Relevant bibliographies by topics / High speed friction stir spot welding

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  1. Journal articles
  2. Dissertations / Theses
  3. Book chapters
  4. Conference papers

Academic literature on the topic 'High speed friction stir spot welding'

Author: Grafiati
Published: 4 June 2021
Last updated: 10 February 2022

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Journal articles on the topic "High speed friction stir spot welding"

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Ramesh Babu, S., M. Nithin, S. Pavithran, and B. Parameshwaran. "Friction Stir Spot Welding of AZ31B Magnesium Alloy." Applied Mechanics and Materials 867 (July 2017): 105–11. http://dx.doi.org/10.4028/www.scientific.net/amm.867.105.

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The Electrical Resistance Welding (ERW) of Magnesium and Aluminium is more difficult than steel because the welding machines must provide high currents and exact pressures in order to provide the heat necessary to melt the magnesium for proper fusion at the interface in order to produce a sound weld. Further, resistance welding of magnesium requires a backup plate made of steel to conduct the heat to the workpiece material. To overcome this problem, Friction Stir Spot Welding (FSSW) has been developed. In this study, the hardness distribution and the tensile shear strength of FSSW welds in the AZ31B Magnesium alloy has been investigated and it has been found that tool rotational speed and dwell time plays a major role in determining the weld strength. From the experimental study, a tool rotational speed of 1100 rpm and dwell time of 20 s produced good shear strength of 2824 N and the corresponding grain size was 4.54 μm. This result is very well supported by microstructural examinations and hardness distribution studies.
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Farmanbar, N., SM Mousavizade, M. Elsa, and HR Ezatpour. "AA5052 sheets welded by protrusion friction stir spot welding: High mechanical performance with considering sheets thickness at low dwelling time and tool rotation speed." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 16 (May 15, 2019): 5836–47. http://dx.doi.org/10.1177/0954406219850202.

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In the present work, AA5052 sheets with thickness of 1 mm were successfully welded by protrusion friction stir spot welding as a low cost single-step method with a simple design that produces the no-keyhole joints with special mechanical properties at short dwell time and low tool rotation speed. By using suitable process parameters, the process is able to produce welds with superior mechanical performance in items of peak load and energy absorption compared to other techniques. The plunging depth and dwell time in this method were set as 0.2 mm and 6 s, respectively. The tool rotation speed was changed as 500, 800, 1250, and 1600 r/min to determine the optimum condition based on the microstructural and mechanical properties. Welds strength produced by the protrusion friction stir spot welding was directly related to the joint thickness, and the effective thickness of the upper sheet was maximum at 500 r/min. Protrusion friction stir spot welding joints presented circumferential failure mode after tensile shear testing. Regarding the sheets thickness used in this study, the joints produced by the current work presented high load bearing ability at dwell time of 6 s and tool rotation speed of 500 r/min compared to other techniques.
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Statsenko, V., and A. Sukhorada. "Research of Heat Power in Friction Stir Spot Welding." Key Engineering Materials 806 (June 2019): 81–86. http://dx.doi.org/10.4028/www.scientific.net/kem.806.81.

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Nowadays the most perspective, high-tech and productive process is friction stir spot welding. The most important part of this technology is to determine the temperature of the material in the stir zone. This parameter is easily counted by the amount of the heat input, put in the welding zone. We made experimental researches about the relation of the heat power, therotation speed and the diameter of the working tool. For that purpose an experimental scheme was chosen, which models a welding material (aluminum alloy AMg5) as an experimental tube 20 mm in diameter. The tool (shear steel P6M5) is modeled as a working plate. Measurements of the frictional moments depending on the rotation speed of the experimental working tube during the constant temperature are made on the prepared stand. By the experimental data the specific heat input and the heat power were counted on every concentric ring, 2 mm in width, in the end of the working tool, 20 mm in diameter. Also, the sum of the heat power for the whole tool during various rotation speed terms was counted too. On the stand throughout the experiment were determined all the thermal conductivity heat losses along the rod, which the experimental tube was pinned on, all the working plate heat losses through the gasket towards the working desk and the convection from the surface of the rotating experimental tube to the environment. According the data, any of these losses is from 3 to 10 percent. This is shown in the heat input counting.
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Campanelli, L. C., U. F. H. Suhuddin, Jorge Fernandez Dos Santos, and N. G. Alcantara. "Preliminary Investigation on Friction Spot Welding of AZ31 Magnesium Alloy." Materials Science Forum 706-709 (January 2012): 3016–21. http://dx.doi.org/10.4028/www.scientific.net/msf.706-709.3016.

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Friction spot welding (FSpW) is a recent solid state welding process developed and patented by GKSS Forschungszentrum (now Helmholtz-Zentrum Geesthacht), Germany. A spot-like connection is produced by means of an especially designed non-consumable tool consisting of pin, sleeve and clamping ring that creates a joint between sheets in overlap configuration through frictional heat and plastic deformation. FSpW offers many advantages over conventional spot joining techniques including high energy efficiency, surface quality and environmental compatibility. Comparing with friction stir spot welding, FSpW produces a weld without keyhole on the surface at the end of the joining process. In the present study, the possibility of joining AZ31 magnesium alloy by FSpW technique was evaluated by using different welding parameters (rotational speed, plunge depth and dwell time), aiming to produce high quality connections. Microstructural features were analyzed by light optical microscope and mechanical performance was investigated by microhardness test and lap shear test. Microstructure analysis revealed that defects free welds could be produced. A slight decrease in grain size of the stir zone was observed causing a slight increase in the microhardness of this region. The preliminary lap shear data demonstrated that the weld strength is comparable to other welding process.
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Venukumar, S., S. Muthukumaran, and Y. Swaroop. "Microstructure and Mechanical Properties of Refilled Friction Stir Spot Welding of Commercial Pure Aluminium." Materials Science Forum 765 (July 2013): 776–80. http://dx.doi.org/10.4028/www.scientific.net/msf.765.776.

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Aluminium and magnesium alloys are expected to make considerable contributions in reducing the weight of automobiles as they are increasingly used as an alternative to steel; improving fuel economy and vehicle performance while simultaneously reducing emissions. Higher electrical and thermal conductivities of these materials make them difficult to weld using existing resistance spot welding leading to high energy consumption. Friction stir spot welding has proven to be a better alternative to weld these materials. But a probe hole left behind is the main problem in conventional Friction Stir Spot welding (FSSW). In the present work a new method has been developed to refill the probe hole using an additional filler plate known as Refill Friction Stir Spot welding (RFSSW). This new refilling technique and the conventional FSSW process were both used to weld commercially pure aluminium lap shear specimens and the results were compared. The effect of tool rotational speed on mechanical and metallurgical properties were studied in both cases. Static shear strength of RFSSW weld samples was found to be better than conventional FSSW process at higher tool rotational speed. This is explained in terms of effective increase in cross sectional area of weld nugget due addition of more material from the filler plate thereby eliminating the probe hole.
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Baskoro, Ario Sunar, Suwarsono, Gandjar Kiswanto, and Winarto. "Effects of High Speed Tool Rotation in Micro Friction Stir Spot Welding of Aluminum A1100." Applied Mechanics and Materials 493 (January 2014): 739–42. http://dx.doi.org/10.4028/www.scientific.net/amm.493.739.

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Technology of Friction Stir Welding (FSW) is a relatively new technique for joining metal. In some cases on Aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and less distortion. The purpose of this study is to analyze the parameters effect of high speed tool rotation onmicro Friction Stir Spot Welding(μFSSW) to theshear strengthof welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. The spindle speed was fixed at 30000 rpm. Tool shoulder diameter was 3 mm, and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of pin diameter (1.5 mm, 2.0 mm, and 2.5 mm), a variable ofplunge speed(2 mm/min, 4 mm/min, 6 mm/min), and the variable ofdwell time(2 seconds, 4 seconds, 6 seconds). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was theshear strength.Response Surface Methods(RSM) was used to analyze μFSSW parameters with theshear strengthof welds. From the result of experiment and analysis, it is shown that the important welding parameters in high speed μFSSW process are pin diameter and plunge speed.
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Gao, Jicheng, Jiachen Dong, Sunyi Zhang, Liang Yu, Huiming Jin, Jianfeng Zhang, and Yifu Shen. "Study of friction stir spot welding for thermotolerant engineering thermoplastic polyimide joints." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 235, no. 11 (February 21, 2021): 1810–17. http://dx.doi.org/10.1177/0954405421995619.

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In this research, thermoplastic polyimide (TPI) were welding via friction stir spot welding (FSSW) in order to evaluate the feasibility of the technology. The welding tool with a tri-flute pin was used for keeping the welding effectiveness. The effect of the rotation speed and dwell time on the microstructure and shear strength was studied. The results shows that the number of gap defects between the shoulder affect zone and the pin affect zone decreased with the increase of the rotation speed. The boundary of the shoulder affect zone and the pin affect zone was no clear when increasing the dwell time from 10 s to 20 s. Long dwell time could increase the mixing time and reduce the materials viscosity, which made the structure was denser. The maximal shear strength was obtained 85.5% of the base materials. The differential scanning calorimetry (DSC) results indicated that the melting behaviour of different regions was no obvious difference. It indicated that FSSW had a feasible and potential technology to join the high temperature resistant engineering plastics.
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Vercauteren, Jeroen, Koen Faes, and Wim De Waele. "Metallographic evaluation of the weldability of high strength aluminium alloys using friction spot welding." International Journal Sustainable Construction & Design 8, no. 1 (October 30, 2017): 8. http://dx.doi.org/10.21825/scad.v8i1.6815.

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Friction spot welding is a recent solid-state welding technique well suited for spot-joining lightweight materials in overlap condition. Aerospace and transport industries show great interest in this technique to join high-strength aluminium alloys, but published research is still limited. In this project, the link between process parameters and weld quality is investigated for EN AW-7075-T6 material. Techniques used are metallographic qualification, measurement of hardness reduction and lap shear strength. This paper focusses on the metallographic investigation of the weld region and its imperfections. Increasing joining time and heat input creates an easier material flow resulting in fewer imperfections. Limited plunge depths lead to typical interface imperfections. Variation in the rotational speed shows distinctive stir zone shapes as a consequence of severe stirring and frictional heat.
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Tasdemir, Munir, Mustafa Kemal Bilici, and Mehmet Kurt. "Relation between Friction Stir Spot Welding Parameters and Mechanical Properties of High Density Polyethylene/Glass Spheres Polymer Composites." Materials Science Forum 860 (July 2016): 49–52. http://dx.doi.org/10.4028/www.scientific.net/msf.860.49.

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In the present study, we attempt to use powder of glass spheres filler and reinforce material in HDPE to produce composite structure and then evaluate its mechanical properties to study the effect of welding parameters and filler content on mechanical properties of HDPE. The effect of welding parameters (tool rotational speed, the plunge depth and the dwell time) on friction stir spot welding properties of high density polyethylene/glass spheres (hollow) polymer composites sheets was studied.
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Baskoro, Ario Sunar, Suwarsono, M. Dz Habibullah, Z. Arvay, G. Kiswanto, Winarto, and Z. W. Chen. "Effects of Dwell-Time and Plunge Speed during Micro Friction Stir Spot Welding on Mechanical Properties of Thin Aluminum A1100 Welds." Applied Mechanics and Materials 758 (April 2015): 29–34. http://dx.doi.org/10.4028/www.scientific.net/amm.758.29.

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Friction Stir Welding is a relatively new technique for joining metal. In some cases on aluminum joining, FSW gives better results compared with the arc welding processes, including the quality of welds and produces less distortion. The purpose of this study is to analyze the effect of high speed tool rotation on micro Friction Stir Spot Welding (μFSSW) to the shear fracture load of the welds. Response Surface Methods was used to analyze μFSSW parameters with the response. The welding material was Aluminum A1100, with thickness of 0.4 mm. The tool was made of HSS material which was shaped by micro grinding process. Tool shoulder diameter is 4 mm, and the pin diameter 1.5 mm with length of pin is 0.6 mm. The spindle speed is fixed at 33,000 rpm. The parameters that varied were the plunge speed (2 mm/min, 3 mm/min, 4 mm/min), and dwell time-1 (0 s, 2 s, 4 s) and variable of dwell time-2 (0 s, 2 s, 4 s). From the results of experiment and analysis, it is shown that the important welding parameter in high speed μFSSW process is dwell time-2.
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Dissertations / Theses on the topic "High speed friction stir spot welding"

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Saunders, Nathan David. "High Speed Friction Stir Spot Welding on DP 980 Steel:Joint Properties and Tool Wear." BYU ScholarsArchive, 2012. https://scholarsarchive.byu.edu/etd/3003.

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With the desire to improve passenger safety and fuel efficiency, Ultra High Strength Steels (UHSS) have been developed for use in the automotive industry. UHSS are high strength steels with high ductility and strength. DP 980 is one of these UHSS being applied in automobile manufacturing. DP 980 is difficult to join with Resistance Spot Welding (RSW) because of the high carbon content and alloying in this material. The weld becomes brittle when it solidifies during the welding process. With the desire and motivation of widely using UHSS, new welding processes are needed to be developed in order to effectively join DP 980. Friction Stir Spot Welding (FSSW) is a developing welding process aimed to replace RSW in the automotive industry because of its ability to join materials at a lower temperature. Currently the welding loads of the tools are higher than 2000 pounds, ranging from 3,000 to 5,000 pounds, which exceeds the limit of the welding robots in the automotive factories. It is proposed that the welding loads can be reduced by increasing the spindle speed of the FSSW tool. Other focuses in the research include increasing the life of the tool and developing acceptable welding parameters for High Speed FSSW. The experimental work done for this thesis provided support that weld strength can be obtained at levels above the acceptable standard for DP 980 material (greater than 2400 pound lap shear fracture load for 1.2 mm material) while keeping the vertical load on the welding machine spindle below 2000 lbs.
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Karki, Utsab. "Experimental and Numerical Study of High-Speed Friction Stir Spot Welding of Advanced High-Strength Steel." BYU ScholarsArchive, 2015. https://scholarsarchive.byu.edu/etd/5521.

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With the desire to lighten the frame while keeping or increasing the strength, Advanced High-Strength Steels (AHSS) have been developed for use in the automotive industry. AHSS meet many vehicle functional requirements because of their excellent strength and acceptable ductility. But joining AHSS is a challenge, because weldability is lower than that of mild steels. Friction stir spot welding (FSSW) is a solid state joining process that can provide a solution to the weldability issues in AHSS, but FSSW has not been studied in great detail for this application. In this work, Si3N4 tools were used for FSSW experiments on DP 980 steel with 1.2mm thickness. Joint strength was measured by lap shear tension testing, while thermocouples were used for the temperature measurements. A finite element model was developed in order to predict material flow and temperatures associated with FSSW. Since a 3D model of the process is very time consuming, a novel 2D model was developed for this study. An updated Lagrangian scheme was employed to predict the flow of sheet material, subjected to the boundary conditions of the fixed backing plate and descending rotating tool. Heat generation by friction was computed by including the rotational velocity component from the tool in the thermal boundary conditions. Material flow was calculated from a velocity field while an isotropic, viscoplastic Norton-Hoff law was used to compute the material flow stress as a function of temperature, strain and strain rate. Shear stress at the tool/sheet interface was computed using the viscoplastic friction law. The model predicted welding temperatures to within 4% of the experiments. The welding loads were significantly over predicted. Comparison with a 3D model of FSSW showed that frictional heating and the proportion of total heat generated by friction were similar. The position of the joint interface was reasonably well predicted compared to experiment.
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Hartman, Trent J. "Friction Stir Spot Welding of Ultra-High Strength Steel." BYU ScholarsArchive, 2012. https://scholarsarchive.byu.edu/etd/3302.

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Friction stir spot welding (FSSW) is quickly becoming a method of interest for welding of high strength steel (HSS) and ultra high strength steel (UHSS). FSSW has been shown to produce high quality welds in these materials, without the drawbacks associated with fusion welding. Tool grade for polycrystalline cubic boron nitride (PCBN) tools has a significant impact on wear resistance, weld quality, and tool failure in FSSW of DP 980 steel sheet. More specifically, for a nominal composition of 90% CBN, the grain size has a significant impact on the wear resistance of the tool. A-type tools performed the best, of the three grades that were tested in this work, because the grain size of this grade was the finest, measuring from 3-6 microns. The effect of fine grain size was less adhesion of DP 980 on the tool surface over time, less abrasive wear, and better lap shear fracture loads of the welds that were produced, compared to the other grades. This is explained by less exposure of the binder phase to wear by both adhesion and abrasion during welding of DP 980. A-type tools were the most consistent in both the number of welds per tool, and the number of welds that reached acceptable lap shear fracture loads. B-type tools, with a bimodal grain size distribution (grain size of 4 – 40 microns) did a little bit better than C-type tools (grain size of 12-15 microns) in terms of wear, but neither of them were able to achieve consistent acceptable lap shear fracture load values after the first 200 welds. In fact only one out of five C-type tools was able to produce acceptable lap shear fracture loads after the first 100 welds.
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Thurlby, Nickolas. "Advances in high rotational speed – friction stir welding for naval applications." Thesis, Wichita State University, 2009. http://hdl.handle.net/10057/2414.

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Changing operational requirements within the Navy defines the need for lighter, faster ships with increased range and payload. To achieve these requirements the Navy is investing in new hull forms and aluminum alloys for the Littoral Combat Ship (LCS), the Landing Helicopter Assault (Replacement) Ship, and the Joint High Speed Vessel. Friction stir welding (FSW) has proven to be a viable means for joining aluminum during the vessel manufacturing process for LCS, and is a likely joining process for other high speed aluminum vessels. While producing welds of high quality, FSW is characterized by high equipment costs and lack of field repair methods. This report outlines a U.S. Navy-Wichita State University research effort to develop high rotational speed – friction stir welding (HRS-FSW), a process that offers the potential for significant reductions in the size, mass, and cost of FSW systems for both assembly and repair (conventional and/or ―in-situ‖) welding.
Thesis (M.S.)--Wichita State University, College of Engineering, Dept. of Mechanical Engineering
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McBride, Stanford Wayne. "A Numerical Model of the Friction Stir Plunge." BYU ScholarsArchive, 2009. https://scholarsarchive.byu.edu/etd/1772.

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A Lagrangian finite-element model of the plunge phase of the friction stir welding process was developed to better understand the plunge. The effects of both modeling and experimental parameters were explored. Experimental friction stir plunges were made in AA 7075-T6 at a plunge rate of 0.724 mm/s with spindle speeds ranging from 400 to 800 rpm. Comparable plunges were modeled in Forge2005. Various simulation parameters were explored to assess the effect on temperature prediction. These included the heat transfer coefficient between the tool and workpiece (from 0 to 2000 W/m-K), mesh size (node counts from 1,200 to 8,000), and material model (five different constitutive relationships). Simulated and measured workpiece temperatures were compared to evaluate model quality. As spindle speed increases, there is a statistically significant increase in measured temperature. However, over the range of spindle speeds studied, this difference is only about 10% of the measured temperature increase. Both the model and the simulation show a similar influence of spindle speed on temperature. The tool-workpiece heat transfer coefficient has a minor influence (<25% temperature change) on simulated peak temperature. Mesh size has a moderate influence (<40% temperature change) on simulated peak temperature, but a mesh size of 3000 nodes is sufficient. The material model has a high influence (>60% temperature change) on simulated peak temperature. Overall, the simulated temperature rise error was reduced from 300% to 50%. It is believed that this can be best improved in the future by developing improved material models.
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Scupin, Peer-Jorge [Verfasser], and Norbert [Akademischer Betreuer] Huber. "Semi-stationary shoulder bobbin tool (S3BT): a new approach in high speed friction stir welding / Peer-Jorge Scupin ; Betreuer: Norbert Huber." Hamburg : Universitätsbibliothek der Technischen Universität Hamburg-Harburg, 2016. http://d-nb.info/1117086445/34.

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Scupin, Peer-Jorge Verfasser], and Norbert [Akademischer Betreuer] [Huber. "Semi-stationary shoulder bobbin tool (S3BT): a new approach in high speed friction stir welding / Peer-Jorge Scupin ; Betreuer: Norbert Huber." Hamburg : Universitätsbibliothek der Technischen Universität Hamburg-Harburg, 2016. http://nbn-resolving.de/urn:nbn:de:gbv:830-88214957.

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Lin, Chien-Hung, and 林建宏. "Study of Friction Stir Spot Welding of High Strength Automotive AZ80-F Magnesium alloy." Thesis, 2010. http://ndltd.ncl.edu.tw/handle/58296672896324093357.

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碩士
國立屏東科技大學
車輛工程系所
98
Lightweighting has become a key issue in automotive industries recently. Magnesium alloy, consequently, has become one of the major materials for structures. In addition, the solid-state bonding and other excellent features of the friction stir spot welding (FSSW) makes it inherently attractive for body assembly and other similar applications. This study aims to investigate the welding characteristics of the AZ80-F magnesium alloy of FSSW. A 3D finite element coupling model is employed to investigate the effects of welding parameters on the thermal-mechanical behavior of the welds. Then, the experimental samples are made by using FSSW process and, the tensile-shear test, direct tensile test, nano-indentation test and metallographic test are performed to understand the corresponding characteristics of the spot welds. The results show that the welding parameters of tool rotation speed and pressure are more sensitive to the temperature distribution of the welds. In addition, the temperature distribution curve can be used to evaluate the properties of the welds. The results obtained from microstructure observation reveal that the geometry of the tool has a strong effect on the plastic flow and grain size in the welds during the welding process. The welds with the dual-conical tool have the best microstructure distribution and welding strength. Its welding strength increases with the increase of tool rotation speed and pressure to a critical value.
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Khan, Mohammad Ibraheem. "Spot Welding of Advanced High Strength Steels (AHSS)." Thesis, 2007. http://hdl.handle.net/10012/2777.

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Efforts to reduce vehicle weight and improve crash performance have resulted in increased application of advanced high strength steels (AHSS) and a recent focus on the weldability of these alloys. Resistance spot welding (RSW) is the primary sheet metal welding process in the manufacture of automotive assemblies. Integration of AHSS into the automotive architecture has brought renewed challenges for achieving acceptable welds. The varying alloying content and processing techniques has further complicated this initiative. The current study examines resistance spot welding of high strength and advance high strength steels including high strength low alloy (HSLA), dual phase (DP) and a ferritic-bainitic steel (590R). The mechanical properties and microstructure of these RSW welded steel alloys are detailed. Furthermore a relationship between chemistries and hardness is produced. The effect of strain rate on the joint strength and failure mode is also an important consideration in the design of welded structures. Current literature, however, does not explain the effects of weld microstructure and there are no comprehensive comparisons of steels. This work details the relationship between the joint microstructure and impact performance of spot welded AHSS. Quasi-static and impact tests were conducted using a universal tensile tester and an instrumented drop tower, respectively. Results for elongation, failure load and energy absorption for each material are presented. Failure modes are detailed by observing weld fracture surfaces. In addition, cross-sections of partially fractured weldments were examined to detail fracture paths during static loading. Correlations between the fracture path and mechanical properties are developed using observed microstructures in the fusion zone and heat-affected-zone. Friction stir spot welding (FSSW) has proven to be a potential candidate for spot welding AHSS. A comparative study of RSW and FSSW on spot welding AHSS has also been completed. The objective of this work is to compare the microstructure and mechanical properties of Zn-coated DP600 AHSS (1.2mm thick) spot welds conducted using both processes. This was accomplished by examining the metallurgical cross-sections and local hardnesses of various spot weld regions. High speed data acquisition was also used to monitor process parameters and attain energy outputs for each process.
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Su, Fang-Hua, and 蘇芳嬅. "Studies on the Friction Stir Welding of Aluminum Alloy Sheetsby Using High Speed Steel Tool Inserted Aluminum Alloy." Thesis, 2011. http://ndltd.ncl.edu.tw/handle/50225063693950572725.

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碩士
國立中山大學
機械與機電工程學系研究所
99
In this study, a novel inserted type of friction welding tool was proposed, where the circular rod was embedded in its central axis using the material same as the workpiece, so that it could effectively promote the friction heat quickly and enhance the welding quality. The welding tool was made of the high-speed steel, the workpiece with its embedded material 6061-T6 aluminum alloy. A vertical milling machine equipped with dynamometer, which could measure the power during the friction stir welding, was employed as the experimental apparatus. During the welding process, the K-type thermocouple was used simultaneously in measuring the welding temperature at the interface of joint. The operating conditions of welding were as followings: the welding speed of 800 rpm, the tool inclination of 1° and the clamping force 2kN, the tool with 12mm in diameter and 0.21mm in depth under the downward force about 2 kN. The experiment was conducted into two stages. The first stage was a spot welding to investigate the effect of the ratio of the diameter of embedded material (d) to the diameter of welding tool (D) on the temperature of the interface of joint, the thickness of plastic flow, and the failure load of weld. Experimental results revealed that the interface temperature, the plastic flow thickness, and the failure load of weld are directly proportional to d/D. In comparison with the welding tool without insert (d/D = 0), the maximum interface temperature increased about 1.12 times at d/D = 0.83, the plastic flow thickness increased about 1.52 times, and the failure load of weld increased about 1.45 times. In the second stage, the feeding process was included to investigate the influence of the diameter and the thickness of embedded material on the interface temperature, the plastic flow thickness, and the failure load of weld. Experimental results revealed that the plastic flow thickness was less than 2 mm when the thickness of embedded material was less than 3 mm. However, when the thickness of embedded material was larger than 5 mm, the plastic flow thickness could achieve to 3 mm. Hence, the thickness of embedded material should be larger than 5mm. Moreover, the effect of the diameter of embedded material on the interface temperature and the plastic flow thickness using the feeding process was almost the same as the spot welding. However, in comparison with the welding tool without insert, the failure load of weld increased about two times.
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Book chapters on the topic "High speed friction stir spot welding"

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Upadhyay, Piyush, Xiao Li, and Tim Roosendaal. "High-Speed Friction Stir Lap Welding of Al Alloys." In Friction Stir Welding and Processing X, 67–75. Cham: Springer International Publishing, 2019. http://dx.doi.org/10.1007/978-3-030-05752-7_7.

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Liu, F. C., and P. Dong. "Promising High-Speed Welding Techniques for Joining Polymers to Metals and Underlying Joining Mechanisms." In Friction Stir Welding and Processing X, 13–22. Cham: Springer International Publishing, 2019. http://dx.doi.org/10.1007/978-3-030-05752-7_2.

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Tanaka, Kunihiro, Tatsuya Nakazawa, Koichi Sakairi, Yutaka Sato, Hiroyuki Kokawa, Toshihiro Omori, and Kiyohito Ishida. "Feasibility of Iridium Containing Nickel Based Superalloy Tool to Friction Stir Spot Welding of High Strength Steel." In The Minerals, Metals & Materials Series, 29–35. Cham: Springer International Publishing, 2017. http://dx.doi.org/10.1007/978-3-319-52383-5_4.

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Shome, M. "Metal inert gas (MIG) brazing and friction stir spot welding of advanced high-strength steels (AHSS)." In Welding and Joining of Advanced High Strength Steels (AHSS), 137–65. Elsevier, 2015. http://dx.doi.org/10.1016/b978-0-85709-436-0.00008-4.

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Huetsch, L. L., J. F. dos Santos, and N. Huber. "Investigations of microstructural, thermal and local strain phenomena of high speed friction stir processed Mg AZ31." In Proceedings of the 1st International Joint Symposium on Joining and Welding, 59–65. Elsevier, 2013. http://dx.doi.org/10.1533/978-1-78242-164-1.59.

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Gupta, Rajat, Kamal Kumar, and Neeraj Sharma. "Multi-Performance Optimization in Friction Stir Welding of Aluminum Alloy Using Response Surface Methodology." In Advances in Computational Intelligence and Robotics, 240–63. IGI Global, 2018. http://dx.doi.org/10.4018/978-1-5225-4766-2.ch011.

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This chapter presents the friction stir welding (FSW) of aluminum alloy AA-5083-O using vertical milling machine. In present FSW experimentation, effects of different process parameter namely tool rotation speed, welding speed, tool geometry, and tool shoulder diameter have been determined on welding quality of two pieces of AA-5083-O using response surface methodology (RSM). The optimal sets of process parameters have been determined for weld quality characteristics namely tensile strength (UTS) and percentage elongation (%EL). In present experimentations, a specially designed tool made of high carbon steel with different shoulder diameters (15mm, 17.5mm, and 20 mm) having constant pin length (6 mm) were used for FSW of two pieces of aluminum alloy. The ANOVA and pooled ANOVA were used to study the effect of FSW parameters on UTS and %EL. Multi response optimization has been carried out using desirability function in conjunction with RSM to obtain the optimal setting of process parameters for higher UTS and lower %EL.
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Conference papers on the topic "High speed friction stir spot welding"

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Mahgoub, Ahmed, Neçar Merah, and Abdelaziz Bazoune. "Effect of Welding Conditions on Sheets’ Interface Properties in Friction Stir Spot Welding of Copper." In ASME 2019 Pressure Vessels & Piping Conference. American Society of Mechanical Engineers, 2019. http://dx.doi.org/10.1115/pvp2019-93635.

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Abstract Friction Stir Spot Welding (FSSW) is a solid-state joining technique widely applied to high conductive metals. In this paper, the effects of FSSW parameters, namely, rotational speed (N), plunging rate (V) and dwell time (DT) on the joint fracture mode and fractured surface morphology were investigated using scanning electron microscopy (SEM). The effect of the abovementioned welding parameters on the microhardness profile along the sheets’ interface was also investigated to gain insight into the strength of the joint and the width of the bonding ligament. Two conditions were considered for each parameter 1200 rpm and 900 rpm for N, 60 mm/min and 20 mm/min for V, 4 and 2 seconds for DT. The welding condition 1200 rpm rotational speed, 20 mm/min plunging rate and 2 seconds dwell time showed a wider bonding ligament, relatively higher elongation, higher tensile failure load, and greater microhardness on the sheets’ interface. Dimple surface morphology (DSM) with regular dimples along the stir zone was also observed at the abovementioned set of process parameters.
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Stan, Felicia, Nicoleta V. Stanciu, Catalin Fetecau, and Laurentiu I. Sandu. "Characterization of Welding Attributes in Friction Spot Stir Welding of High-Density Polyethylene/Multi-Walled Carbon Nanotube Composites." In ASME 2018 13th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2018. http://dx.doi.org/10.1115/msec2018-6317.

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In this work, friction spot stir welding (FSSW) is applied to join high-density polyethylene/multi-walled carbon nanotube (HDPE/MWCNTs) composites. Injection-molded coupons were welded with a single lap-shear configuration under different welding conditions (tool rotational speed, plunge depth, and dwell time). By analyzing the lap-shear tensile load and the fracture surface of the welded joints, it is found that the weld attributes (e.g. weld area and maximum lap-shear tensile load) increase with increasing dwell time, tool rotational speed, and plunging depth. The maximum lap-shear tensile load increases with nanotube loading up to a threshold, followed by a decreasing trend at nanotube loading higher than 1.0 wt.%. It is hypothesized that the bonding mechanism for FSSW of HDPE/MWCNT composites is mainly through the co-crystallization across the interface. When more nanotubes are involved in the welding zone (>1.0 wt.%), saturation of nucleation is reached, the positive effect on the crystallization is vanished, and consequently the overall mechanical properties decrease. Interface failure of the welded joints and bulk fracture originated from the upper coupon within the weld nugget perimeter were identified as the two main failure mechanisms.
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Chen, Kai, Xun Liu, and Jun Ni. "Effects of Process Parameters on Friction Stir Spot Welding of Aluminum Alloy to Advanced High-Strength Steel." In ASME 2016 11th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/msec2016-8589.

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Friction stir spot welding (FSSW) process has been successfully applied for joining aluminum alloy 6061 to TRIP 780/800 steel. Effects of tool plunge speed and dwell time on the weld strength were studied through design of experiments and analysis of variance. It is shown that dwell time is a more dominant parameter in affecting the weld strength than plunge speed. Cross sections of weld specimens show the formation of hook with a swirling structure. Higher magnified SEM view with EDS analysis reveals the swirling structure to be composed of alternating thin layers of steel and Al-Fe intermetallic compounds (IMCs). During tensile shear test, cross nugget failure is the only failure mode. Cracks are initiated in the swirling structure at the tensile side of the weld nugget and cleavage feature can be observed on the fractured surface.
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Li, YongBing, ZeYu Wei, YaTing Li, ZhaoZhao Wang, and Xiaobo Zhu. "Friction Self-Piercing Riveting (F-SPR) of AA6061-T6 to AZ31B." In ASME 2013 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2013. http://dx.doi.org/10.1115/imece2013-64212.

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Implementation of lightweight low-ductility materials such as aluminum alloys, magnesium alloys and composite materials has become urgently needed for automotive manufacturers to improve the competitiveness of their products. However, the hybrid use of these materials poses big challenges to joining processes. Self-piercing riveting (SPR) is currently the most popular technique for joining dissimilar materials and has been widely used in joining all-aluminum and multi-material vehicle bodies. However, in riveting magnesium alloys, cracks always occur for its low ductility. In this paper, a hybrid joining process named friction self-piercing riveting (F-SPR), which combines mechanical joining mechanism of SPR with solid-state joining mechanism of friction stir spot welding (FSSW) by making rivet rotating at high speed in riveting process, was proposed aiming at joining the low ductility materials. 1-mm-thick AA6061-T6 and 2-mm-thick AZ31B were used to validate the effectiveness of the F-SPR process. The results showed that the F-SPR process could significantly improve the rivetability of magnesium alloys, and greatly increase the joint strength, comparing with traditional SPR process.
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Ma, YunWu, YongBing Li, and ZhongQin Lin. "Joint Formation and Mechanical Performance of Friction Self-Piercing Riveted Aluminum Alloy AA7075-T6 Joints." In ASME 2019 14th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2019. http://dx.doi.org/10.1115/msec2019-2857.

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Abstract AA7xxx series aluminum alloys have great potentials in mass saving of vehicle bodies due to pretty high specific strength. However, the use of these high strength materials poses significant challenges to traditional self-piercing riveting (SPR) process. To address this issue, friction self-piercing riveting (F-SPR) was applied to join aluminum alloy AA7075-T6 sheets. F-SPR is realized by feeding a high speed rotating steel rivet to aluminum alloy sheets to form a dissimilar material joint. The effects of spindle speed and rivet feed rate on F-SPR joint cross-section geometry evolution, riveting force and energy input were investigated systematically. It was found that the rivet shank deformation, especially the buckling of the shank tip before penetrating through the top sheet has significant influence on geometry and lap-shear failure mode of the final joint. A medium rivet feed rate combined with a high spindle speed was prone to produce a defect free joint with sound mechanical interlocking. F-SPR joints with the failure mode of rivet shear fracture was observed to have superior lap-shear peak load and energy absorption over the joints with mechanical interlock failure. The optimized F-SPR joint in this study exhibited 67.6% and 13.9% greater lap-shear peak load compared to, respectively, SPR and refill friction stir spot welding joints of the same sheets. This research provides a valuable reference for further understanding the F-SPR process.
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Forsmark, Joy H. "Friction Stir Spot Welding of a High Ductility Aluminum Alloy." In SAE 2014 World Congress & Exhibition. 400 Commonwealth Drive, Warrendale, PA, United States: SAE International, 2014. http://dx.doi.org/10.4271/2014-01-0793.

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Mourad, Abdel-Hamid I., Khalifa H. Harib, and Aly El-Domiaty. "Fracture Behavior of Friction Stir Spot Welded Joint." In ASME 2010 Pressure Vessels and Piping Division/K-PVP Conference. ASMEDC, 2010. http://dx.doi.org/10.1115/pvp2010-25986.

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The fracture behaviour of lap-shear joints manufactured by friction stir spot welding (FSSW) technique is examined in this paper. Two aluminium sheets of 2.8 mm thickness were welded using different process parameters to form a lap-shear joint. Special tool was designed and fabricated for the stir-spot welding process. Tensile-shear tests were performed to determine the tensile-shear load bearing capacity and toughness of the weld. The stress intensity factor and the J-integral around a weld are determined in order to characterize the fracture behavior. The effect of different main process controlling parameters, e.g., the tool prop pin rotating speed, duration action time and sinking/penetration depth into the lower welded sheet on the weld fracture behaviour has been investigated through an intensive experimental program. Optical and scanning electron microscopes fractographes were obtained to examine the weld fracture modes. The results show that higher frictional heat due to relatively higher tool probe pin rotational speed and penetration depth into the lower sheet produces improved joint static strength and toughness.
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Feng, Z., M. L. Santella, S. A. David, R. J. Steel, S. M. Packer, T. Pan, M. Kuo, and R. S. Bhatnagar. "Friction Stir Spot Welding of Advanced High-Strength Steels - A Feasibility Study." In SAE 2005 World Congress & Exhibition. 400 Commonwealth Drive, Warrendale, PA, United States: SAE International, 2005. http://dx.doi.org/10.4271/2005-01-1248.

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Raikoty, Harsha, Ikram Ahmed, and George E. Talia. "High Speed Friction Stir Welding: A Computational and Experimental Study." In ASME 2005 Summer Heat Transfer Conference collocated with the ASME 2005 Pacific Rim Technical Conference and Exhibition on Integration and Packaging of MEMS, NEMS, and Electronic Systems. ASMEDC, 2005. http://dx.doi.org/10.1115/ht2005-72833.

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A three-dimensional numerical analysis of friction stir welding at high speed (HS-FSW) is presented here. The temperature distribution in the workpiece has been calculated for a number of processing conditions. The analysis adopts a thermal model based on the simple laws of friction. This model translates to having a moving heat source along the weld-line on the top surface of the workpieces. Results have been validated experimentally using an infrared camera as well as thermocouple measurements. By comparing actual welds performed on Aluminum 6061-T6 and the numerical predictions, it is observed that the appropriate range for the (maximum) surface temperatures for obtaining a sound weld is between 570°C and 530°C, and that these temperatures are achieved between spindle translation velocities of 125 mm/min and 250 mm/min, respectively.
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Chen, Kai, Xun Liu, and Jun Ni. "Electrically Assisted Friction Stir Spot Welding of Aluminum Alloy to Advanced High Strength Steel." In ASME 2017 12th International Manufacturing Science and Engineering Conference collocated with the JSME/ASME 2017 6th International Conference on Materials and Processing. American Society of Mechanical Engineers, 2017. http://dx.doi.org/10.1115/msec2017-2803.

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This paper studies an electrically assisted friction stir spot welding (FSSW) process for joining aluminum alloy 6061-T6 to TRIP 780 steel. The electrical current shows to reduce the axial plunge force and assist the material flow of the aluminum matrix during the welding process. When electrical pulses and direct current (DC) with the same energy input are applied, the results show insignificant differences. Bulk material flow can be observed in the weld cross sections. A more uniform hook is generated at the Fe/Al interface after applying the current. Besides, the diffusion of aluminum atoms into the steel matrix is enhanced. Regarding the weld quality, electrically assisted FSSW improves the joint lap shear strength when compared with regular FSSW process.
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