curves are used to determine JIc, as the measure of fracture toughness. The Taguchi method with a special design of orthogonal matrices to reduce the number of experiments to a reasonable level has been applied

Crack resistance of aluminium alloy friction stir welded joint

Charpy testing is conducted on a high-speed data acquisition instrument, using instrumented pendulum to separate energies for crack initiation and propagation. The J-R curves are used to determine JIc, as the measure of fracture toughness. The Taguchi method with a special design of orthogonal matrices to reduce the number of experiments to a reasonable level has been applied

Advantages of friction stir welding over arc welding with respect to health and environmental protection and work safety [Prednosti zavarivanja trenjem sa mešanjem u odnosu na elektrolučno zavarivanje - Zaštita zdravlja i životne sredine i bezbednost na r

In modern industrial production, every manufacturing and assembly process should be assessed with respect to its influence on the environment. For a company that invests in a new process, a careful analysis of HSE problems (Health, Safety and Environment) is very important. Friction stir welding (FSW) process offers numerous advantages regarding health protection, environmental effects and work safety in comparison with other welding procedures, such as arc welding. Arc welding produces a broad spec-trum of UV radiation, harmful for human health (skin, eyes). Exposure to this radiation without an adequate protection can lead to severe injuries. If appropriate protective measures are undertaken, the welder can easily be exposed to heat injuries. This is especially pronounced for arc welding of aluminium alloys, because high material conductivity of Al requires a high-energy arc, and also because its surface has more pronounced reflection than steel. This work deals with the FSW welding process and its advantages in comparison with arc welding processes with respect to health protection, environmental problems and work safety

Advantages of friction stir welding over arc welding with respect to health and environmental protection and work safety [Prednosti zavarivanja trenjem sa mešanjem u odnosu na elektrolučno zavarivanje - Zaštita zdravlja i životne sredine i bezbednost na r

In modern industrial production, every manufacturing and assembly process should be assessed with respect to its influence on the environment. For a company that invests in a new process, a careful analysis of HSE problems (Health, Safety and Environment) is very important. Friction stir welding (FSW) process offers numerous advantages regarding health protection, environmental effects and work safety in comparison with other welding procedures, such as arc welding. Arc welding produces a broad spec-trum of UV radiation, harmful for human health (skin, eyes). Exposure to this radiation without an adequate protection can lead to severe injuries. If appropriate protective measures are undertaken, the welder can easily be exposed to heat injuries. This is especially pronounced for arc welding of aluminium alloys, because high material conductivity of Al requires a high-energy arc, and also because its surface has more pronounced reflection than steel. This work deals with the FSW welding process and its advantages in comparison with arc welding processes with respect to health protection, environmental problems and work safety

Numerical analysis of heat transfer during friction stir welding

The paper deals with the heat input and maximum temperature that develops in friction stir welding with different welding parameters. The finite element method has been used for numerical analysis of temperature distribution in a friction stir welded Al alloy. Results of temperature distribution in the friction stir welded T-joint and butt joint are presented

Impact Toughness of Friction Stir Welded Al-Mg Alloy

Al-Mg 5083 alloy was friction stir welded by varying welding variables, i.e., rotational speed, traversal speed and tool tilt angle. Welded specimens have been tested by the instrumented Charpy test to evaluate total absorbed energy, as well as the energy for crack initiation and the energy for crack growth. Subsequently, the fracture surface was examined by optical and scanning electron microscopy (SEM) to evaluate surface type of fracture, and to correlate the microstructure with the impact energy. Based on this, the optimum windows of FSW parameters for Al-Mg 5083 alloy welding have been defined

Numerical analysis of heat transfer during friction stir welding

The paper deals with the heat input and maximum temperature that develops in friction stir welding with different welding parameters. The finite element method has been used for numerical analysis of temperature distribution in a friction stir welded Al alloy. Results of temperature distribution in the friction stir welded T-joint and butt joint are presented

Impact Toughness of Friction Stir Welded Al-Mg Alloy

Al-Mg 5083 alloy was friction stir welded by varying welding variables, i.e., rotational speed, traversal speed and tool tilt angle. Welded specimens have been tested by the instrumented Charpy test to evaluate total absorbed energy, as well as the energy for crack initiation and the energy for crack growth. Subsequently, the fracture surface was examined by optical and scanning electron microscopy (SEM) to evaluate surface type of fracture, and to correlate the microstructure with the impact energy. Based on this, the optimum windows of FSW parameters for Al-Mg 5083 alloy welding have been defined

Numerička simulacija faze uranjanja kod zavarivanja trenjem mešanjem

This paper investigates the plunge stage using numerical modeling. A three-dimensional finite element model (FEM) of the plunge stage is developed using the commercial code ABAQUS to study the thermo-mechanical processes involved during the plunge stage. A coupled thermo-mechanical 3D FE model uses the arbitrary Lagrangian-Eulerian formulation, the Johnson-Cook material law and Coulomb's Law of friction. The model is developed to study the temperature fields of alloy Al2024-T351 under different process parameters (rotating speed) during the friction stir welding (FSW) process. Numerical results indicate that the maximal temperature of the FSW process can be increased with the increase of rotational speed and that temperature is lower than the melting point of the welding material. In this analysis, temperature, displacement, and mechanical responses are determined simultaneously. The heat generation in FSW can be divided into three parts: frictional heat generated by the tool shoulder, frictional heat generated by the tool pin, and heat generated by material deformation near the pin region.U ovom radu je istražena faza uranjanja alata primenom numeričkog modeliranja. Trodimenzionalni model konačnih elemenata (FEM) faze uranjanja je razvijen primenom softvera ABAQUS radi proučavanja termomehaničkih procesa koji se odvijaju tokom faze uranjanja. Spregnuti termomehanički 3D FE model se bazira na proizvoljnim formulacijama Lagranža-Ojlera, zakonu materijala Džonson-Kuk i Kulonovom zakonu trenja. Model je razvijen radi proučavanja temperaturskih polja legure Al2024-T351 pod različitim parametrima postupka (brzina rotacije) kod postupka zavarivanja trenjem mešanjem (FSW). Numerički rezultati pokazuju da se maksimalna temperatura postupka FSW može povećati sa povećanjem brzine rotacije, kao i da je temperatura niža od tačke topljenja zavarenog materijala. U ovoj analizi, temperatura, pomeranje i mehanički odzivi se određuju simultano. Izdvajanje toplote kod FSW se može podeliti na tri dela: toplota trenja koja se razvija kretanjem čela alata, toplota trenja dobijena kretanjem trna alata, kao i toplota usled plastične deformacije materijala u blizini oblasti trna alata

Numerical simulation of the plunge stage in friction stir welding

U ovom radu je istražena faza uranjanja alata primenom numeričkog modeliranja. Trodimenzionalni model konačnih elemenata (FEM) faze uranjanja je razvijen primenom softvera ABAQUS radi proučavanja termomehaničkih procesa koji se odvijaju tokom faze uranjanja. Spregnuti termomehanički 3D FE model se bazira na proizvoljnim formulacijama Lagranža-Ojlera, zakonu materijala Džonson-Kuk i Kulonovom zakonu trenja. Model je razvijen radi proučavanja temperaturskih polja legure Al2024-T351 pod različitim parametrima postupka (brzina rotacije) kod postupka zavarivanja trenjem mešanjem (FSW). Numerički rezultati pokazuju da se maksimalna temperatura postupka FSW može povećati sa povećanjem brzine rotacije, kao i da je temperatura niža od tačke topljenja zavarenog materijala. U ovoj analizi, temperatura, pomeranje i mehanički odzivi se određuju simultano. Izdvajanje toplote kod FSW se može podeliti na tri dela: toplota trenja koja se razvija kretanjem čela alata, toplota trenja dobijena kretanjem trna alata, kao i toplota usled plastične deformacije materijala u blizini oblasti trna alata.This paper investigates the plunge stage using numerical modeling. A three-dimensional finite element model (FEM) of the plunge stage is developed using the commercial code ABAQUS to study the thermo-mechanical processes involved during the plunge stage. A coupled thermo-mechanical 3D FE model uses the arbitrary Lagrangian-Eulerian formulation, the Johnson-Cook material law and Coulomb's Law of friction. The model is developed to study the temperature fields of alloy Al2024-T351 under different process parameters (rotating speed) during the friction stir welding (FSW) process. Numerical results indicate that the maximal temperature of the FSW process can be increased with the increase of rotational speed and that temperature is lower than the melting point of the welding material. In this analysis, temperature, displacement, and mechanical responses are determined simultaneously. The heat generation in FSW can be divided into three parts: frictional heat generated by the tool shoulder, frictional heat generated by the tool pin, and heat generated by material deformation near the pin region