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Friction Stir Welding and Friction Stir Processing for 6061-T6 Aluminum

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Friction Stir Welding and Friction Stir Processing for 6061-T6 Aluminum 40 Journal of Advanced Sciences and Engineering Technologies (2019) Vol 2 No1, 40 -53 ISSN: 2617-2070 (Print) ; 2617-2070 (Online) Journal of Advanced Sciences and Engineering Technologies available online at: http://www.Jaset.isnra.org * Riyah Najim Kiter 1 Invest Hussam Jumma Chalob2 Friction Stir welding and Friction Stir 1Department of Mechanical Processing for 6061-T6 Aluminum Alloy Engineering, College of Engineering, Anbar University, Iraq [email protected] [email protected] ABSTRACT Keywords: FSW, FSP, Double pass, 6061-T6 Aluminum Alloy plates were welded by using Residual stress, welding aluminum alloy, chnologies Friction Stir Welding (FSW) at different rotation and welding optimization FSW parameters, speeds. The effects of two factors on Ultimate Tensile Strength Taguchi, ANOVA (UTS), which include rotation and welding speed at 2o tool tilt ARTICLE INFO angle, were investigated. Ultimate Tensile strength increases Article history: with decrease the welding speeds and increases the rotational Received 01 jan 2019 speeds. The rotation speeds have a higher effect on ultimate Accepted 10-Aug -2019 Available online 04 -Sep 2019 tensile strength when compared with the welding speeds. Friction Stir Processing (FSP, Double pass) led to increasing the ultimate tensile strength and elongation at same welding DOI: http://dx.doi.org/10.32441/jaset.02.01.04 and rotation speeds. FSP lead to improve fatigue life and reduce residual stress. Copyright © 2018 by author(s) and This work is licensed under the Creative Commons Attribution International License (CC BY 4.0). http://creativecommons.org/licenses/by/4.0/ Open Access of Advanced Sciences and Engineering Technologies Journal of Advanced Sciences and Engineering Te Journal © 201x JASET, International Scholars and Researchers Association Riyah N. Kiter. et al. / Journal of Advanced Sciences and Engineering Technologies 41 Introduction Friction stir welding (FSW) considered solid- Welding. FSP worked on reduce inherent state welding; was discovered in 1991 by The defects in the starting material and locally Welding Institute [1]. In Friction stir welding, refines microstructures and also enhance its the work-pieces were firmly clamped onto the ductility, formability, fatigue resistance, worktable to prevent it from moving and corrosion resistance, and other properties [5]. vibration. At the start welding the pin rotates at Basically, FSP is a local thermo-mechanical specified rotation speed and then plunges into metal working process, the change in the the line interface between the two plates. The properties occurs only in local properties heat generated is a product from the friction without affecting properties of the remaining between the tool and welded material, and the structure [6]. weld material rising to a relative steady-state The main advantages of FSW over conventional temperature and becomes plasticized. The tool welding methods are the defects like voids and is moved along a predefined weld path when porosity are less from conventional welding, plasticized state is reached. The material in the low tensile residual stresses and distortion weld zone remove from the pin entering and stresses in the resultant welded region, higher travelling during the part try to extrude out of mechanical properties, the environmentally the pinhole but is kept in place by shoulder[2]. safe process due to the absence of radiation and The generator temperature due to welding toxic fumes, FSW is operated in all positions, as operation reached to 70 - 90% from the melting there is no weld pool. Disadvantages of FSW point for the base material and its causes soften are, the work-piece clamping is a very in the weld regions and permits moving the important criterion in the operation, the lower tool along the welding line. The welding tool welding speed leads to longer process times, will transfer the material from the advance side the thickness of weld line will reduce during to return side, FSW presented in figure (1)[3]. the welding process due to no filler material, Friction Stir Processing (FSP) consider as a when the tool is withdrawn FSW caused hole solid – state welding process which firstly left. When used large down forces must use utilized in 1999 by Mishra et al [4]. FSP is an heavy duty clamping to hold the plates emerging surface engineering technology together, lower flexible than arc and manual depends on the principles of Friction Stir Process[7-11]. 42 Journal of Advanced Sciences and Engineering Technologies (2019) Vol 2 No1, 40 -53 Figure (1,2) Friction stir welding and friction stir processing [12] The welding zones are dividing into three main zones are presented in figure (3): II-Friction Stir Welding Zones A. Heat affected zone (HAZ): This zone is recrystallization, and product fine equiaxed closer to the weld zone because of the grain structure evolves[13]. nearness to the heat source, changes in C. Thermo-mechanically affected zone mechanical properties due to changes in (TMAZ): This zone relative to positions that microstructural changes. as well as, no have undergone deformation, moreover plastic deformation[13]. have been influenced by heat. In this region B. Weld nugget: This zone occurs when the no recrystallization in this region. TMAZ is material complete undergoes placed so near to the pin[13]. Figure (3): Welding zones for FSW process [14] Riyah N. Kiter. et al. / Journal of Advanced Sciences and Engineering Technologies 43 III-EXPERIMENTAL WORK A. Chemical composition The material which used was aluminum alloy good toughness and high strength. The AA6061 with the 4 mm thickness. Aluminum chemical composition is explained in the table alloy AA 6061, consider one of the most used of (1) heat treatment alloys, It has good feature as B. Welding operation In the current study, using 6061 aluminum carbon low steel with dimension explained in alloy with 4mm thickness and length 200 mm figure (4). and width 100 mm. friction stir welding parameters were (rotation speed, welding Table (1) chemical composition for studies Speed and constant tilt angle of the too), it’s material shown in table (2). A cylindrical tool made of Sample Si% Fe% Cu% Mn% Mg% Cr% Ni% Zn% Pb% Ti% Standard [15] 0.4- 0.7 0.15- 0.15 0.8- 0.04- 0.25 0.15 0.005 0.07 0.8 max 0.4 max 1.2 0.35 max max Plate 6061 0.57 0.33 0.253 0.097 1.151 0.185 0.003 0.063 0.004 0.0216 5 1 4 2 3 t= 4 mm Table (2) welding parameters parameter Rotation speed Welding speed Welding speed Welding speed (rpm) (mm/min) (mm/min) (mm/min) Case 1 630 20 32 45 Case 2 1000 20 32 45 Case 3 1600 20 32 45 Figure (4): welding tool. 44 Journal of Advanced Sciences and Engineering Technologies (2019) Vol 2 No1, 40 -53 C. Tensile test pass as well as the base material. The location of the welding line is near to the fixed point as The tensile test was carried out in university of shown in figure (6). technology with production engineering and metallurgy department at room temperature by using computerized (WDW-200E – 200KN) as shown in figure (4) at constant crosshead speed 1mm/min. The tensile test specimen cutting by using water Jet CNC machine and perpendicular on welding line, its dimension Figure (6): the position of welding line. explain in figure (5). E. HARDNESS TEST The hardness test was performed by digital micro Vickers hardness Th714 shown in figure (4.18) in the mechanical engineering department in Tikrit University. The test is done under applied load (200 g) with a time of 15 sec. The specimens were taken perpendicular on the weld line. Figure (5): Dimension of tensile test sample F. X-RAY TEST [16]. The X-Ray diffraction tests were performed in the Ministry of Science and Technology by the D. Fatigue Test (XRD-6000/ ShIMADZU) machine type. The supplied current was (20 mA) and voltage Fatigue test is done at the mechanical (40KV). The target is Copper with a wavelength engineering department laboratory in Nahrain (λ=1.5406 A0), and the filter is Nickel. University by using fatigue (HI-TE Ch)-Rotating device. It is done at a constant stress amplitude cantilever with fully reversed (R=-1), and the IV-RESULTS specimen dimensions were 60, 10, 4 mm length, width, thickness respectively. Samples G. Tensile test results were taken from the welded plate with 1600 rpm and 20 mm/min for both single and double The tensile test results for base material are presented in table (3) Table (3): Tensile test results for base material. Material Proof Ultimate strength Modules of Elongation max (%) strength (MPa) elasticity 0.2% (MPa) (GPa) 6061-T6 [15] 255 289 69 12 Plate 4 mm 241 280 68.9 15.43 5 7 6 Riyah N. Kiter. et al. / Journal of Advanced Sciences and Engineering Technologies 45 8 The figure (7) showed that reduction in 9 the decrease in welding efficiency in ultimate tensile strength for weldment case 630 rpm and 45mm/min may be when compared with the base material due to a random distribution of these for all rotation and welding speeds. The components in this alloy. From figure weld efficiency is defined as the (9) the ultimate strength reduces with ultimate tensile strength for welded increasing welding speed whereby the material to the ultimate tensile test for ultimate strength was 242 at 20 base material. The ultimate tensile mm/min and at increase the feed rate strength for base material was 280 MPa (welding speed) it reduces to 236 MPa while the higher ultimate tensile at 32 mm/min after this it also reduces strength for weldment was 242 MPa to 231.5 MPa at 45 mm/min. The with weld efficiency 86.5 % at 1600 rotation speeds 630 and 1000 have the rpm and welding speed 20 mm/min.
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