Stir Weld Ppt

11

EFFECT OF TOOL SHAPE ON MECHANICAL EFFECT OF TOOL SHAPE ON MECHANICAL PROPERTIES AND MICROSTRUCTURE PROPERTIES AND MICROSTRUCTURE

DEVELOPMENT IN SINGLE AND SEQUENTIAL DEVELOPMENT IN SINGLE AND SEQUENTIAL DOUBLE SIDED FRICTION STIR WELD ON DOUBLE SIDED FRICTION STIR WELD ON

ALUMINIUM ALLOY AA1100ALUMINIUM ALLOY AA1100

Presented by : Guided by :Presented by : Guided by :

22

ContentsContents IntroductionIntroduction

Friction WeldingFriction Welding Friction Stir WeldingFriction Stir Welding Principle of OperationPrinciple of Operation Important Welding ParametersImportant Welding Parameters Microstructure ClassificationMicrostructure Classification ApplicationsApplications Advantages And DisadvantagesAdvantages And Disadvantages

Literature ReviewLiterature Review Problem FormulationProblem Formulation Experimental MethodologyExperimental Methodology ResultsResults ConclusionsConclusions Scope for Further WorkScope for Further Work ReferencesReferences

33

Friction Stir WeldingFriction Stir Welding

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

44

Principle of Operation Principle of Operation

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

55

Continued…Continued…

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

66

Important Welding ParametersImportant Welding Parameters

Tool Rotational Speed (RPM)Tool Rotational Speed (RPM) Traverse SpeedTraverse Speed Tool Tilt And Plunge DepthTool Tilt And Plunge Depth Tool DesignTool Design Welding ForcesWelding Forces

77

Microstructure ClassificationMicrostructure Classification

A. Unaffected MaterialA. Unaffected Material B. Heat Affected Zone (HAZ)B. Heat Affected Zone (HAZ) C. Thermo-mechanically Affected Zone (TMAZ)C. Thermo-mechanically Affected Zone (TMAZ) D. Weld NuggetD. Weld Nugget

88

Different Microstructure Regions Of Different Microstructure Regions Of A Single Pass Friction Stir Weld A Single Pass Friction Stir Weld

99

Different Microstructure Regions Of Different Microstructure Regions Of A Double Pass Friction Stir Weld A Double Pass Friction Stir Weld

1010

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

1111

Applications Of Friction Stir Applications Of Friction Stir WeldingWelding

Automotive ApplicationsAutomotive Applications Shipbuilding And Marine IndustriesShipbuilding And Marine Industries Aerospace IndustryAerospace Industry Railway IndustryRailway Industry Land TransportationLand Transportation Other Industry SectorsOther Industry Sectors

1212

AdvantagesAdvantages Good mechanical propertiesGood mechanical properties Easily automated on milling machinesEasily automated on milling machines Non consumable toolNon consumable tool Improved safety due to absence of toxic fumesImproved safety due to absence of toxic fumes Low distortionLow distortion No porosityNo porosity Fine grain structureFine grain structure Low shrinkageLow shrinkage Good weld appearanceGood weld appearance Can weld in any position i.e. horizontal, Can weld in any position i.e. horizontal,

vertical, overhead etc.vertical, overhead etc.

1313

DisadvantagesDisadvantages

Exit hole or key hole left when tool is Exit hole or key hole left when tool is withdrawnwithdrawn

Large down forces required with heavy duty Large down forces required with heavy duty clamping to hold plates togetherclamping to hold plates together

Less flexible weldsLess flexible welds Often slower traverse rateOften slower traverse rate

1414

Literature ReviewLiterature Review In recent years, FSW has been widely developed for mostly In recent years, FSW has been widely developed for mostly

aluminum and magnesium alloys. aluminum and magnesium alloys. Over 30 papersOver 30 papers (given in (given in references) on this topic were reviewed which studied the references) on this topic were reviewed which studied the various aspects of FSW by experimentation & applying FEM various aspects of FSW by experimentation & applying FEM & CFD techniques. In spite of these achievements, the effect & CFD techniques. In spite of these achievements, the effect of tool shape on friction stir welding has not yet been of tool shape on friction stir welding has not yet been systematically classified in a single and sequential double systematically classified in a single and sequential double sided friction stir weld . In order to design effective tool the sided friction stir weld . In order to design effective tool the following characteristics are required:following characteristics are required:

1. As simple a shape as possible to reduce cost1. As simple a shape as possible to reduce cost

2. Sufficient stirring effect to produce sound welds.2. Sufficient stirring effect to produce sound welds.

Hence an attempt has been made to study the effect of Hence an attempt has been made to study the effect of influence of tool shape on the mechanical properties and influence of tool shape on the mechanical properties and microstructure properties of AA 1100 in during a single and microstructure properties of AA 1100 in during a single and sequential double sided friction stir weld in this projectsequential double sided friction stir weld in this project ..

1515

Problem FormulationProblem Formulation

Aluminum alloys have gathered wide acceptance in Aluminum alloys have gathered wide acceptance in the fabrication of light weight structures requiring a the fabrication of light weight structures requiring a high strength to weight ratio. For most of the high strength to weight ratio. For most of the aluminum alloys, many difficulties are associated aluminum alloys, many difficulties are associated with the traditional welding such as with the traditional welding such as high solubility of high solubility of gases in molten stategases in molten state, , solidification shrinkagessolidification shrinkages, , crack crack sensitivitysensitivity and and presence of oxide inclusionspresence of oxide inclusions. It also . It also suffers from poor welded joint strength. The loss of suffers from poor welded joint strength. The loss of

strength is due to melting & quick re-solidificationstrength is due to melting & quick re-solidification . .

1616

Problem Formulation Contd…Problem Formulation Contd… Compared to many of fusion welding processes FSW is an Compared to many of fusion welding processes FSW is an

emerging emerging solid state joiningsolid state joining process in which the material that process in which the material that is being welded does not melt and recast. The welding is being welded does not melt and recast. The welding parameters and tool pin profile play a major role in deciding parameters and tool pin profile play a major role in deciding weld qualityweld quality

So the present investigation is an attempt to understand the So the present investigation is an attempt to understand the influences of rotational speed and pin profile of the tool on influences of rotational speed and pin profile of the tool on friction stir processed zone formation during a single and friction stir processed zone formation during a single and sequential double sided friction stir weld in aluminum alloy.sequential double sided friction stir weld in aluminum alloy.

In this study four different tool pin profiles viz. straight In this study four different tool pin profiles viz. straight cylindrical, threaded, triangular and square were used to cylindrical, threaded, triangular and square were used to fabricate the joints. fabricate the joints. Tool rotation and traverse speeds are kept Tool rotation and traverse speeds are kept constant i.e. 1200 rpm and 20 mm/min.constant i.e. 1200 rpm and 20 mm/min. The four joints were The four joints were fabricated by passing the tool pin with length 4.7 to 4.8 mm 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 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 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) mm through the joint in double pass and total 8 joints (4x2) were fabricated.were fabricated.

1717

Experimental Methodology Experimental Methodology In this experimental work an extensive investigation is carried In this experimental work an extensive investigation is carried

out on AA1100 grade aluminum strips of 5 mm thick to out on AA1100 grade aluminum strips of 5 mm thick to fabricate FSW joints with HCHCR tool on a vertical type fabricate FSW joints with HCHCR tool on a vertical type milling machine.milling machine.

Four tool pin profiles viz., straight cylindrical (SC), threaded Four tool pin profiles viz., straight cylindrical (SC), threaded (TH), triangular (TR) and square (SQ) have been used to (TH), triangular (TR) and square (SQ) have been used to produce joints at rotational speeds i.e. 1200 rpm .produce joints at rotational speeds i.e. 1200 rpm .

Tensile testing has been done on UTM and ultimate tensile Tensile testing has been done on UTM and ultimate tensile strength, percentage elongation and joint efficiency have been strength, percentage elongation and joint efficiency have been noted.noted.

The hardness values were obtained at 4 mm steps to a distance 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 of 12 mm in advancing side (A) and retreating side(R) of the weld centre line. weld centre line.

Finally micro-structural analysis has been done with Finally micro-structural analysis has been done with metallurgical microscope.metallurgical microscope.

1818

FSW Tool Pin ProfilesFSW Tool Pin Profiles

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

1919

Tool Pin ProfilesTool Pin Profiles

2020

Tool Material and DimensionsTool Material and Dimensions

SpecificationsSpecifications ValuesValues

Tool MaterialTool Material HCHCR SteelHCHCR Steel

Length of ToolLength of Tool 50 mm50 mm

Tool Shoulder DiameterTool Shoulder Diameter 18 mm18 mm

Pin DiameterPin Diameter 6 mm6 mm

Pin Length For Single PassPin Length For Single Pass 4.7 to 4.8 mm4.7 to 4.8 mm

Pin Length For Double PassPin Length For Double Pass 2.7 to 2.8 mm2.7 to 2.8 mm

Pitch and included angle of Pitch and included angle of threaded pinthreaded pin

1 metric1 metric

2121

Work Piece MaterialWork Piece Material

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

100100 100100

200200

5

2222

Work Piece CompositionWork Piece Composition

ElementsElements (<, >, = )(<, >, = ) PercentagePercentage

AluminumAluminum >=>= 99.099.0

Silicon + FerrousSilicon + Ferrous <=<= 0.10.1

ManganeseManganese <=<= 0.10.1

MolybdenumMolybdenum <=<= 0.050.05

CopperCopper <=<= 0.05 to 0.10.05 to 0.1

Total Other ElementsTotal Other Elements <=<= 0.10.1

2323

Milling Machine SpecificationsMilling Machine Specifications

SpecificationsSpecifications ValuesValues

MakeMake PACMILL (semi automatic)PACMILL (semi automatic)

Spindle PositionSpindle Position VerticalVertical

RPM rangeRPM range 90-248090-2480

Longitudinal Bed RangeLongitudinal Bed Range 900 mm900 mm

Cross Bed RangeCross Bed Range 600 mm600 mm

Diameter of Tool HolderDiameter of Tool Holder 50 mm50 mm

MotorMotor 3 hp, 1430 rpm3 hp, 1430 rpm

Longitudinal Feed RangeLongitudinal Feed Range 14-900 mm/min14-900 mm/min

2424

Machine SetupMachine Setup

2525

Welding ParametersWelding Parameters

ParametersParameters ValuesValues

Rotational speeds (rpm)Rotational speeds (rpm) 12001200

Welding SpeedWelding Speed 20 mm/min20 mm/min

Shoulder deepness insertedShoulder deepness inserted

into weldinto weld0.05 mm0.05 mm

2626

Welded SpecimensWelded SpecimensS.No.S.No. Specimen No.Specimen No. Type of PassType of Pass Tool Pin ProfileTool Pin Profile

1.1. S-1S-1 Single PassSingle Pass Straight CylindricalStraight Cylindrical

2.2. S-2S-2 Double PassDouble Pass Straight CylindricalStraight Cylindrical

3.3. S-3S-3 Single PassSingle Pass SquareSquare

4.4. S-4S-4 Double PassDouble Pass SquareSquare

5.5. S-5S-5 Single PassSingle Pass ThreadedThreaded

6.6. S-6S-6 Double PassDouble Pass ThreadedThreaded

7.7. S-7S-7 Single PassSingle Pass TriangularTriangular

8.8. S-8S-8 Double PassDouble Pass TriangularTriangular

2727

Clamping of Work PiecesClamping of Work Pieces

2828

Welding ProcessWelding Process

2929

Tensile TestTensile Test

Tensile test specimens were tested on UTM and Tensile test specimens were tested on UTM and ultimate tensile strength , percentage elongation and ultimate tensile strength , percentage elongation and joint efficiency have been evaluated.joint efficiency have been evaluated.

Dimensions of Tensile Test Specimen

3030

Specifications of UTMSpecifications of UTM

Machine ModelMachine Model UTN-40UTN-40

MakeMake F.I.E.F.I.E.

RangeRange 0 -40 kN0 -40 kN

CapacityCapacity 400 kN400 kN

Testing TemperatureTesting Temperature Room TemperatureRoom Temperature

3131

Hardness TestHardness Test

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

3232

Specifications of Hardness TesterSpecifications of Hardness Tester

NameNameMicro Vickers Hardness Tester Micro Vickers Hardness Tester XHV 100 (METCO)XHV 100 (METCO)

MakeMake ChennaiChennai

RangeRange 0.491 to 1.962 KN0.491 to 1.962 KN

IndenterIndenter Diamond pyramid with 136Diamond pyramid with 136°°

3333

Micro hardness tester is based upon indentation Micro hardness tester is based upon indentation method of testing. A diamond pyramid was used to method of testing. A diamond pyramid was used to create a permanent deformation in the surface of create a permanent deformation in the surface of test sample and then the hardness of the test sample test sample and then the hardness of the test sample was determined from the load required to create the was determined from the load required to create the deformation and dimensions of permanent deformation and dimensions of permanent deformation. deformation.

The load used in Vickers hardness testing was The load used in Vickers hardness testing was 0.981 N for a period of 15 seconds. After the 0.981 N for a period of 15 seconds. After the indentation, the dimensions of the diamond indentation, the dimensions of the diamond impression were recorded i.e. the horizontal and impression were recorded i.e. the horizontal and vertical diagonals were recorded using the scale of vertical diagonals were recorded using the scale of the eye piece. The tester was calibrated to directly the eye piece. The tester was calibrated to directly give the values of micro hardness. give the values of micro hardness.

3434

Micro-structural analysisMicro-structural analysis

For micro-structural For micro-structural analysis welding analysis welding specimens were specimens were sliced at the centre of sliced at the centre of the weld across the the weld across the joint to make joint to make microscopic microscopic specimens.specimens.

3535

Specifications of MicroscopeSpecifications of Microscope

NameName MetscopeMetscope

Type of MachineType of Machine Metallurgical MicroscopeMetallurgical Microscope

MakeMake JapanJapan

RangeRange 10 -1000X10 -1000X

3636

These specimens were polished using C-180 grit, C-These specimens were polished using C-180 grit, C-220 grit, C-320 grit, C-400 grit, C-600 grit, and C-220 grit, C-320 grit, C-400 grit, C-600 grit, and C-1000 and lavigated alumina grade 1. Final polishing 1000 and lavigated alumina grade 1. Final polishing was done on polishing machine so that the specimen was done on polishing machine so that the specimen becomes very smooth without any void or scratches. becomes very smooth without any void or scratches. Then etching was done by Methanol to visualize the Then etching was done by Methanol to visualize the microstructure of the surface. Then microstructure microstructure of the surface. Then microstructure was reveled with the help of metallurgical was reveled with the help of metallurgical microscope with a magnification power of 100X, microscope with a magnification power of 100X, with the help of camera mounted on the eye piece of with the help of camera mounted on the eye piece of the microscope. Then still photographs have been the microscope. Then still photographs have been taken and visualized on computer screen.taken and visualized on computer screen.

3737

Results of Tensile TestingResults of Tensile Testing

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

3838

Failure of Base Metal Specimen Failure of Base Metal Specimen in Tensile Testin Tensile Test

3939

Failure of Welded Specimen in Failure of Welded Specimen in Tensile TestTensile Test

4040

Tensile Test Tensile Test ResultsResults of Base Metal of Base Metal

Ultimate Tensile Ultimate Tensile StrengthStrength

Percentage ElongationPercentage Elongation

Load Load (KN)(KN)

Stress Stress (N/mm(N/mm22))

Elongated Elongated Length Length (mm)(mm)

% % ElongationElongation

8.88.8 117.33117.33 57.357.3 14.614.6

4141

Tensile Test Results of Welded Tensile Test Results of Welded Specimens in Single PassSpecimens in Single Pass

Specimen No.

Ultimate Tensile Strength Percentage Elongation

Joint Efficiency

%

Load (KN) Stress (N/mm2)ElongatedLength (mm)

% Elongation

S-1 8.4 112 54.4 8.8 95.4

S-3 8.48 113 59.5 19 96.3

S-5 8.96 119.4 52.9 5.8 101.7

S-7 9.52 126.9 58.3 16.6 108.1

4242

Tensile Test Results of Welded Tensile Test Results of Welded Specimens in Single PassSpecimens in Single Pass

Specimen No.

Ultimate Tensile Strength Percentage Elongation

Joint Efficiency

%

Load (KN) Stress (N/mm2)Elongated Length (mm)

% Elongation

S-2 8.88 118.4 61.3 22.6 100.9

S-4 8.92 118.9 63.6 27.2 101.3

S-6 10 133.3 55.5 11 113.6

S-8 9.6 128 62.2 24.4 109.9

4343

Variation of Ultimate Tensile Variation of Ultimate Tensile StrengthStrength

SC TH TP TR SQ

SC TH TP TR S

Variation of Ultimate Tensile Strength

0

20

40

60

80

100

120

140

SC SQ TH TR

Tool Profile

Ult

imat

e T

ensi

le S

tren

gth

Single Pass

Double Pass

4444

Variation of Percentage Variation of Percentage ElongationElongation

Variation Of Percentage Elongation

0

5

10

15

20

25

30

SC SQ TH TR

Tool Profile

Per

cen

tag

e E

lon

gat

ion

Single Pass

Double Pass

4545

Variation of Joint EfficiencyVariation of Joint Efficiency

Variation of Joint Efficiency

85

90

95

100

105

110

115

SC SQ TH TR

Tool Profile

Join

t E

ffic

ien

cy

Single Pass

Double Pass

4646

Micro Hardness Results of Welded Micro Hardness Results of Welded Specimens in Single PassSpecimens in Single Pass

Sr. No. Distance from the Weld Centre (mm)

Specimen No.

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

1 A12 32.1 30.28 33.47 30.96

2 A8 32.93 31.47 33.9 31.51

3 A4 33.03 32.37 33.64 31.81

4 0 33.77 33.9 36.4 33.38

5 R4 33.93 32.9 34.08 31.64

6 R8 33.1 31.33 33.64 31.7

7 R12 32.42 30.41 33.5 30.52

4747

Micro-Hardness of Specimen S-1Micro-Hardness of Specimen S-1

Microhardness of Specimen S-1

0

5

10

15

20

25

30

35

40

45

-15 -10 -5 0 5 10 15

Distance from Weld

Mic

roh

ard

ness

Microhardness

4848



0

5

10

15

20

25

30

35

40

45

-15 -10 -5 0 5 10 15

Distance from Weld

Mic

roh

ard

ness

Microhardness

4949



0

5

10

15

20

25

30

35

40

45

-15 -10 -5 0 5 10 15

Distance from Weld

Mic

roh

ard

ness

Microhardness

5050



0

5

10

15

20

25

30

35

40

-15 -10 -5 0 5 10 15

Distance from Weld

Mic

roh

ard

ne

ss

Microhardness

5151

Micro Hardness Results of Welded Micro Hardness Results of Welded Specimens in Double PassSpecimens in Double Pass

Sr. No. Distance from the Weld Centre (mm)

Specimen No.

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

1 A12 29.81 26.6 33.65 31.47

2 A8 30.93 29.48 33.41 31.56

3 A4 31.23 29.12 34.73 32.64

4 0 32.98 30.48 35.18 33.9

5 R4 31.25 28.36 34.59 33.64

6 R8 30.86 28.89 34.22 32.79

7 R12 29.62 25.67 33.65 31.69

5252



0

5

10

15

20

25

30

35

40

45

-15 -10 -5 0 5 10 15

Distance from Weld

Mic

roh

ard

ness

Microhardness

5353



0

5

10

15

20

25

30

35

40

45

-15 -10 -5 0 5 10 15

Distance From Weld

Mic

roh

ard

nes

s

Microhardness

5454



0

5

10

15

20

25

30

35

40

45

-15 -10 -5 0 5 10 15

Distance from Weld

Mic

roh

ard

ness

Microhardness

5555



0

5

10

15

20

25

30

35

40

45

-15 -10 -5 0 5 10 15

Distance from Weld

Mic

roh

ard

ness

Microhardness

5656

Microstructure of the Base MetalMicrostructure of the Base Metal

Metal Microstructure of Base Metal Microstructure of Base

5757

Microstructure of Best SpecimenMicrostructure of Best Specimen

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

5858

Microstructure of Worst SpecimenMicrostructure of Worst Specimen

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

5959

Microstructure of Worst SpecimenMicrostructure of Worst Specimen

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

6060

ConclusionsConclusions Welded specimens failed in region corresponding to the outer Welded specimens failed in region corresponding to the outer

HAZ .HAZ . The microstructure of the specimen with best weld quality is The microstructure of the specimen with best weld quality is

found for threaded pin profile tool in double pass. Threaded pin found for threaded pin profile tool in double pass. Threaded pin profiled tool produced defect free FSP region and showed superior profiled tool produced defect free FSP region and showed superior tensile properties in double pass .tensile properties in double pass .

Micro-structure of the welded specimens shows the smaller grains Micro-structure of the welded specimens shows the smaller grains size as compared to the base metal.size as compared to the base metal.

Micro hardness analysis of the welded specimens shows an Micro hardness analysis of the welded specimens shows an increase in micro hardness in the welded region .increase in micro hardness in the welded region .

The joints fabricated by double passes have shown higher ultimate The joints fabricated by double passes have shown higher ultimate tensile strength and also percentage of elongation as compared to tensile strength and also percentage of elongation as compared to the joints fabricated by single pass and this trend is common for the joints fabricated by single pass and this trend is common for all the tool profilesall the tool profiles..

For the straight cylindrical pin profile tool, crack like defects are For the straight cylindrical pin profile tool, crack like defects are found in both single and double pass jointsfound in both single and double pass joints..

6161

ConclusionsConclusions Welded specimens failed in region corresponding to the outer Welded specimens failed in region corresponding to the outer

HAZ .HAZ . The microstructure of the specimen with best weld quality is The microstructure of the specimen with best weld quality is

found for threaded pin profile tool in double pass. Threaded pin found for threaded pin profile tool in double pass. Threaded pin profiled tool produced defect free FSP region and showed superior profiled tool produced defect free FSP region and showed superior tensile properties in double pass .tensile properties in double pass .

Micro-structure of the welded specimens shows the smaller grains Micro-structure of the welded specimens shows the smaller grains size as compared to the base metal.size as compared to the base metal.

Micro hardness analysis of the welded specimens shows an Micro hardness analysis of the welded specimens shows an increase in micro hardness in the welded region .increase in micro hardness in the welded region .

The joints fabricated by double passes have shown higher ultimate The joints fabricated by double passes have shown higher ultimate tensile strength and also percentage of elongation as compared to tensile strength and also percentage of elongation as compared to the joints fabricated by single pass and this trend is common for the joints fabricated by single pass and this trend is common for all the tool profilesall the tool profiles..

For the straight cylindrical pin profile tool, crack like defects are For the straight cylindrical pin profile tool, crack like defects are found in both single and double pass jointsfound in both single and double pass joints..

6262

Scope for Further WorkScope for Further Work By selecting different rotational speed of the tool By selecting different rotational speed of the tool

(rpm) Variation in the tool material may be taken into (rpm) Variation in the tool material may be taken into consideration.consideration.

Determine the fatigue behaviors of notched Determine the fatigue behaviors of notched specimens of friction stir welded aluminum alloys. specimens of friction stir welded aluminum alloys.

Welding can be done on high melting point alloys Welding can be done on high melting point alloys such as steels etc.such as steels etc.

Mathematical models can be developed to study Mathematical models can be developed to study various parameters.various parameters.

Temperatures at various points and heat input per unit Temperatures at various points and heat input per unit volume can be calculated. volume can be calculated.

6363

REFERENCES AND BIBLIOGRAPHYREFERENCES AND BIBLIOGRAPHY 1.1. P.Cavaliere , A.De Santis, F. Panella , A. Squillace, “Effect of welding parameters on mechanical and P.Cavaliere , A.De Santis, F. Panella , A. Squillace, “Effect of welding parameters on mechanical and

micro structural properties of dissimilar AA6082–AA2024 joints produced by friction stir welding”, micro structural properties of dissimilar AA6082–AA2024 joints produced by friction stir welding”, Materials and Design Journal 30 (2009) pp 609–616.Materials and Design Journal 30 (2009) pp 609–616.

2.2. P.M.G.P. Moreira., F.M.F. De Oliveira, P.M.S.T. De Castro, “Fatigue behaviour of notched P.M.G.P. Moreira., F.M.F. De Oliveira, P.M.S.T. De Castro, “Fatigue behaviour of notched specimens of friction stir welded aluminium alloy 6063-T6”, Journal of Materials processing specimens of friction stir welded aluminium alloy 6063-T6”, Journal of Materials processing technology 207 (2008) pp 283–292.technology 207 (2008) pp 283–292.

3.3. Zheng, D. Petry, H. Rapp, T. Wierzbicki, “A characterization of material and fracture of AA6061 butt Zheng, D. Petry, H. Rapp, T. Wierzbicki, “A characterization of material and fracture of AA6061 butt weld”, Thin-Walled Structures 40 (2008) pp 1-11.weld”, Thin-Walled Structures 40 (2008) pp 1-11.

4.4. A. Simar, Y. Br´echet, B. de Meester, A. Denquin, T. Pardoen, “Microstructure, local and global A. Simar, Y. Br´echet, B. de Meester, A. Denquin, T. Pardoen, “Microstructure, local and global mechanical properties of friction stir welds in aluminium alloy 6005A-T6”, Materials Science and mechanical properties of friction stir welds in aluminium alloy 6005A-T6”, Materials Science and Engineering Journal A 486 (2008) pp 85–95.Engineering Journal A 486 (2008) pp 85–95.

5.5. V. Balasubramanian, “Relationship between base metal properties and friction stir welding process V. Balasubramanian, “Relationship between base metal properties and friction stir welding process parameters”, Materials Science and Engineering Journal A 480 (2008) pp 397–403.parameters”, Materials Science and Engineering Journal A 480 (2008) pp 397–403.

6.6. P. Cavalierea, A. Squillaceb, F. Panellaa, “Effect of welding parameters on mechanical and micro P. Cavalierea, A. Squillaceb, F. Panellaa, “Effect of welding parameters on mechanical and micro structural properties of AA6082 joints produced by friction stir welding”, Journal of Materials structural properties of AA6082 joints produced by friction stir welding”, Journal of Materials processing technology 200 (2008) pp 364–372.processing technology 200 (2008) pp 364–372.

7.7. K Kumar K., Satish V, Kailas., “On the role of axial load and the effect of interface position on the K Kumar K., Satish V, Kailas., “On the role of axial load and the effect of interface position on the tensile strength of a friction stir welded aluminum alloy”, Materials and Design Journal 29 (2008) pp tensile strength of a friction stir welded aluminum alloy”, Materials and Design Journal 29 (2008) pp 791-797.791-797.

8.8. M. Cabibbo, H.J. McQueenbM. Cabibbo, H.J. McQueenb,, E. Evangelista , S. Spigarelli ,M. Di Paola , A. Falchero, “ E. Evangelista , S. Spigarelli ,M. Di Paola , A. Falchero, “ Microstructure and mechanical property studies of AA6056 friction stir welded plate”, Materials Microstructure and mechanical property studies of AA6056 friction stir welded plate”, Materials Science and Engineering Journal A 460-461 (2007) pp 86–94.Science and Engineering Journal A 460-461 (2007) pp 86–94.

9.9. Hidetoshi Fujii , Ling Cui, Masakatsu Maeda, Kiyoshi Nogi, “ Effect of tool shape on mechanical Hidetoshi Fujii , Ling Cui, Masakatsu Maeda, Kiyoshi Nogi, “ Effect of tool shape on mechanical properties and microstructure of friction stir welded aluminum alloys”, Materials Science and properties and microstructure of friction stir welded aluminum alloys”, Materials Science and Engineering Journal A 419 (2006) pp 25–31.Engineering Journal A 419 (2006) pp 25–31.

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References Contd…References Contd…10.10. P. Cavaliere, G. Campanile, F. Panella, A. Squillace, “Effect of welding parameters on mechanical and P. Cavaliere, G. Campanile, F. Panella, A. Squillace, “Effect of welding parameters on mechanical and

micro structural properties of AA6056 joints produced by Friction Stir Welding”, Journal of Materials micro structural properties of AA6056 joints produced by Friction Stir Welding”, Journal of Materials Processing Technology 180 (2006) pp 263–270.Processing Technology 180 (2006) pp 263–270.

11.11. K. Surekha, B.S. Murty, K. Prasad Rao, “Micro structural characterization and corrosion behavior of K. Surekha, B.S. Murty, K. Prasad Rao, “Micro structural characterization and corrosion behavior of multipass friction stir processed AA2219 aluminium alloy”, Journal of Surface & Coatings Technology multipass friction stir processed AA2219 aluminium alloy”, Journal of Surface & Coatings Technology 202 (2008) pp 4057–4068.202 (2008) pp 4057–4068.

12.12. K. Nakata aK. Nakata a,, Y.G. Kima, H. Fujii , T. Tsumura , T. Komazaki, “Improvement of mechanical properties Y.G. Kima, H. Fujii , T. Tsumura , T. Komazaki, “Improvement of mechanical properties of aluminum die casting alloy by multi-pass friction stir processing”, Materials Science and of aluminum die casting alloy by multi-pass friction stir processing”, Materials Science and Engineering Journal A 437 (2006) pp 274–280.Engineering Journal A 437 (2006) pp 274–280.

13.13. S.J. Barnes, A. Steuwerb, S. Mahawisha, R. Johnsond, P.J. Withersa, “Residual strains and S.J. Barnes, A. Steuwerb, S. Mahawisha, R. Johnsond, P.J. Withersa, “Residual strains and microstructure development in single and sequential double sided friction stir welds in RQT-701 steel”, microstructure development in single and sequential double sided friction stir welds in RQT-701 steel”, Materials Science and Engineering Journal A 492 (2008) pp 35–44.Materials Science and Engineering Journal A 492 (2008) pp 35–44.

14.14. K.Kumar, SatishV.Kailas & T.S.Srivatsan, “Influence of Tool Geometry in Friction Stir Welding”, K.Kumar, SatishV.Kailas & T.S.Srivatsan, “Influence of Tool Geometry in Friction Stir Welding”, Journal of Materials and Manufacturing Proceesses, 23 (2008) pp 188-194.Journal of Materials and Manufacturing Proceesses, 23 (2008) pp 188-194.

15.15. Ling Cui, Hidetoshi Fujii, Nobuhiro Tsujib and Kiyoshi Nogi, “Friction stir welding of a high carbon Ling Cui, Hidetoshi Fujii, Nobuhiro Tsujib and Kiyoshi Nogi, “Friction stir welding of a high carbon steel”, Scripta Materialia 56 (2007) pp 637–640.steel”, Scripta Materialia 56 (2007) pp 637–640.

16.16. A.P. Gerlicha, and T. Shibayanagi, “Grain boundary sliding during friction stir spot welding of an A.P. Gerlicha, and T. Shibayanagi, “Grain boundary sliding during friction stir spot welding of an aluminum alloy”, Scripta Materialia 60 (2009) pp 236–239.aluminum alloy”, Scripta Materialia 60 (2009) pp 236–239.

17.17. S.R. Sharma and R.S. Mishra, “Fatigue crack growth behavior of friction stir processed aluminum S.R. Sharma and R.S. Mishra, “Fatigue crack growth behavior of friction stir processed aluminum alloy”, Scripta Materialia 59 (2008) pp 395–398.alloy”, Scripta Materialia 59 (2008) pp 395–398.

18.18. M.J. Starink, A. Deschampsb and S.C. Wanga, “The strength of friction stir welded and friction stir M.J. Starink, A. Deschampsb and S.C. Wanga, “The strength of friction stir welded and friction stir processed aluminium alloys”, Scripta Materialia 58 (2008) pp 377–382.processed aluminium alloys”, Scripta Materialia 58 (2008) pp 377–382.

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References Contd…References Contd…19.19. Stefano Maggiolino, Chaired Schmid, “Corrosion resistance in FSW and in MIG welding techniques of Stefano Maggiolino, Chaired Schmid, “Corrosion resistance in FSW and in MIG welding techniques of

AA6XXX”, Journal of Materials processing technology 197 (2008) pp 237–240.AA6XXX”, Journal of Materials processing technology 197 (2008) pp 237–240.

20.20. Wanchuck Woo, Hahn ChooaWanchuck Woo, Hahn Chooa,, Donald W. Brownc, Zhili Feng, Peter K. Liawa, “Angular distortion and Donald W. Brownc, Zhili Feng, Peter K. Liawa, “Angular distortion and through-thickness residual stress distribution in the Friction-stir processed 6061-T6 aluminum alloy”, through-thickness residual stress distribution in the Friction-stir processed 6061-T6 aluminum alloy”, Materials Science and Engineering Journal A 437 (2006) pp 64–69.Materials Science and Engineering Journal A 437 (2006) pp 64–69.

21.21. Hidetoshi Fujii Hidetoshi Fujii ,, Ling Cui, Nobuhiro Tsuji ,Masakatsu Maedac, Kazuhiro Nakata , Kiyoshi Nogi ,“Friction Ling Cui, Nobuhiro Tsuji ,Masakatsu Maedac, Kazuhiro Nakata , Kiyoshi Nogi ,“Friction stir welding of carbon steels”, Materials Science and Engineering Journal A 429 (2006) pp 50–57.stir welding of carbon steels”, Materials Science and Engineering Journal A 429 (2006) pp 50–57.

22.22. Scialpi A., De Filppis LAC., Cavaliere P., “Influence of shoulder geometry on micro-structure and Scialpi A., De Filppis LAC., Cavaliere P., “Influence of shoulder geometry on micro-structure and mechanical properties of friction stir welded 6082 aluminum alloy”, Materials and Design Journal 28 (2007) mechanical properties of friction stir welded 6082 aluminum alloy”, Materials and Design Journal 28 (2007) pp 1124-1129.pp 1124-1129.

23.23. Barcellona A, Buffa G, Fratini L, Palmeri D, “Microstructural phenomena occurring in friction stir welding Barcellona A, Buffa G, Fratini L, Palmeri D, “Microstructural phenomena occurring in friction stir welding of aluminum alloys”, Journal of Materials Processing Technology 177 (2006) pp 340-343.of aluminum alloys”, Journal of Materials Processing Technology 177 (2006) pp 340-343.

24.24. Minton T., Mynors D.J., “Utilization of engineering workshop equipment for friction stir welding”, Journal Minton T., Mynors D.J., “Utilization of engineering workshop equipment for friction stir welding”, Journal of Materials Processing Technology 177 (2006) pp 336-339.of Materials Processing Technology 177 (2006) pp 336-339.

25.25. Fratini L., Buffa G., Shivpuri R., “Improving friction stir welding of blanks of different thicknesses”, Fratini L., Buffa G., Shivpuri R., “Improving friction stir welding of blanks of different thicknesses”, Materials Science and Engineering Journal A 459 (2007) pp 211-219. Materials Science and Engineering Journal A 459 (2007) pp 211-219.

26.26. Ren S.R., Ma Z.Y., Chen L.Q., “Effect of welding parameters on tensile properties and fracture behavior of Ren S.R., Ma Z.Y., Chen L.Q., “Effect of welding parameters on tensile properties and fracture behavior of friction stir welded Al-Mg-Si alloy”, Scripta Matererialia 56 (2007) pp 69-72.friction stir welded Al-Mg-Si alloy”, Scripta Matererialia 56 (2007) pp 69-72.

27.27. Sato Y.S., Kokawa H., Enomoto M., Jogan S., “ Microstructural evolution of 6083 aluminum during friction Sato Y.S., Kokawa H., Enomoto M., Jogan S., “ Microstructural evolution of 6083 aluminum during friction stir welding”, Metallurgical and Materials Transactions A 30 (1999) pp 2429-2433.stir welding”, Metallurgical and Materials Transactions A 30 (1999) pp 2429-2433.

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Materials Research, vol 7, no. 4, (2004), pp 569-574.Materials Research, vol 7, no. 4, (2004), pp 569-574. Dequing W., Shuhua L., Zhaoxia C., “Study of friction stir welding of Dequing W., Shuhua L., Zhaoxia C., “Study of friction stir welding of

aluminum”, Material Science and Engineering Journal 39 (2004) pp 1689-1693.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., 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 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.friction stir welded AA2024-T351” Corrosion Science 49 (2007) pp 877-909.

Cabibbo M., McQueenb H.J., Evangelista E., Spigarelli S., Di Paola M., Cabibbo M., McQueenb H.J., Evangelista E., Spigarelli S., Di Paola M., Falchero A., “ Microstructure and mechanical property studies of AA6056 Falchero A., “ Microstructure and mechanical property studies of AA6056 friction stir welded plate”, and Journal of Materials Science and Engineering A friction stir welded plate”, and Journal of Materials Science and Engineering A 460 (2007) 86-94.460 (2007) 86-94.

Rao P.N., Manufacturing Technology, Second Edition, Tata McGraw Hill Rao P.N., Manufacturing Technology, Second Edition, Tata McGraw Hill Edition, 2006.Edition, 2006.

Kalpakjian S., Manufacturing Engineering and Technology, Pearson Education Kalpakjian S., Manufacturing Engineering and Technology, Pearson Education Edition, 2002.Edition, 2002.

Khanna O.P., “A Text Book on Welding Technology”, Revised Edition, Khanna O.P., “A Text Book on Welding Technology”, Revised Edition, Dhanpat Rai Publications, 1998.Dhanpat Rai Publications, 1998.

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