EFFECT OF TOOL SHAPE ON MECHANICAL PROPERTIES AND MICROSTRUCTURE DEVELOPMENT IN SINGLE AND SEQUENTIAL DOUBLE SIDED FRICTION STIR

WELD ON ALUMINIUM ALLOY AA1100

Presented by :

Guided by :

Contents

Introduction Friction Welding Friction Stir Welding Principle of Operation Important Welding Parameters Microstructure Classification Applications Advantages And Disadvantages Literature Review Problem Formulation Experimental Methodology Results Conclusions Scope for Further Work References

Friction Stir Welding

Friction Stir Welding is one of a solid state joining processes. It was invented at The Welding Institute (TWI), UK in 1991. 3

Principle of Operation

In Friction Stir Welding a cylindrical shouldered tool with a profiled probe is rotated and slowly plunged into the joint line between two pieces of sheet or plate material which are butted together rigidly.
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Continued

Frictional heat generated between the wear resistant welding tool and the material of the work pieces causes the latter to soften without reaching the melting point and allows traversing of the tool along the weld line. The plasticized material is transferred from the leading edge of the tool to the trailing edge of the tool probe and is forged by the intimate contact of the shoulder with the two pieces.
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Important Welding Parameters

Tool Rotational Speed (RPM) Traverse Speed Tool Tilt And Plunge Depth Tool Design Welding Forces

Microstructure Classification

A. Unaffected Material B. Heat Affected Zone (HAZ) C. Thermo-mechanically Affected Zone (TMAZ) D. Weld Nugget
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Different Microstructure Regions Of A Single Pass Friction Stir Weld

Different Microstructure Regions Of A Double Pass Friction Stir Weld

Different microstructure regions of the single pass and double pass welds are shown in Figure When we are comparing double and single pass welds, the weld nugget formed during the second pass is similar in extent and microstructure to that for the single pass weld. The HAZ regions of the second pass overlay upon transformed microstructures and the various heat affected zones from first pass. The first pass weld is well below the weld tool on the second pass and thus only mildly affected by the heat from the
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Applications Of Friction Stir Welding

Automotive Applications Shipbuilding And Marine Industries Aerospace Industry Railway Industry Land Transportation Other Industry Sectors

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Advantages

Good mechanical properties Easily automated on milling machines Non consumable tool Improved safety due to absence of toxic fumes Low distortion No porosity Fine grain structure Low shrinkage Good weld appearance Can weld in any position i.e. horizontal, 12 vertical, overhead etc.

Disadvantages

Exit hole or key hole left when tool is withdrawn Large down forces required with heavy duty clamping to hold plates together Less flexible welds Often slower traverse rate

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Literature Review

In recent years, FSW has been widely developed for mostly aluminum and magnesium alloys. Over 30 papers (given in references) on this topic were reviewed which studied the various aspects of FSW by experimentation & applying FEM & CFD techniques. In spite of these achievements, the effect of tool shape on friction stir welding has not yet been systematically classified in a single and sequential double sided friction stir weld . In order to design effective tool the following characteristics are required: 1. As simple a shape as possible to reduce cost 2. Sufficient stirring effect to produce sound welds. Hence an attempt has been made to study the effect of influence of tool shape on the mechanical properties and microstructure properties of AA 1100 in during a single and sequential double sided friction stir weld in this project. 14

Problem Formulation

Aluminum alloys have gathered wide acceptance in the fabrication of light weight structures requiring a high strength to weight ratio. For most of the aluminum alloys, many difficulties are associated with the traditional welding such as high solubility of gases in molten state, solidification shrinkages, crack sensitivity and presence of oxide inclusions. It also suffers from poor welded joint strength. The loss of strength is due to melting & quick re-solidification.
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Compared to many of fusion welding processes FSW is an emerging solid state joining process in which the material that is being welded does not melt and recast. The welding parameters and tool pin profile play a major role in deciding weld quality So the present investigation is an attempt to understand the influences of rotational speed and pin profile of the tool on friction stir processed zone formation during a single and sequential double sided friction stir weld in aluminum alloy. In this study four different tool pin profiles viz. straight cylindrical, threaded, triangular and square were used to fabricate the joints. Tool rotation and traverse speeds are kept constant i.e. 1200 rpm and 20 mm/min. The four joints were fabricated by passing the tool pin with length 4.7 to 4.8 mm through the joint in single pass and in the same way 4 joints were fabricated by passing the tool pin with length 2.7 to 2.8 mm through the joint in double pass and total 8 joints (4x2) 16 were fabricated.

Problem Formulation Contd

Experimental Methodology

In this experimental work an extensive investigation is carried out on AA1100 grade aluminum strips of 5 mm thick to fabricate FSW joints with HCHCR tool on a vertical type milling machine. Four tool pin profiles viz., straight cylindrical (SC), threaded (TH), triangular (TR) and square (SQ) have been used to produce joints at rotational speeds i.e. 1200 rpm . Tensile testing has been done on UTM and ultimate tensile strength, percentage elongation and joint efficiency have been noted. The hardness values were obtained at 4 mm steps to a distance of 12 mm in advancing side (A) and retreating side(R) of the weld centre line. Finally micro-structural analysis has been done with metallurgical microscope.
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FSW Tool Pin Profiles

Straight Cylindrical (SC) Square (SQ) Threaded Cylindrical (TH) Triangular (TR)

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Tool Pin Profiles

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Tool Material and Dimensions

Specifications
Tool Material Length of Tool Tool Shoulder Diameter Pin Diameter Pin Length For Single Pass Pin Length For Double Pass Pitch and included angle of threaded pin

Values
HCHCR Steel 50 mm 18 mm 6 mm 4.7 to 4.8 mm 2.7 to 2.8 mm 1 metric
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Work Piece Material

200 200 5 100 100 100 100

The material used for experimental work is aluminum AA1100 grade sheet having thickness 5mm, length 200mm, width 100mm.
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Work Piece Composition

Elements Aluminum Silicon + Ferrous Manganese Molybdenum Copper Total Other Elements (<, >, = ) >= <= <= <= <= <= Percentage 99.0 0.1 0.1 0.05 0.05 to 0.1 0.1

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Milling Machine Specifications

Specifications Make Spindle Position RPM range Longitudinal Bed Range Cross Bed Range Diameter of Tool Holder Motor Longitudinal Feed Range Values PACMILL (semi automatic) Vertical 90-2480 900 mm 600 mm 50 mm 3 hp, 1430 rpm 14-900 mm/min
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Machine Setup

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Welding Parameters
Parameters Rotational speeds (rpm) Welding Speed Shoulder deepness inserted into weld Values 1200 20 mm/min 0.05 mm

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Welded Specimens
S.No. 1. 2. 3. 4. 5. 6. 7. 8. Specimen No. S-1 S-2 S-3 S-4 S-5 S-6 S-7 S-8 Type of Pass Single Pass Double Pass Single Pass Double Pass Single Pass Double Pass Single Pass Double Pass Tool Pin Profile Straight Cylindrical Straight Cylindrical Square Square Threaded Threaded Triangular Triangular

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Clamping of Work Pieces

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Welding Process

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Tensile Test

Dimensions of Tensile Test Specimen

Tensile test specimens were tested on UTM and ultimate tensile strength , percentage elongation and joint efficiency have been evaluated.
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Specifications of UTM
Machine Model Make Range Capacity Testing Temperature UTN-40 F.I.E. 0 -40 kN 400 kN Room Temperature

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Hardness Test

Micro hardness testing has been done using Vickers micro-hardness testing machine for all specimens.The hardness values were obtained at 4 mm steps to a distance of 12 mm in advancing side (A) and retreating side (R) of the weld centre line.

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Specifications of Hardness Tester

Name Make Range Indenter Micro Vickers Hardness Tester XHV 100 (METCO) Chennai

0.491 to 1.962 KN
Diamond pyramid with 136

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Micro hardness tester is based upon indentation method of testing. A diamond pyramid was used to create a permanent deformation in the surface of test sample and then the hardness of the test sample was determined from the load required to create the deformation and dimensions of permanent deformation. The load used in Vickers hardness testing was 0.981 N for a period of 15 seconds. After the indentation, the dimensions of the diamond impression were recorded i.e. the horizontal and vertical diagonals were recorded using the scale of the eye piece. The tester was calibrated to directly give the values of micro hardness.
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Micro-structural analysis

For micro-structural analysis welding specimens were sliced at the centre of the weld across the joint to make microscopic specimens.
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Specifications of Microscope
Name Type of Machine Make Range Metscope Metallurgical Microscope Japan 10 -1000X

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These specimens were polished using C-180 grit, C220 grit, C-320 grit, C-400 grit, C-600 grit, and C1000 and lavigated alumina grade 1. Final polishing was done on polishing machine so that the specimen becomes very smooth without any void or scratches. Then etching was done by Methanol to visualize the microstructure of the surface. Then microstructure was reveled with the help of metallurgical microscope with a magnification power of 100X, with the help of camera mounted on the eye piece of the microscope. Then still photographs have been taken and visualized on computer screen.
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Results of Tensile Testing

The welded specimens were put under testing and the values of ultimate tensile strength, percentage elongation and joint efficiency were noted.

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Failure of Base Metal Specimen in Tensile Test

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Failure of Welded Specimen in Tensile Test

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Tensile Test Results of Base Metal

Ultimate Tensile Strength Percentage Elongation

Load (KN)

Stress (N/mm2)

% Elongated Length Elongation (mm) 57.3 14.6

8.8

117.33

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Tensile Test Results of Welded Specimens in Single Pass

Specimen No. Ultimate Tensile Strength % Percentage Elongation Joint Efficiency Load (KN) Stress (N/mm2) Elongated Length (mm) % Elongation

S-1 S-3 S-5 S-7

8.4 8.48 8.96 9.52

112 113 119.4 126.9

54.4 59.5 52.9 58.3

8.8 19 5.8 16.6

95.4 96.3 101.7 108.1

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Tensile Test Results of Welded Specimens in Single Pass

Specimen No. Ultimate Tensile Strength % Load (KN) Stress (N/mm2) Elongated (mm) Length% Elongation Percentage Elongation Joint Efficiency

S-2 S-4 S-6 S-8

8.88 8.92 10 9.6

118.4 118.9 133.3 128

61.3 63.6 55.5 62.2

22.6 27.2 11 24.4

100.9 101.3 113.6 109.9

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Variation of Ultimate Tensile Strength

Variation of Ultimate Tensile Strength 140 120 Ultimate Tensile Strength 100 80
SC TH TP

Single Pass
TR

SQ

60 40 20 0 SC SQ TH TR Tool Profile
SC TH TP

Double Pass

TR

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Variation of Percentage Elongation

Va ria tion Of Perce ntage Elonga tion 30 25 Percentage Elongation 20 15 10 5 0 SC SQ TH TR Tool Profile Single Pass Double Pass

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Variation of Joint Efficiency

Variation of Joint Efficiency 115 110 Joint Efficiency 105 100 95 90 85 SC SQ TH TR Tool Profile Single Pass Double Pass

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Micro Hardness Results of Welded Specimens in Single Pass

Sr. No. Distance from the Weld Centre (mm) Specimen No. S-1 S-3 S-5 S-7

1 2 3 4 5 6 7

A12 A8 A4 0 R4 R8 R12

32.1 32.93 33.03 33.77 33.93 33.1 32.42

30.28 31.47 32.37 33.9 32.9 31.33 30.41

33.47 33.9 33.64 36.4 34.08 33.64 33.5

30.96 31.51 31.81 33.38 31.64 31.7 30.52

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Micro-Hardness of Specimen S-1

Microhardness of Specimen S-1
45 40 35 Microhardness 30 25 20 15 10 5 0 -15 -10 -5 0 5 10 15 Distance from Weld Microhardness

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Micro-Hardness of Specimen S-3

Microhardness of Specimen S-3
45 40 35 Microhardness 30 25 20 15 10 5 0 -15 -10 -5 0 5 10 15 Distance from Weld Microhardness

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Micro-Hardness of Specimen S-5

Microhardness of Specimen S-5
45 40 35 Microhardness 30 25 20 15 10 5 0 -15 -10 -5 0 5 10 15 Distance from Weld Microhardness

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Micro-Hardness of Specimen S-7

Microhardness of Specimen S-7
40 35 Microhardness 30 25 20 15 10 5 0 -15 -10 -5 0 5 10 15 Distance from Weld Microhardness

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Micro Hardness Results of Welded Specimens in Double Pass

Sr. No. Distance from the Weld Centre (mm) Specimen No. S-2 S-4 S-6 S-8

1 2 3 4 5 6 7

A12 A8 A4 0 R4 R8 R12

29.81 30.93 31.23 32.98 31.25 30.86 29.62

26.6 29.48 29.12 30.48 28.36 28.89 25.67

33.65 33.41 34.73 35.18 34.59 34.22 33.65

31.47 31.56 32.64 33.9 33.64 32.79 31.69

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Micro-Hardness of Specimen S-2

Microhardness of Specimen S-2
45 40 35 Microhardness 30 25 20 15 10 5 0 -15 -10 -5 0 5 10 15 Distance from Weld Microhardness

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Micro-Hardness of Specimen S-4

Microhardness of Specimen S-4
45 40 35 Microhardness 30 25 20 15 10 5 0 -15 -10 -5 0 5 10 15 Distance From Weld Microhardness

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Micro-Hardness of Specimen S-6

Microhardness of Specimen S-6
45 40 35 Microhardness 30 25 20 15 10 5 0 -15 -10 -5 0 5 10 15 Distance from Weld Microhardness

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Micro-Hardness of Specimen S-8

Microhardness of Specimen S-8
45 40 Microhardness 35 30 25 20 15 10 5 0 -15 -10 -5 0 5 10 15 Distance from Weld Microhardness

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Metal Microstructure of Base

Microstructure of the Base Metal

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Microstructure of Best Specimen

Microstructure of Specimen S-6 at 10 mm from 57 Centre of Weld in Double pass

Microstructure of Worst Specimen

Microstructure of Specimen S-1 at 10 mm from 58 Centre of Weld in Single Pass

Microstructure of Worst Specimen

Microstructure of Specimen S-2 at 10 mm from 59 Centre of Weld in Double Pass

Conclusions

Welded specimens failed in region corresponding to the outer HAZ . The microstructure of the specimen with best weld quality is found for threaded pin profile tool in double pass. Threaded pin profiled tool produced defect free FSP region and showed superior tensile properties in double pass . Micro-structure of the welded specimens shows the smaller grains size as compared to the base metal. Micro hardness analysis of the welded specimens shows an increase in micro hardness in the welded region . The joints fabricated by double passes have shown higher ultimate tensile strength and also percentage of elongation as compared to the joints fabricated by single pass and this trend is common for all the tool profiles. For the straight cylindrical pin profile tool, crack like defects 60 are found in both single and double pass joints.

Conclusions

Welded specimens failed in region corresponding to the outer HAZ . The microstructure of the specimen with best weld quality is found for threaded pin profile tool in double pass. Threaded pin profiled tool produced defect free FSP region and showed superior tensile properties in double pass . Micro-structure of the welded specimens shows the smaller grains size as compared to the base metal. Micro hardness analysis of the welded specimens shows an increase in micro hardness in the welded region . The joints fabricated by double passes have shown higher ultimate tensile strength and also percentage of elongation as compared to the joints fabricated by single pass and this trend is common for all the tool profiles. For the straight cylindrical pin profile tool, crack like defects 61 are found in both single and double pass joints.

Scope for Further Work

By selecting different rotational speed of the tool (rpm) Variation in the tool material may be taken into consideration. Determine the fatigue behaviors of notched specimens of friction stir welded aluminum alloys. Welding can be done on high melting point alloys such as steels etc. Mathematical models can be developed to study various parameters. Temperatures at various points and heat input per unit volume can be calculated.
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REFERENCES AND BIBLIOGRAPHY

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References Contd
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References Contd
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References Contd

Colligan K., Material flow behavior during friction stir welding of aluminum, Materials Research, vol 7, no. 4, (2004), pp 569-574. Dequing W., Shuhua L., Zhaoxia C., Study of friction stir welding of aluminum, Material Science and Engineering Journal 39 (2004) pp 1689-1693. Jariyaboon M., A.J., Davenport A.J., Ambat R., Connolly B.J., Williams S.W., Price D.A., The effect of welding parameters on the corrosion behavior of friction stir welded AA2024-T351 Corrosion Science 49 (2007) pp 877-909. Cabibbo M., McQueenb H.J., Evangelista E., Spigarelli S., Di Paola M., Falchero A., Microstructure and mechanical property studies of AA6056 friction stir welded plate, and Journal of Materials Science and Engineering A 460 (2007) 8694. Rao P.N., Manufacturing Technology, Second Edition, Tata McGraw Hill Edition, 2006. Kalpakjian S., Manufacturing Engineering and Technology, Pearson Education Edition, 2002. Khanna O.P., A Text Book on Welding Technology, Revised Edition, Dhanpat Rai Publications, 1998.

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Thank You

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Q/A?

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