Influence of FSW Parameters & Tool Pin Profile

On Formation of FSW Zone & Tensile Properties

In 5083 Aluminum Alloy


Presentation By,
Ravindra Thube (10ME61R17),
Under the guidance of,
Dr. Surjya K. Pal,
Department of Mechanical Engineering ,
Indian Institute of Technology Kharagpur.
Background
Literature Review
Methodology
Results and discussion
Conclusions
Contents

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BACKGROUND
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Aluminum: Due to light weight & high
strength to weight ratio the consumption has
increased in automobile, shipbuilding &
aerospace industries


The unique combination of light weight and relatively high strength makes
aluminum the second most popular metal that is used in industry
Typical Applications of Aluminum Alloy
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5xxx Series Aluminum Alloys (AA 5083)

5xxx alloys are strengthened with magnesium addition from 4- 5.5 %
Non Heat treatable & work hardened alloy
Excellent toughness, weldability and corrosion resistance even at salt
water
Representative alloys: 5052, 5083 and 5754
Typical ultimate tensile strength range: 125 to 350 MPa

Text book of Friction Stir welding & Processing by: R.S.Mishra & M.W. Mahoney
Defects like porosity, slag inclusion, solidification cracks etc. which
deteriorate the weld quality
Melting of the material causes loss of alloying elements
Distortion of workpiece
Environmentally hazardous, requires shielding gas
Requires additional process
Difficulties in welding of AA5083 by conventional welding

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Friction Stir Welding

(b)
(a))
(c)
(d)
(a) Principle of FSW
[13]
(b) Showing AS & RS
[14]
(c) Keyhole
[12]
(d) Actual FSW
[15]

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Advantages of FSW Over Fusion Welding
Retain near-parent metal properties across the weld
Join similar and dissimilar materials
The weld quality is excellent
Because no melting of materials it avoids the weaknesses caused by
distortion and metallurgical reactions
No consumables (filler material, shielding gases)
Improved safety absence of toxic fumes & absence of spatter of
molten material
Easily automated on simple milling machines
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Author

Year Contribution

Peel et al. 2003 Found that the weld properties were dominated by the
thermal input rather than mechanical deformation by the
tool for AA5083, 3 mm plate thickness.
Fujii et al. 2005 Studied the effect of tool shape on mechanical properties
and microstructure and found that for 5083-0, 5mm plate
thickness whose deformation resistance is relatively high,
weldability is significantly affected by the rotation speed.
Hirata et al. 2006 Found that the hardness of stir zone increased with
decrease in friction heat flow because the grain size in stir
zone decrease with friction heat flow for AA5083.
Elangovan et al. 2007 Studied the influence of tool pin profile and welding speed
on formation of FSW zone in AA2219 aluminum alloy of
6 mm plate thickness and found that square pin profiled
tool produces mechanically sound welds.
Literature Review
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Author

Year Contribution

Han et al. 2009 Weld fracture were observed at the stir zone and optimum
FSW conditions are weld speed of 124 mm/min and
rotational speed of 800 rpm.
Rajkumar et al.

2010 Studied the influence of FSW process and tool parameters
on strength properties of AA7075-T6 of 5 mm plate
thickness and found that joint fabricated at 1400 rpm, 60
mm/min weld speed, 8kN axial force, 15 mm shoulder
diameter, 5 mm pin diameter showed higher strength
properties with threaded tool.
Kumar et al. 2011 Results show that tool rotational speed, welding speed and
tool shoulder diameter are most significant parameters
affecting axial force and heat input.
Leitao et al. 2012 Studied the high temperature plastic behaviour and its
relation with weldability in FSW for AA5083 & AA6082.
Literature Review

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Formation of FSW joints by using five different tools (taper
cylindrical, triangular, straight cylindrical, square and cone)
and different process parameters for 2.5 mm plate
thickness of AA5083 aluminium alloy

Study the effect of tool pin profiles and welding parameters
on the formation of
Friction stir weld zone
Tensile properties
Hardness profile
Following are the objectives of the present work :
Objectives

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METHODOLOGY
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Sheet Material
AA5083 aluminum alloy
Plate thickness 2.5 mm


Material Selection for FSW
Chemical Composition (wt%)
AA5083
[16]
Fe 0.4
Si 0.4
Mn 0.4 - 0.1
Mg 4.0 4.9
Zn 0.25
Ti 0.15
Cr 0.05- 0.25
XRD
Tensile yield strength 125 MPa
Ultimate tensile strength 175 MPa
Elongation (%) 6.668
Vickers microhardness 75 HV
Melting temperature 639 C
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Stainless steel 316 (SS 316)

Tool Design and Tool Material
Chemical Composition (wt%) of SS 316
[16]
Mn 2.00
Si 1.00
S 0.030
P 0.045
Cr 16-18
Ni 10-14
Iron Remaining
Shoulder diameter (D) = 15 mm
Pin length (L) = 2 mm
(b) Tool Design
(a) Square
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Tool Pin Profiles
Taper
cylindrical
Triangular Square Straight
cylindrical
Cone
Swept vol. 39.269 39.269 39.269 39.269 39.269
Area in static
cond.


Area in
dynamic
cond.


(a) Taper
cylindrical
(b) Triangular (c) Square
(d) Straight
cylindrical
(e) Cone
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Experiments
Process parameters Values
Rotational speed (rpm) 900, 1400, 1800
Welding speed (mm/min) 16
D/d ratio of tool 3.75
Pin length (mm) 2
Tool shoulder diameter, D (mm) 15
Pin diameter, d (mm) 5
Plunge depth (mm) 0.1 mm
No of tools = 5
No. of rotational speeds = 3
No. of welding speed = 1

Total weld = 5 x 3 = 15
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Measurement of Power Input
(e) LabVIEW Display
(d) Data Acquisition Card
(a) Power Supply
(b) Power Sensor
(c) FSW Machine
Power data recording
frequency is 1 sample
per second
Output in KW
Power consumption w.r.t.
time was measured

(f) Power Sensor
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Measurement of Temperature
(c) LabVIEW Display
(b) Data Acquisition Card
(a) FSW Machine
Temperature data recording
frequency is 1 sample per
second
Output in millivolts (1 mv= 1
0
C)
Temperature w.r.t. time were
measured

(d) Handheld infrared thermometer
mounted over tripod
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FSW Setup
(e) HIT
(f) LabVIEW Display
(d) Data Acquisition Card
(a) Power Supply
(b) Power Sensor
(c) FSW Machine
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Standard specimens (a)
To evaluate the tensile
properties of the base metals
and welded joints

The standard tensile properties:
0.2% yield strength (YS), ultimate
tensile strength (UTS),%
elongation, % joint efficiency,
fracture location

Strain rate = 2 mm/min
Uniaxial Tensile Testing

INSTRON Uniaxial Tensile
Testing Machine
(a)
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(a) Macrostructure analysis

Inspecting cross-sectional weld quality
(b) Microhardness measurements

Vickers micro hardness testing- hardness
variation of the metals in the friction stir weld
zone (FSW), thermo mechanically affected
zone (TMAZ), heat affected zones(HAZ)
and the base metals

50 gmf ; 15s dwell time

Metallographic Observations

Vickers micro hardness
testing apparatus
Etched sample
LEICA stereo zoom microscope with
Qwin-V3 display
(a)
(b)
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RESULTS & DISCUSSION
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Surface temperature of Weld Nugget Zone

(a) = plunging & dwelling

(b) = Actual welding

(c) = Pulling the tool out
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Discussions
1) As rpm increases power
consumption increases
irrespective of tool pin profile
2) % increase in power
consumption is more from 900
to 1400 than 1400 to 1800 rpm
Power Input
(a) = plunging & dwelling

(b) = Actual welding

(c) = Pulling the tool out
(a) (c) (b)
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Surface Appearance of Welded Samples
Flash at
retreating
side
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Flash defect occurs at retreating side for all four pin profile tools at
1800 rpm except straight cylindrical pin profile tool
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Fracture locations in tensile tested welded specimens
(a)
(b)
Effect of Pin Profile & rpm on Tensile Properties
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Effect of Pin Profile & rpm
on Tensile Properties
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Effect of Pin Profile & rpm on FSW Zone
900 rpm 1400 rpm 1800 rpm
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Effect of Weld Speed on Tensile
Properties

Rotational speed 1400 rpm
Welding speed
(mm/min)
16, 20, 25 & 31.5
No. of joints
formed
8 (2 x 4)
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Effect of Weld Speed on Tensile Properties

Square pin tool
As weld speed increases UTS decreases for
square pin profiled tool


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16 mm/min
25 mm/min
20 mm/min
31.5 mm/min
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Square pin tool
Straight cylindrical
16 mm/min
20 mm/min
25 mm/min
31.5 mm/min
FSW Zone
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Discussion

Square pin tool
20 mm/min
25 mm/min
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Hardness Profile
Straight cylindrical
1400 rpm & 16 mm/min
50 gmf, 15 sec.
Microhardness varying
from 54-71 VH
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10
20
30
40
50
60
70
80
-12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12
H
a
r
d
n
e
s
s

(
H
V
)

Lateral distance from weld line (mm)
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For AA5083 whose deformation resistance is relatively high, tool
pin profiled designs had little effect on heat input and power
consumption but considerable effect is observed on tensile
properties

As rotational speed increases surface temperature of nugget zone
and power consumption increases but % increase in both form 900
to 1400 rpm is more than % increase from 1400 to 1800 rpm
irrespective of tool pin profiled

Joints fabricated at rotational speed of 1400 rpm and weld speed of
16 mm/min exhibited superior tensile strength properties and
produces defect free FSW zone irrespective of tool pin profile
except triangular pin tool

Conclusions
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Weldability is significantly affected by the rotational speed. At high
1800 rpm straight cylindrical tool is the best; at rotational speed 1400
rpm straight cylindrical and square tool are the best; while for 900
rpm triangular and square tool are the best

Maximum strength properties of 105 MPa yield strength, 149 MPa of
tensile strength and 84.9 % of joint efficiency respectively was
attained without any defect for the joint fabricated using straight
cylindrical tool at rotational speed of 1400 rpm and weld speed of 16
mm/min


Conclusions
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Acknowledgements
I acknowledge my sincere thanks to my project guide, Dr. Surjya K. Pal,
for his kind permission to pursue project work under his supervision and
the technical staff at the Department of Metallurgical & Materials
Engineering, Central Research Facility (CRF), Steel Technology Centre
(STC),Central Workshop & Instruments Service Section (CWISS) for their
unalloyed co-operation while working in their various laboratories and
workshops.

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References

[1] European Aluminum Association, Aluminum in Commercial Vehicles, Brussels Rev.1. April 2011.
Chapter II Aluminum in Transport, p.7-13, Chapter V Typical Alloys for Commercial Vehicles, 2011.
p. 449.

[2] G. Raynaud, P. Gomiero, The Potential of 5383 Alloy in Marine Applications. Proceedings of
Alumitech97 - Transportation, Sponsored by Aluminum Association, Inc., May 20-23, Atlanta; 1997;
1997. p. 35366.

[3] A. Duran, R. Dif, New Alloy Development at Pechiney: a New Generation of 5383. In: Wilson PA,
Hearn GE, editors. Conf. Proc. FAST 2001, vol. 3. Southampton: Southampton University; 2001. p.
22330.

[4] C. Leitao, R. Louro, D. Rodrigues, Analysis of high temperature plastic behaviour and its relation
with weldability in friction stir welding for aluminium alloys AA5083-H111 and AA6082-T6, Journals
of Materials and Design 37 (2012) 402409.

[5] C. Zhou, X. Yang, G. Luan, Fatigue properties of friction stir welds in Al 5083 alloy, Scripta
Materialia 53 (2005) 11871191.

[6] H. Fujii, L. Cui, M. Maeda, K. Nogi, Effect of tool shape on mechanical properties and
microstructure of friction stir welded aluminum alloys, Materials Science and Engineering A 419
(2006) 2531.


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References

[7] H. Lombard, D. Hattingh , A. Steuwer, M. James, Optimising FSW process parameters to
minimise defects and maximise fatigue life in 5083-H321 aluminium alloy, Engineering Fracture
Mechanics 75 (2008) 341354.

[8] R. Kumar, K. Singh, S. Pandey, Process forces and heat input as function of process
parameters in AA5083 friction stir welds, Trans. Nonferrous Met. Soc. China 22(2012) 288298.

[9] M. Han, S. Lee, J. Park, S. Ko, Y. Woo, S. Kim; Optimum condition by mechanical characteristic
evaluation in friction stir welding for 5083-O Al alloy, Trans. Nonferrous Met. Soc. China 19(2009)
s17-s22.

[10] S. Rajakumar, C. Muralidharan, V. Balasubramanian; Influence of friction stir welding process
and tool parameters on strength properties of AA7075-T6 aluminium alloy joints, Materials and
Design 32 (2011) 535549.

[11] K. Elangovana, V. Balasubramanianb; Influences of tool pin profile and welding speed on the
formation of friction stir processing zone in AA2219 aluminium alloy, Journal of materials
processing technology 200 (2008) 163175.

[12] R. Mishra, Z. Ma, Friction stir welding and processing, Materials Science and Engineering: R:
Reports, Volume 50, Issues 1-2, 31 August 2005, Pages 1-78.


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References

[13] http://www.thefabricator.com/article/forengineers/an-introduction-to-friction-stir-welding

[14] http://www.alcotec.com/us/en/education/knowledge/qa/What-is-friction-stir- welding-of-
aluminum.cfm

[15] http://www.dlr.de/wf/en/desktopdefault.aspx/tabid-2132/2294_read-3738/

[16] http://www.referansmetal.com

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