Friction St welding

8/18/2019 Friction St welding

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“EXPERIMENTAL STUDY ON MECHANICAL PROPERTIES

OF DISSIMILAR ALUMINIUM ALLOY BY FRICTION STIR

WELDING”


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CONTENTS

Page No

Chapter 1 GENERAL INTRODUCTION

1.1 Welding 8

1.2 Types Of Friction Welding 10

1.3 Friction Stir Welding 11

1.4 Principle Of Operations 11

1.5 d!antages Of Friction Stir Welding 13

1." pplications Of Friction Stir Welding 13

Chapter LITERATURE RE!IEW

2.1 #iterat$re %e!ie& 1"

Chapter " PRO#ECT DESCRIPTION

3.1 'ntrod$ction of Plates 2"

3.2 Tool (esign 2"

Chapter $ MATERIAL DIAGRAM AND

MATERIAL PROPERTIES

4.1 )*e+ical)o+position ,l"0"1- l05/ 3"

4.2 ec*anicalProperties ,l"0"1 -l05/ 3"

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4.3 Welding Para+eters andTool eo+etry 3"

Chapter % TEST REPORT

5.1 Plate Sa+ple 1 38



Chapter & TEST RESULT

".1 Test %es$lt 44

Chapter ' CONCLUSIONS

.1 )oncl$sions 4

REFERENCE 48

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LIST OF FIGURES Page No

Fig 1 Types of Friction Welding 10

Fig 2 Welding ones 11

Fig 3 Tool Pin Profiles 18

Fig 4 l$+in$+ 05 32

Fig 5 l$+in$+ "0"1 33

Fig " Weld Prod$ct 35

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ABSTRACT

Friction stir &elding ,FSW/ a solid state oining tec*ni$e is &idely $sed for oining

l$+in$+alloys in +arine aerospace a$to+oti!e and +any ot*er applications of co++erciali+portance. 'n t*e present st$dy dissi+ilar l$+in$+ alloy plates &ere FS &elded 6y !arying

t*e &eld para+eters s$c* as Tool rotational speed &eld speed and a7ial force &it* cylindrical

tool pin profile. T*e +ec*anical properties ,Tensile strengt*/ of t*e (issi+ilar Friction Stir

&elded ,(FSW/ speci+ens &ere tested and co+pared &it* t*e 6ase +aterials.

Keywords l$+in$+ alloy Frictions stirs &elding dissi+ilar &eldsec*anical properties

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1.INTRODUCTION1(1 WELDING

Welding is a fa6rication or sc$lpt$ral process t*at oins +aterials $s$ally +etals or

t*er+oplastics 6y ca$sing coalescence. T*is is often done 6y +elting t*e &or9 pieces and adding

a filler +aterial to for+ a pool of +olten +aterial ,t*e &eld pool/ t*at cools to 6eco+e a strong

oint &it* press$re so+eti+es $sed in con$nction &it* *eat or 6y itself to prod$ce t*e &eld.

T*is is in contrast &it* soldering and 6ra:ing &*ic* in!ol!e +elting a lo&er-+elting-point

+aterial 6et&een t*e &or9 pieces to for+ a 6ond 6et&een t*e+ &it*o$t +elting t*e &or9 pieces.

any different energy so$rces can 6e $sed for &elding incl$ding a gas fla+e an electric

arc a laser an electron 6ea+ friction and $ltraso$nd. W*ile often an ind$strial process &elding

+ay 6e perfor+ed in +any different en!iron+ents incl$ding open air $nder &ater and in o$ter

space. Welding is a potentially *a:ardo$s $nderta9ing and preca$tions are re$ired to a!oid

6$rns electric s*oc9 !ision da+age in*alation of poisono$s gases and f$+es and e7pos$re to

intense $ltra!iolet radiation.

;ntil t*e end of t*e 1


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T*e +arine and t*e aerona$tic ind$stries are definitely t*e +ost Wanted interested and

foc$sed fields of researc* no&-a-days predo+inantly on oining tec*ni$es. ct$ally +ec*anical

strengt* and perfor+ances corrosion resistance resid$al stress state and &eig*t red$ction are

so+e of t*e +ost significant iss$es &*ic* are painsta9ing in t*e asse+6ly of aerona$tical

co+ponents and also in transport ind$stry =1>. ?eat treata6le &ro$g*t al$+in$+-+agnesi$+-

silicon alloy confor+ing to "2"2 is of +edi$+ strengt* and possess good &elding

c*aracteristics o!er t*e *ig* strengt* al$+in$+ alloys and also *a!e si+ilar c*e+istry to

"0"1 e7cept s+all addition of lead and 6is+$t* to en*ance +ac*ina6ility &*ereas al$+in$+-

:inc-+agnesi$+ alloy na+ely 05=2> is of *ig* strengt* and possess lo& &elding

c*aracteristics. @ot* t*e +aterials "2"2 and 05 are e7tensi!ely e+ployed in +arine

fittings co$plings and *inge pins ca+era parts and scre& +ac*ine prod$cts a$to+o6iles and

aircraft applications.

'n contrast to +any of t*e f$sion &elding processes t*at are ro$tinely $sed for oining

str$ct$ral alloys FSW is an e+erging solid state oining process in &*ic* t*e +aterial t*at is

6eing &elded does not +elt and recast. FSW &as in!ented at T*e Welding 'nstit$te FSW is a

contin$o$s *ot s*ear a$togeno$sly process in!ol!ing a non-cons$+a6le rotating tool of *arder +aterial t*an t*e s$6strate +aterial. (efect-free &elds &it* good +ec*anical properties *a!e

6een +ade in a !ariety of al$+in$+ alloys. W*en alloys are friction stir &elded solid-state p*ase

transfor+ations &ill occ$r d$ring t*e cooling of t*e &eld. ($e to t*e a6sence of parent +etal

+elting t*e ne& FSW process is o6ser!ed to offer se!eral ad!antages o!er f$sion &elding. T*e

+aterial flo& 6e*a!ior is predo+inantly infl$enced 6y t*e FSW tool profiles FSW tool

di+ensions and FSW process para+eters na+ely tool rotational speed &eld speed and a7ial

force.


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1( TYPES OF FRICTION WELDING )

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1.3 FRICTION*STIR WELDING +FSW,

FSWis a solid-state oining process ,t*e +etal is not +elted/ t*at $ses a t*ird 6ody tool to

oin t&o faying s$rfaces. ?eat is generated 6et&een t*e tool and +aterial &*ic* leads to a

!ery soft region near t*e FSW tool. 't t*en +ec*anically inter+i7es t*e t&o pieces of +etal at

t*e place of t*e oin t*en t*e softened +etal ,d$e to t*e ele!ated te+perat$re/ can 6e oined

$sing +ec*anical press$re ,&*ic* is applied 6y t*e tool/ +$c* li9e oining clay or do$g*. 't

is pri+arily $sed on al$+in$+ and +ost often on e7tr$ded al$+in$+ and on str$ct$res

&*ic* need s$perior &eld strengt* &it*o$t a post &eld *eat treat+ent. ,non-*eat treata6le

alloys/

1.4PRINCIPLE OF OPERATION

F-.(1 S/he0at-/ -a.ra0 23 the FSW pr2/e44) +A, T52 -4/rete 0eta6 52r7 p-e/e4

89tte t2.ether: a62;. 5-th the t226 +5-th a pr28e,(


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3-.( +B, pr2.re44 23 the t226 thr29.h the the t226 4h296er(

constantly rotated non cons$+a6le cylindrical-s*o$ldered tool &it* a profiled ni6 is

trans!ersely fed at a constant rate into a 6$tt oint 6et&een t&o cla+ped pieces of 6$tted +aterial.

T*e ni6 is slig*tly s*orter t*an t*e &eld dept* re$ired &it* t*e tool s*o$lder riding atop t*e

&or9 s$rface.

Frictional *eat is generated 6et&een t*e &ear-resistant &elding co+ponents and t*e &or9

pieces. T*is *eat along &it* t*at generated 6y t*e +ec*anical +i7ing process and t*e adia6atic

*eat &it*in t*e +aterial ca$se t*e stirred +aterials to soften &it*o$t +elting. s t*e pin is

+o!ed for&ard a special profile on its leading face forces plastici:ed +aterial to t*e rear &*ere

cla+ping force assists in a forged consolidation of t*e &eld.

T*is process of t*e tool tra!ersing along t*e &eld line in a plastici:ed t$6$lar s*aft of

+etal res$lts in se!ere solid state defor+ation in!ol!ing dyna+ic recrystalli:ation of t*e 6ase

+aterial..

10

http://en.wikipedia.org/wiki/File:Anand-FSW-Figure1-B.jpg


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1(% AD!ANTAGES

So+e of t*e ad!antages of friction stir &elding are

• s a solid state process it can 6e applied to all t*e +aor al$+in$+ alloys and a!oids

pro6le+s of *ot crac9ing porosity ele+ent loss etc. co++on to al$+in$+ f$sion

&elding processes

• 't $ses non-cons$+a6le tool to perfor+ &elding

• 't generates anticipated +icrostr$ct$res in t*e &eld

•

)on!entionally i+possi6le +aterial co+6inations can 6e &elded 6y FSW• 't is en!iron+ent friendly as t*ere is no for+ation of *a:ardo$s gas noise or fla+e

• FSW does not rely on speciali:ed &elding s9illsA indeed +an$al inter!ention is seldo+

re$ired

1(& APPLICATION

)o++ercial applications *a!e 6een reported across +any ind$stries and so+e selected

e7a+ples are s*o&n 6elo& &*ic* ill$strate t*e &idening appeal of t*e process. T*is list is

representati!e rat*er t*an e7*a$sti!e and it s*o$ld 6e e+p*asi:ed t*at ne& applications are

appearing all t*e ti+e. 't s*o$ld 6e noted t*at FSW does not restrict t*e operating te+perat$re

range of al$+in$+ alloys &it* applications ranging fro+ cryogenic te+perat$res ,e.g. li$id

o7ygen and li$id *ydrogen roc9et f$el tan9s/ to +ildly ele!ated te+perat$res ,e.g. *eat

e7c*angers in *eating syste+s/. ost FSWs $sed in prod$ction are 6$tt &elds alt*o$g* lap

&elds and friction stir spot &elds are also 6eing applied &it* increasing fre$ency.

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Mar-;e

't is 6elie!ed t*at t*e first co++ercial application of FSW &as t*e oining of "777 series

alloy e7tr$sions for $se in fis* free:ing plants for fis*ing !essels. T*ere *a!e 6een n$+ero$s

applications of t*e process for oining "777 e7tr$sions for incorporation in 6$l9*eads and dec9s

in !ario$s *ig* speed al$+in$+ !essels and in large steel cr$ise s*ips &*ic* no& often *a!e

lig*t&eig*t al$+in$+ s$perstr$ct$res. 'n s$c* applications t*e FSW panels are !ery flat d$e to

t*e lo& distortion and are c$t $p and &elded into larger str$ct$res $s$ally 6y ' &elding.

Friction stir &elding *as 6een $sed e7tensi!ely in t*e al$+in$+ s$perstr$ct$res of cr$ise s*ips

s$c* as t*e BSe!en Seas Na!igatorB &*ic* contain +any 9ilo+eters of friction stir &elds +ostly

in "777 grade e7tr$sions. T*e &orldBs largest al$+in$+ !essel t*e Capanese fast ferry

BOgasa&araB la$nc*ed in 2004 +a9es e7tensi!e $se of FSW in its s$perstr$ct$re.

Aer24pa/e

T*e first +aor application &as t*e $se of t*e process to replace f$sion &elding in f$el

tan9s for $n+anned (elta '' and later (elta 'D roc9ets. T*e +an$fact$rer ,@oeing/ *as reported

!irt$ally :ero defect incidence and significant cost sa!ings o!er t*e pre!io$s !aria6le polarity

plas+a arc ,DPP/ process. T*e process *as also 6een adopted for t*e large f$el tan9 for t*eSpace S*$ttle.

l+ost all t*e +aor airfra+e +an$fact$rers are in!estigating t*e $se of FSW ,alongside

ot*er &elding processes s$c* as laser &elding/ to replace +any of t*e ri!ets in c$rrent str$ct$res.

T*e first aircraft to +a9e e7tensi!e $se of FSW in its airfra+e t*e Eclipse 500 6$siness et *as

recently co+pleted certification and is no& in prod$ction. 'n t*is aircraft o!er 300 fasteners

,appro7i+ately "0 of t*e total/ are replaced 6y 2"3 friction stir &elds.

Ra-6

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?ig* speed al$+in$+ railcars s$c* as t*e Capanese S*in9ansen are nor+ally 6$ilt fro+

co+ple7 do$6le s9in e7tr$sions in "777 alloys. Since t*e &elds &*ic* oin t*ese are long ,$p to

25+/ and straig*t FSW is an ideal process and t*e !ery lo& distortion is cited as a +aor 6enefit

A9t202t-?e

T*ere are fe& long straig*t &elds in road !e*icles and so adoption of FSW *as pri+arily

6een for co+ponents s$c* as s$spension parts &*eels seat co+ponents cras* 6o7es etc. &*ere

se!eral leading co+panies are already $sing t*e process in prod$ction. T*e needs of t*e

a$to+oti!e sector *a!e dri!en t*e de!elop+ent of ro6otic FSW to cope &it* t*e co+ple7 s*apes

and *ig* !ol$+eGlo& cost c$lt$re of t*is +ar9et. Significant interest is no& 6eing s*o&n in

friction stir spot &elding &*ere t*e linear translation of t*e tool is eit*er !ery s+all or :ero.

Friction stir spot &elding is rapidly gaining acceptance as an efficient +et*od of oining

al$+in$+ s*eet and is already in prod$ction for e7a+ple on t*e a:da %7-8 sports car &*ere it

is $sed on t*e al$+in$+ 6onnet and rear doors. Friction stir &elding is also 6eing de!eloped for

lig*t&eig*t ar+ored !e*icles &*ere t*e a6ility of t*e process to &eld +aterial of aro$nd 25-

40++ t*ic9ness in one pass is 6eing e7ploited.

( LITERATURE RE!IEW

T*ere is !ario$s &elding process a!ail for al$+in$+ alloy. ?ere &e &ere $sing friction

stir &elding ,FSW/ to t&o !ario$s al$+in$+ alloys to oin it .T*e friction stir &elding ,FSW/ of

steel &as a c*allenging tas9. E7peri+ents &ere cond$cted *ere &it* a tool *a!ing a conical pin

of 0.4++ clearance. T*e process para+eters &ere opti+i:ed 6y $sing t*e Tag$c*i tec*ni$e.

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T*e !ario$s list of #iterat$res are re!ie&ed for t*is proect are gi!en $nder references

. Hoilra et al =1> oining of dissi+ilar lI)$ alloy 221


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. Si+oncini et al =3> in!estigated t*e effect of &elding para+eters and tool

config$ration on t*e s$rface appearance +ec*anical and +icro str$ct$ral properties of si+ilar

and dissi+ilar friction stir &elded oints in 554 and 31 t*in s*eets &as &idely

in!estigated. T&o different tool config$rations &it* and &it*o$t t*e pin &ere $sed. s far as t*e

si+ilar friction stir &elded oints in 31 and in 554 alloys &ere concerned it &as s*o&n

t*at t*e JJpinlessKK tool leads to t*e o6taining of *ig*er !al$es of t*e tensile strengt* and d$ctility

as co+pared to t*e JJpinKK one. On t*e contrary 6y considering t*e dissi+ilar friction stir &elding

6et&een 31 and 554 t*in s*eets t*e &elding process 6eco+es !ery critical as t*e JJpin

lessKK tool &as $sed. So$nd dissi+ilar oints &ere o6tained $sing t*e JJpinKK tool config$ration

e!en t*o$g* t*e effect of t*e +aterial position &it* respect to t*e &elding tool &as a !ery

i+portant factor to 6e considered. +ar9ed i+pro!e+ent in t*e s$rface appearance and

+ec*anical properties &as o6tained 6y placing al$+in$+ alloy in t*e ad!ancing side and

+agnesi$+ alloy in t*e retreating one. n in!estigation *ad 6een also carried o$t in order to

e!al$ate t*e +icro str$ct$ral properties of si+ilar and dissi+ilar &elded oints

andeep Sing* Sid*$ et al =4> descri6ed t*e friction stir &elding process !ario$s

&elding !aria6les li9e tool rotation trans!erse speed tool tilt pl$nge dept* and tool design for

t*e &elding of al$+in$+ alloys or !ario$s dissi+ilar alloys

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Fig.4. Tool pin profile

@o #i et al =5> in!estigated t*e effects of &elding para+eters especially t*e !al$e of pin

off-set on &eld for+ation +icrostr$ct$res and +ec*anical tensile properties of t*e lapI6$tt

oints of dissi+ilar al$+in$+ &ere in!estigated. T*e para+eter of pin off-set played a !ery

i+portant role and e7erted stronger infl$ence $pon t*e oint $ality. T*ree typical +icro flo&-

patterns of plastici:ed +aterials &ere fo$nd in t*e &eld-:ones circ$+fl$ence la+inar-flo& and

t$r6$lent-flo&. So+e &eld-defects and t*e +orp*ologies of Jonion ringsK &ere detected.

H. Hala&asel!an et al ="> foc$sed on t*e effect of FSW para+eters on t*e tensile strengt*

of lL@4) co+posite oints. T*e central co+posite design of fo$r factors and fi!e le!els &as

$sed to control t*e n$+6er of e7peri+ents. +at*e+atical +odel &as de!eloped to analy:e t*e

infl$ence of FSW para+eters. T*e res$lts indicated t*at t*e oint fa6ricated $sing rotational

speed of 1000 rG+in &elding speed of 1.3 ++Gs a7ial force of 10 9N and t*e reinforce+ent of

12 s*o&ed larger tensile strengt* co+pared &it* t*e ot*er oints. T*e de!eloped +odel &as

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opti+i:ed to +a7i+i:e t*e tensile strengt* $sing generali:ed red$ced gradient +et*od. T*e

+etallograp*ic analysis of t*e oints s*o&ed t*e presence of !ario$s :ones s$c* as &eld n$gget

,WN/ :one t*er+o +ec*anically affected :one ,T/ and *eat affected :one ,?/. T*e

s$6stantial grain refine+ent of al$+in$+ +atri7 as &ell as significant si:e red$ction of @4)

particles &as o6ser!ed in t*e &eld n$gget. T &as plastically defor+ed t*er+ally affected

and e7*i6ited elongated al$+in$+ grains.

S. alar!i:*i et al => 'n t*at &or9 t*e infl$ences of t*e tool s*o$lder dia+eter ,one of

t*e *eat generation so$rce/ on t*e +acrostr$ct$re +icrostr$ct$re and tensile properties of t*e

dissi+ilar "0"1 l$+in$+ and 31 agnesi$+ alloys &ere e7peri+ented. Fro+ t*at

in!estigation it &as fo$nd t*at t*e oints fa6ricated $sing a s*o$lder dia+eter of 21 ++ ,3.5

ti+es t*e plate t*ic9ness/ e7*i6ited s$perior tensile properties co+pared to its co$nterparts.

. (e*g*ani et al =8> Coints of l518" to +ild steel &ere perfor+ed 6y $sing friction stir

&elding ,FSW/ tec*ni$e. T*e effects of !ario$s FSW para+eters s$c* as tool tra!erse speed

pl$nge dept* tilt angle and tool pin geo+etry on t*e for+ation of inter +etallic co+po$nds

,')s/t$nnel for+ation and tensile strengt* of oints &ere in!estigated. t lo& &elding speeds

d$e to t*e for+ation of t*ic9 ')s ,&*ic* &as c*aracteri:ed asl"Fe and l5Fe2/ in t*e &eld

:one t*e tensile strengt* of oints &as !ery poor. E!en at lo& &elding speeds t*e t$nnel defect

&as for+ed. s t*e &elding speed increased t*e ')s decreased and t*e oint e7*i6ited *ig*er

tensile strengt*. T*e t$nnel defect co$ld not 6e a!oided 6y $sing cylindrical 4++and 3++ pin

dia+eter. @y $sing a standard t*readed 3tool pin t*e t$nnel &as a!oided and a 6ell s*ape

n$gget for+ed. T*erefore tensile strengt* of t*e oint increased to


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Partic$larly a distinct rise in *ardness &as noticed at t*e lG)$ interface. E7cellent +etall$rgical

6onding 6et&een l and )$ ga!e rise to good 6e*a!iors in t*e tensile and 6ending strengt*.

(eia #i$ et al =10>dissi+ilar friction stir &elding ,FSW/ of H"0 and 31+agnesi$+alloys &as st$died. T&o 9inds of +aterial arrange+ents &it* H "0 or 31in ad!ancing side

,S/&ere applied. T*e res$lts s*o&ed t*at t*e dissi+ilar plates &it* 6ot* +aterial arrange+ents

&ere oined s$ccessf$lly .No o6!io$s defect &as o6ser!ed. icrostr$ct$re and te7t$re !ariation

across t*e oints &ere e7a+ined 6y scanning electron +icroscope,SE/ and electron 6ac9

scatteddiffraction,E@S(/.T*e grains in stir :one,S/&ere significantly refined d$ring FSW,M8.

++ in31sideand M2. ++ inH"0side/.T*ese condp*ases in H"0side &ere 6ro9en $p

&*ic* contri6$ted to grain refine+ent. T&o-di+ensional,2(/*ardness +aps across t*e nor+al

direction,N(/trans!erse direction,T(/sections in t*e oints &ere o6tained. )lear 6o$ndary &as

o6ser!ed 6et&een S and 31 6ase +etal 6$t it &as less clear 6et&een S and H"0 6ase

+etal. T*e +i7t$re of +aterials grain refine +en and 6ro9en $p of particles &ere responsi6le

for t*e s*arp increasing of *ardness 6et&een S and 31 6ase +etal. T*e trans!erse $lti+ate

tensile strengt* ,;TS/of t*e oints &as8I82 of 31 6ase +etal. T*e oints consistently

fract$red in t*e transition region of t*e 31 side. T*e s$dden *ardness decrease fro+ S to

31 6ase +etal +ig*t res$lt in defor+ation in co+pati6ility at t*e interface &*ic* &as

considered as t*e +ain ca$se for t*e failing in t*e31side.'n addition t*e acti!ation of

t&inning in S-side,&it* c-a7&asparalleltoT(/ and slip in t*e region adacent to t*e S-

side,&it* c-a7&asat M451 angle toT(/ aggregated t*e defor+ation in co+pati6ility in t*e

transition region oft*e31side.s a res$lt t*e 6rea9 of t*e speci+ens started at t*e 6o$ndary of

transition :one,T/GS. any e7tension t&ins &ere o6ser!ed in31IS-side after fract$re.

lt*o$g* t*eH"0IS-side presented t*e si+ilar te7t$re &it* t*e 31IS-side +$c* less

e7tension t&ins &ere o6ser!ed in t*e for+er 6eca$se of t*e *indering effects 6y t*ere fined

grains and secondary particles

P. )a!aliere et al =11> Friction stir &elding ,FSW/ de+onstrated t*e en*ance+ent of

fatig$e resistance for al$+in$+ and +agnesi$+ alloys &it* respect to traditional f$sion

tec*ni$es. 'n addition t*e possi6ility to oin dissi+ilar alloys representing an i+portant aspect

for s$c* tec*nology as &ell as t*e red$ction of resid$al stresses and apparent necessity to a!oid

*ea!y *eat treat+ents &ere also positi!e factors. 'n t*at paper t*e res$lts a6o$t t*e fatig$e

properties and t*e fatig$e crac9 gro&t* 6e*a!ior of dissi+ilar 2024-05 ointed al$+in$+

s*eets &ere presented for FSW

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Woong-Seong et al =12> )*ang For t*e p$rpose of i+pro!ing t*e strengt* of t*at

dissi+ilar oint t*e present st$dy &as carried o$t to in!estigate t*e i+pro!e+ent in inter +etallic

layer 6y $sing a t*ird +aterial foil 6et&een t*e faying edges of t*e friction stir &elded and *y6rid

&elded l"0"1-T"G31 alloy plates. T*e difference in +icro str$ct$ral and +ec*anical

c*aracteristics of friction stir &elded and *y6rid &elded l"0"1-T"G31 oint &as co+pared.

?y6rid 6$tt &elding of al$+in$+ alloy plate to a +agnesi$+ alloy plate &as s$ccessf$lly

ac*ie!ed &it* Ni foil as filler +aterial &*ile defect-free laser-friction stir &elding ,FSW/ *y6rid

&elding &as ac*ie!ed 6y $sing a laser po&er of 2 9W. Trans!erse tensile strengt* of t*e oint

reac*ed a6o$t "" of t*e g 6ase +etal tensile strengt* in t*e case of *y6rid &elding &it* Ni

foil and s*o&ed *ig*er !al$e t*an t*at of t*e friction stir &elded oint &it* and &it*o$t t*e t*ird

+aterial foil. T*at +ay 6e d$e to t*e presence of less 6rittle Ni-6ased inter +etallic p*ases

instead of l12g1.

. (e*g*ani et al =13> (efect-free 6$tt oints of 3003 l alloy to +ild steel plates &it* 3

++ t*ic9ness &ere perfor+ed $sing friction stir &elding ,FSW/. *eat inp$t +odel reported for

si+ilar FSW &as si+plified and $sed to in!estigate t*e effects of &elding speed rotation speed

and tool s*o$lder dia+eter on t*e +icrostr$ct$re and properties of dissi+ilar &elds. T*e

co+parison 6et&een +icrostr$ct$re inter +etallicKs and strengt* of &elds s*o&s t*e good

confor+ity 6et&een t*e res$lts and t*e calc$lated *eat inp$t factor ,?'F/ ac*ie!ed fro+ t*e

+odel. T*e oint strengt* &as controlled 6y lGFe interface at ?'F of 0.2L0.4 6y T at ?'F

of 0.4L0.8 and 6y inter+etallics andGor defects at ?'F0.

@.T. i6sona et al =14> article pro!ides an introd$ction to t*e 6asic principles of friction

stir &elding ,FSW/ as &ell as a s$r!ey of t*e latest researc* and applications in t*e field. T*e

6asic principles co!ered incl$de ter+inology +aterial flo& oint config$rations tool design

+aterials and defects. aterial flo& &as disc$ssed fro+ 6ot* an e7peri+ental and a +odeling perspecti!e. Process !ariants &ere disc$ssed as &ell &*ic* incl$de self-reacting ,S%-FSW/

stationary s*o$lder friction stir processing ,FSP/ and friction stir spot &elding ,FSSW/ assisted

FSW and p$lsed FSW. $ltiple aspects of ro6otic friction stir &elding &ere co!ered incl$ding

sensing control and oint trac9ing. et*ods of e!al$ating &eld $ality &ere s$r!eyed as &ell.

T*e latest applications &ere disc$ssed &it* an e+p*asis on recent ad!ances in aerospace

a$to+oti!e and s*ip 6$ilding. Finally t*e direction of f$t$re researc* and potential applications

&ere e7a+ined.

1


20/40

H. Elango!an et al=15> paper reports on st$dies of t*e infl$ences of !ario$s post-&eld

*eat treat+ent proced$res on tensile properties of friction stir-&elded "0"1 al$+in$+ alloy

oints. %olled plates of "-++ t*ic9 "0"1 al$+in$+ alloy &ere $sed to fa6ricate t*e oints.

Sol$tion treat+ent an artificial aging treat+ent and a co+6ination of 6ot* &ere gi!en to t*e

&elded oints. Tensile properties s$c* as yield strengt* tensile strengt* elongation and oint

efficiency &ere e!al$ated. icrostr$ct$res of t*e &elded oints &ere analy:ed $sing optical

+icroscopy and trans+ission electron +icroscopy. si+ple artificial aging treat+ent &as fo$nd

to 6e +ore 6eneficial t*an ot*er treat+ent +et*ods to en*ance t*e tensile properties of t*e

friction stir-&elded "0"1 al$+in$+ alloy oints

#ei )$i et al =1"> 'n t*e present st$dy "0"1-T4 T-oints &ere s$ccessf$lly fa6ricated

6y friction stir &elding ,FSW/ in t*ree different co+6ination &ays of s9ins and stringers.

(istri6$tions and for+ation +ec*anis+s of t$nnel defects 6ond defects original oint line &it*

se!ere plastic defor+ation ,OC#&SP(/ defects and :ig:ag line defects in T-oints &ere

in!estigated 6y +acro- and +icro-o6ser!ations. 'nfl$ences of defects distri6$tions and &elding

para+eters on t*e tensile 6e*a!iors of T-oints &ere e7a+ined. To a 6etter $nderstanding of

fail$re 6e*a!iors of T-oints fract$re locations and fract$re s$rfaces of tensile sa+ples &ere also

in!estigated.

?. Ca+s*idi!al et al =1> 'n t*at &or9 t*er+o-+ec*anical 6e*a!ior and +icro

str$ct$ral e!ol$tion in si+ilar and dissi+ilar friction stir &elding of "0"1-T" and 508"-O

*a!e 6een in!estigated. Firstly t*e t*er+o-+ec*anical 6e*a!iors of +aterials d$ring si+ilar and

dissi+ilar FSW operations *a!e 6een predicted $sing t*ree di+ensional finite ele+ent soft&are

@;S t*en t*e +ec*anical properties and t*e de!eloped +icrostr$ct$res &it*in t*e &elded

sa+ples *a!e 6een st$died &it* t*e aid of e7peri+ental o6ser!ations and +odel predictions. 't

&as fo$nd t*at different strengt*ening +ec*anis+s in 508" and "0"1 res$lt in co+ple7

6e*a!iors in *ardness of t*e &elded cross section &*ere t*e *ardness !ariation in si+ilar

508"-O oints +ainly depends on re crystalli:ation and generation of fine grains in &eld

n$gget *o&e!er t*e *ardness !ariations in t*e &eld :one of "0"1G"0"1 and

"0"1G508" oints &ere affected 6y s$6se$ent aging p*eno+enon. lso 6ot*

e7peri+ental and predicted data ill$strate t*at t*e pea9 te+perat$re in FSW of "0"1G"0"1

&as t*e *ig*est co+pared to t*e ot*er oints e+ploying t*e sa+e &elding para+eters.

20


21/40

#.. ar:oli et al =18> esta6lis*ed a friction stir &elding ,FSW/ process para+eters

en!elope for an "0"1 alloy reinforced &it* 20 of l2O3 particles and deter+ine properties

of t*e o6tained oints. fter a 6rief description of t*e FSW tec*ni$e and t*e diffic$lties in

oining )s e7peri+ental proced$re &as ill$strated. icrostr$ct$re *as 6een o6ser!ed &it*

optical +icroscope and i+ages *a!e 6een analy:ed &it* i+age analysis soft&are. icro

*ardness and tensile tests *a!e 6een also carried o$t. T*e tools stirring effect *as a s$6stantial

infl$ence on t*e reinforce+ent particles distri6$tion and s*ape. Tensile testing re!ealed oint

efficiencies o!er 80 for t*e %p0 2 and of slig*tly +ore t*an 0 for t*e %+ &it* fail$re

o$tside t*e stir :one. T*e para+eter en!elope deter+ined in t*e present st$dy res$lted in defect

free *ig* strengt* &elds. %es$lts also indicate t*at t*e alloy in!estigated co$ld 6e &elded &it*

process para+eter co+para6le to t*ose $sed for its $nreinforced co$nterpart.

H. Elango!an et al =1 "0"1 al$+in$+ alloy ,lIgISi alloy/ *ad gat*ered &ideacceptance in t*e fa6rication of lig*t &eig*t str$ct$res re$iring a *ig* strengt*-to-&eig*t ratio

and good corrosion resistance. )o+pared to t*e f$sion &elding processes t*at &ere ro$tinely

$sed for oining str$ct$ral al$+in$+ alloys friction stir &elding ,FSW/ process &as an e+erging

solid state oining process in &*ic* t*e +aterial t*at &as 6eing &elded does not +elt and recast.

T*at process $ses a non-cons$+a6le tool to generate frictional *eat in t*e a6$tting s$rfaces. T*e

&elding para+eters s$c* as tool rotational speed &elding speed a7ial force etc. and tool pin

profile play a +aor role in deciding t*e &eld $ality. 'n t*at in!estigation an atte+pt *as 6een

+ade to $nderstand t*e effect of tool pin profile and tool s*o$lder dia+eter on FSP :one

for+ation in "0"1 al$+in$+ alloy. Fi!e different tool pin profiles ,straig*t cylindrical

tapered cylindrical t*readed cylindrical triang$lar and s$are/ &it* t*ree different s*o$lder

dia+eters *a!e 6een $sed to fa6ricate t*e oints. T*e for+ation of FSP :one *as 6een analy:ed

+acroscopically. Tensile properties of t*e oints *a!e 6een e!al$ated and correlated &it* t*e FSP

:one for+ation. Fro+ t*at in!estigation it &as fo$nd t*at t*e s$are pin profiled tool &it* 18 ++

s*o$lder dia+eter prod$ced +ec*anically so$nd and +etall$rgically defect free &elds co+pared

to ot*er tool pin profiles.

P$neet%o*illa et al =20> "0"1 *as gat*ered &ide acceptance in t*e

fa6rication of t*e lig*t str$ct$res re$ired to *ig* strengt*. )o+pared to t*e f$sion &elding

processes t*at &ere $sed for oining str$ct$ral al$+in$+ alloys friction stir &elding ,FSW/

process &as an e+erging solid state oining process in &*ic* t*e +aterial t*at &as 6eing &elded

does not +elt and recast. 'n t*at e7peri+ental &or9 an e7tensi!e in!estigation *as 6een carried

21


22/40

o$t on FSW 6$tt oint. Welded oints &ere +ade &it* t*e *elp of tool +ade of *ig* speed steel

,?SS/ alloy steel. Tools &ere of t&o different pin profiles !i:. straig*t cylindrical and s$are.

T*e &elded oints &ere +ade on al$+in$+ grade "0"1 plates of " ++ t*ic9. Tests &ere

cond$cted to deter+ine t*e tensile strengt* percentage elongation and +icro *ardness. 'n +y

in!estigation tool rotation and tra!erse speeds &ere 9ept constant i.e. 2000 rp+ and 20 ++G+in.

T*e !aria6les &ere s*ape of t*e tool and *a!ing passes one sided and 6ot* sided. )ylindrical tool

pin profile e7*i6ited s$perior tensile properties co+pared to ot*er oints irrespecti!e of tool

rotational speed in do$6le pass. T*e oints fa6ricated 6y single pass *a!e s*o&n lo&er tensile

strengt* and also percentage of elongation co+pared to t*e oints fa6ricated 6y do$6le pass and

t*at trend &as co++on for all t*e tool profiles.

?. Ca+s*idi!al et al =21> 221< al$+in$+ alloy *ad gat*ered &ide acceptance in t*e

fa6rication of lig*t &eig*t str$ct$res re$iring a *ig* strengt* to &eig*t ratio. )o+pared to t*ef$sion &elding processes t*at &ere ro$tinely $sed for oining str$ct$ral al$+in$+ alloys friction

stir &elding ,FSW/ process &as an e+erging solid state oining process in &*ic* t*e +aterial t*at

&as 6eing &elded does not +elt and recast. T*at process $ses a non-cons$+a6le tool to generate

frictional *eat in t*e a6$tting s$rfaces. T*e &elding para+eters and tool pin profile play +aor

roles in deciding t*e &eld $ality. 'n t*at in!estigation an atte+pt *as 6een +ade to $nderstand

t*e effect of &elding speed and tool pin profile on FSP :one for+ation in 221< al$+in$+

alloy. Fi!e different tool pin profiles ,straig*t cylindrical tapered cylindrical t*readed

cylindrical triang$lar and s$are/ *a!e 6een $sed to fa6ricate t*e oints at t*ree different &elding

speeds. T*e for+ation of FSP :one *as 6een analy:ed +acroscopically. Tensile properties of t*e

oints *a!e 6een e!al$ated and correlated &it* t*e FSP :one for+ation. Fro+ t*at in!estigation it

&as fo$nd t*at t*e s$are pin profiled tool prod$ces +ec*anically so$nd and +etall$rgically

defect free &elds co+pared to ot*er tool pin profiles.

E$r.'ng. ).E.(.%o&e et al =22> t*at paper loo9s at so+e c$rrent $ses !ariations in tool

design i+pro!ed &elding tec*ni$es and ne& tool +aterials 6eing de!eloped for t*e &elding of

+ore diffic$lt al$+in$+ alloys to gi!e increased tool life.

.#a9s*+an%ao et al =23> indicates to&ards f$rt*er e7tension of t*e process to oin

dissi+ilar +etal co+6inations li9e Fe-l and l-)$ &as c$rrently $nder&ay. T*at paper

*ig*lig*ts t*e role of tool geo+etry 6eca$se tool geo+etry plays a +aor role in FSW. Proper

selection of a tool +aterial and s*ape of t*e pin red$ces n$+6er of trials and tooling cost. 'n

addition t*at st$dy also *ig*lig*ts t*e &ear effect d$e to friction 6et&een sliding s$rfaces.

22


23/40

ay H$+ar %e!$ri et al =24> T*e &elding tool its pin profile s*ape and di+ensions

plays a !ital role in +a9ing t*e &eld oint. 'n Friction Stir Welding t*e stress distri6$tion of tool

pin &as affected 6y t*e t*er+o +ec*anical c*aracteristics of t*e &or9 piece. 'n t*at paper t*ree

tools &it* different pin s*apes s$c* as )onical )ylindrical and Fr$st$+ &ere designed &it*

t*reads in t*eir profiles .'nitially t*e tools di+ensions &ere 6ased on t*e 6ase +aterial plate

t*ic9ness ta9en in to consideration t*e ind$ced str$ct$ral stresses &ere c*ec9ed &it* in t*e

per+issi6le stress li+its. T*e tools &ere +odeled in )T' and analysis &as perfor+ed in

NSQS soft&are for e7ploring stress distri6$tions and displace+ent !ector s$+ in t*e pin at

different speeds and te+perat$res. T*e frictional force 6et&een t*e tool s*o$lder and &or9 piece

&as considered for si+$lating t*e stress and displace+ent !ector in t*e pin profiles. T*e tool pin

profiles considered for str$ct$ral and t*er+al analysis &as $sed in t*at st$dies are cylindrical

conical and fr$st$+. T*e !anis*es stress distri6$tions in pin profiles displace+ent !ector s$+ of

t*e pin profiles &ere o6tained fro+ NSQS soft&are and t*e pin &it* opti+$+ strengt* &as

deter+ined.

?. S. Patil et al =25> in!estigated t*e effects of different &elding speeds and tool pin

profiles on t*e &eld $ality of "082-O al$+in$+. T*at +aterial *ad gat*ered &ide

acceptance in t*e fa6rication of lig*t &eig*t str$ct$res re$iring a *ig* strengt*-to-&eig*t ratio.

Tri-fl$tes and taper scre& t*read pin &ere $sed as tool pin profiles in t*at researc*. T*e

appearance of t*e &eld &as &ell and no o6!io$s defect &as fo$nd $sing t*ese tools.

)onse$ently t*e o6tained res$lts e7plain t*e !ariation of stress as a f$nction of strain and t*e

effect of different &elding speed and pin profiles on yield strengt* $lti+ate tensile strengt* and

elongation. T*e friction stir &elded plates of "082-O 6y $sing t*e taper scre& t*read pin

profile reac*es t*e $lti+ate tensile strengt* of


24/40

"( PRO#ECT DESCRIPTION

"(1 INTRODUCTION TO PLATES

?ere in t*is proect t&o dissi+ilar al$+in$+ alloy plates ,"0"1 R 05/ of si:e

10074


25/40

AWS e4-.;at-2;4 32r 5r29.ht A6 a662> .r29p4 a; 8a4-/ te0per

e4-.;at-2;4 app6-/a86e t2 heat*treata86e A6 a662>4

Wr29.ht a662> .r29p4 Ba4-/ te0per e4-.;at-2;4

1777Unalloyed 99% Al

F s fa6ricated

2777

)opper principal alloying ele+ent

gi!es s$6stantial increases in

strengt* per+its precipitation

*ardening red$ces corrosion

resistance d$ctility and &elda6ility

Onnealed t*ere +ay 6e a s$ffi7 to indicate t*e

specific *eat treat+ent.

3777

anganese increases strengt*

t*ro$g* solid sol$tion strengt*ening

and i+pro!es &or9 *ardening

?

Strain *ardened ,cold &or9ed/ it is al&ays

follo&ed 6y t&o or +ore digits to signify t*e

a+o$nt of cold &or9 and any *eat treat+ents

t*at *a!e 6een carried o$t

4777

Silicon increases strengt* and

d$ctility in co+6ination &it*

+agnesi$+ prod$ces precipitation

*ardening

W

Sol$tion *eat treated applied to alloys t*at precipitation *ardens at roo+ te+perat$re

,nat$ral aging/ after a sol$tion *eat treat+ent.

T*e designation is follo&ed 6y a ti+e indicating

t*e nat$ral aging period e.g. W 1 *

5777 agnesi$+ increases strengt*

t*ro$g* solid sol$tion strengt*ening

and i+pro!es &or9 *ardening a6ility

T T*er+ally aged

T1 cooled and nat$rally aged

T2 cooled cold &or9ed and nat$rally aged

T3 sol$tion *eat treated cold &or9ed and

nat$rally aged

T4 sol$tion *eat treated and nat$rally aged

T5 cooled and artificially aged

T" sol$tion *eat treated and artificially aged

T sol$tion *eat treated and a!eraged or

sta6ili:ed

25


26/40

T8 sol$tion *eat treated cold &or9ed and

artificially aged

T


27/40

FLOW MECHANISMS AND TOOL DESIGN

T*e +etal flo& and *eat generation in t*e softened +aterial aro$nd t*e tool are

f$nda+ental to t*e friction stir process. aterial defor+ation generates and redistri6$tes *eat

prod$cing t*e te+perat$re field in t*e &eld. @$t since t*e +aterial flo& stress is te+perat$re and

strain rate sensiti!e t*e distri6$tion of *eat is itself go!erned 6y t*e defor+ation and te+perat$re

fields. 'n fact t*eir control lies at t*e core of al+ost all aspects of FSW for e7a+ple t*e

opti+i:ation of process speeds and +ac*ineloading t*e a!oidance of +acroscopic defects t*e

e!ol$tion of t*e +icrostr$ct$re and t*e res$lting &eld properties.

s noted a6o!e al+ost all t*e +aterial in t*e &eld is e7tr$ded 6et&een t*e rotating pin on t*eretreating side and t*e s$rro$nding +aterial &*ic* is too cold and too lig*tly stressed to defor+

,see Fig.1/. 'n its si+plest for+ t*is essential flo& +ec*anis+ can 6e ill$strated 6y t&o-

di+ensional si+$lations depicting strea+lines ro$nd a rotating tool placed in a steady flo& of

+aterial. Figure 3a s*o&s strea+lines past a cylindrical tool redacted 6y co+p$tational fl$id

dyna+ics ,)F(/. longit$dinal &eld sea+ is for+ed 6e*ind t*e ad!ancing edge of t*e tool

&*ere t*e t&o flo&s co+e toget*er. F$rt*er +odeling st$dies *a!e in!estigated *o& t*is t&o-

di+ensional flo& is pert$r6ed 6y

1. t*e addition of tool feat$res s$c* as flats and fl$tes

2. )*anges in t*e contact conditions 6et&een tool and &or9 piece fro+ stic9ing friction to

slipping at a lo&er interfacial s*ear stress.

Predicted strea+lines ro$nd a fl$ted tool are s*o&n in Fig.3b and c. )o+plete stic9ing generates

a dead +etal :one ro$nd t*e tool &*ereas t*e flo& interacts closely &it* t*e tool feat$res &*en

slipping ta9es place. not*er c*aracteristic of t*e process - a line initially perpendic$lar to t*e&elding direction is s&ept into a 6ac9&ards B6$lgeB in t*e &a9e of t*e tool - can also 6e seen

in Fig.3b and c. ar9er e7peri+ents *a!e confir+ed t*is 6e*a!ior , Fig.3d /. One &ay of

$antifying t*e +i7ing effect of t*e tool is t*e ratio of t*e s&ept !ol$+e to t*e pin !ol$+e.For

25++ t*ic9 plates t*is *as fo$nd to 6e 1⋅1 1 for a cylindrical pin 1⋅8 1 for t*e W*orl and 2⋅"

1 for t*e -Trifoliate pin ,see Fig.2c/ eac* *a!ing si+ilar root dia+eters and lengt*&it* t*e

Trifoliate gi!ing t*e +ore parallel sided &eld :one. F$rt*er refine+ents incl$de t*e

Tri!e7tool&*ic* &as designed to red$ce t*e do&n and tra!erse forces re$ired and t*e Triflat

tool for t*ic9er section +aterials.

2


28/40

a/ typical generic flo& pat* of plate +aterial ro$nd cloc9&ise rotating pin in FSW ta9en fro+

t&o-di+ensional )F( +odel &it* cylindrical tool +o!ing fro+ left to rig*t ,after Seidel and

%eynolds/

6 c/ effect of interfacial 6o$ndary conditions ,b stic9A c slip/ on predicted flo& fro+ t&o-

di+ensional )F( +odel &it* profiled tool ,after )ole gro!e and S*e cliff/ c*ange in t*ic9ness

of strea+lines indicates final location of points initially for+ing straig*t line trans!erse to &eld

line ,analogo$s to )$ foil in d / and

d/ etallograp*ic +ar9er e7peri+ent $sing trans!erse copper foil ill$strating flo& ind$ced 6y

pin ,after %eynolds/

28


29/40

MATERIALS DIAGRAM AND MATERIAL

PROPERTIES

2


30/40

S/he0at-/ -a.ra0 32r a690-;90 a662> '@'%

30


31/40

S/he0at-/ -a.ra0 32r a690-;90 a662> &@&1

31


32/40

F-.("(Fr-/t-2; 4t-r 5e6-;. 6athe

32


33/40

S/he0at-/ -a.ra0 23We6 pr29/t

S/he0at-/ -a.ra0 23We6 pr29/t

33


34/40

Ta6le1.)*e+ical co+position ,&t / of @Ks

E6e0e;t4 S- C9 M; M. ; A6

"0"1 0."40 0.2"2 0.15 0.88 0.25 @al

05 0.104 1.5"0 0.0"3 2.32 5.


35/40

Ta6le 3 Welding Para+eters and Tool geo+etry

35


36/40

Te4t-;.

3"


37/40

CONCLUSION

T*e Friction stir &elding $sed s$ccessf$lly to oin dissi+ilar al$+ini$+ alloys ,"0"1

and 05/.

@etter +ec*anical properties ,tensile strengt*/ &ere o6tained &it* t*e FSW plate fa6ricated

&it*


38/40

REFERENCES

1. . Hoilra D. S$ndares&aran Friction stir &elding of dissi+ilar al$+in$+ alloys 221<

to 5083 IOpti+i:ation of process para+eters $sing Tag$c*i tec*ni$eU on 0


39/40

11. P. Cavaliere∗ , F. Panella Effect of tool position on t*e fatig$e properties of dissi+ilar 2024-

05 s*eets oined 6y friction stir &eldingU On "G12G200.

12. Woong-Seong )*ang S.%. %aes* )*ang-He$n )*$n and ?e$ng-C$ Hi+V icrostr$ct$re

and ec*anical Properties of ?y6rid #aser-Friction Stir Welding 6et&een "0"1-T" l

lloy and 31 g lloyU on 18G12G200


40/40

23. (r. .#a9s*+an%ao P. S$res* @a6$ T. %a++o*anand Q. Seenaaia*. St$dy of Tool

eo+etry in Friction Stir Welding pplicationsU

24. ay H$+ar %e!$riX Prof. [email protected]. %ao. “)o+p$tational nalysis Of Friction Stir Welding

Tools Wit* Dario$s T*readed Pin ProfilesU

25. ?. S. Patil S. N. So+an. E7peri+ental st$dy on t*e effect of &elding speed and tool pin

profiles on "082-O al$+ini$+ friction stir &elded 6$tt ointsU

Friction St welding

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