TL;DR: In this article, the flow of metal during friction stir welding is investigated using a faying surface tracer and a nib frozen in place during welding, showing that material is transported by two processes: a wiping of material from the advancing front side of the nib onto a zone of material that rotates and advances with the nib.
Abstract: Friction Stir Welding is a relatively new technique for welding that uses a cylindrical pin or nib inserted along the weld seam. The nib (usually threaded) and the shoulder in which it is mounted are rapidly rotated and advanced along the seam. Extreme deformation takes place leaving a fine equiaxed structure in the weld region., The flow of metal during Friction Stir Welding is investigated using a faying surface tracer and a nib frozen in place during welding. It is shown that material is transported by two processes. The first is a wiping of material from the advancing front side of the nib onto a zone of material that rotates and advances with the nib. The material undergoes a helical motion within the rotational zone that both rotates and advances and descends in the wash of the threads on the nib and rises on the outer part of the rotational zone. After one or more rotations, this material is sloughed off in its wake of the nib, primarily on the advancing side. The second process is an entrainment of material from the front retreating side of the nib that fills in between the sloughed off pieces from the advancing side.
TL;DR: In this article, the authors tried to butt-weld an aluminum alloy plate to a mild steel plate by friction stir welding, and investigated the effects of a pin rotation speed, the position for the pin axis to be inserted on the tensile strength and the microstructure of the joint.
TL;DR: In this paper, a finite element analysis environment is used to evaluate the shape and size of weld nuggets and the effects of welding parameters on temperature of faying surface, which can assist in adjusting welding parameters so that costly experimental works can be avoided.
TL;DR: In this paper, two methods were used to eliminate the hook defect in pinless FSSW joints, including changing welding parameters such as rotating speed and dwell time, and subsequent friction stir welding (FSSW-FSW), which is an innovative method proposed in this study.
TL;DR: In this article, an axisymmetric finite element model employing coupled thermal-electrical-mechanical analysis of resistance spot welding is presented, and the welding parameters considered include: heat generation at the faying surface and the workpiece-electrode surface, Joule heating at the work piece and the electrode; and the thermal contact conductance between the electrode and workpiece.
Abstract: An axisymmetric finite element model employing coupled thermal–electrical–mechanical analysis of resistance spot welding is presented. The welding parameters considered include: heat generation at the faying surface and the workpiece–electrode surface; Joule heating at the workpiece and the electrode; and the thermal contact conductance between the electrode and the workpiece. The latent heat of phase change due to melting is accounted for. The effect of friction coefficient on the workpiece interface is also studied. The computed results agree well with the experimental data. Heat generation at the faying surface in the initial stages of welding dominates the nugget development, and Joule heating at long times governs the weld nugget growth. A parametric study is carried out for the nugget growth with specific consideration of resistance spot welding of Al alloys. Process control and modelling of resistance spot welding of Al alloys is more difficult than that for steel because of their high elec...