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Go to Editorial ManagerFriction stir welding (FSW), a solid-state welding process, it’s involve a welding by friction between two metals or alloys, and also using for the joining of dissimilar materials due to the lower processing temperature over conventional fusion welding, it's include only one pass of welding. Friction Stir Processing (FSP) is a recent outgrowth of the Friction Stir Welding (FSW) process and relies on solid-state deformation to modify the structure of the workpiece, it's involve two pass or more of welding and applied either on the base metal(BM) or to join the two alloys/metals. In this paper the new method used, namely reverse rotation friction stir processing (RFSP), this research aims to study the effect of (RFSP) technique on the mechanical properties of welded alloys. (FSW) includes a single pass of the welding line but the second method (RFSP) involves two pass of welding (forth and back) but the 1st pass with a rotation speed in clockwise and the 2nd pass in counter-clockwise. The alloys used of dissimilar AA 2024 and AA6061 aluminum alloys of (3mm) thickness, the parameters used in this research include different rotational speed (1600, 1800, 2000 and 2200) RPM and one feed speed (25) mm/min. In the tensile test the results of reverse rotation friction stir processing (RFSP) was higher than friction stir welding (FSW) for all rotation speeds of welding except (1800 RPM). In the microhardness measurement the values of hardness for all samples at the nugget zone is higher than the basemetal of 6061-T6 and lower than the basemetal of 2024-T3. The efficiency of ultimate tensile strength reaches to about (72 %) for (RFSP) as compare with value of (FSW) and it’s about (44%) at rotation speed (1600 RPM).The only exception of welding was when the rotational speed of (1800 RPM), where the (FSW) is better than (RFSP), efficiency was approximately (77%) for the (FSW) compared with the results of (71%) (RFSP).
Friction Stir welding (FSW) parameters, which play a vital principle, that impact on the mechanical, microstructural properties of the weldment because of the warmth produced by the contact between the instrument and work-piece, An AA6061-T6 aluminum composite plate with measurements (186*150*4) mm3 welded through various rotational paces 800, 1000, 1200 and 1450 rpm, the created heat measured through thermocouples embedded in study zones of the Weldment, a Finite Element model have been executed by utilizing ANSYS 12.1 bundle charges to ponder the temperature appropriation amid stay stage, the outcomes demonstrates a decent assention between the after effects of exploratory and hypothetical tests. The most extreme temperature measured at this condition was 0.71 from the liquefying temperature of the sample at a maximum rotational speed of (1450) r/min.
Friction Stir Welding is one of the most practical welding process at the solid state. Friction Stir Processing is used to enhance the microstructure of FSW welded zone. The present study investigates the effect of welding parameters on the tensile properties of FSW and FSP joining 3 mm AA 5083 - H111 aluminum alloy by means of stress – strain curve with a uniaxial tensile test and by comparing the efficiency between FSW , FSP and base metal .The experiments were conducted with 1000,1500 and 2000 rpm rotation speeds ,and 20,40 and 60 mm/min travel speed. The best result of the welding joint was shown at the 20 mm/min feed speed and 1500 rpm rotational speed for FSW, and 40 mm/min feed speed and 1500 rpm rotation speed for FSP. The efficiency of ultimate tensile strength reaches to 92% for FSW and 94% for FSP.
In this work, Aluminum alloy (AA2024-T3) was welded by friction stir (FSW) method using different pin profile design types; straight cylinder, threaded cylinder, tapered cylinder hexagonal, square, and threaded taper. For each type, a flat and concave shoulder was used, as well as, the welding process was single and double. The results of mechanical tests are analyzed using design of experiments method (DOE). The best and weaken mechanical properties (tensile strength, bending force and hardness) are observed when the welding is achieved by hexagonal and straight cylinder pin profile respectively. A concave shoulder gave higher mechanical properties as compared with flat shoulder. The change in welding process type presented a sensible effect. Nugget zone hardness is higher than that of base metal for all specimens. The optimum hardness result is recorded by hexagonal pin with concave shoulder profile.