Search results for "friction welding"
showing 10 items of 71 documents
Influence of material characteristics on plastomechanics of the fsw process for T-joints
2009
Abstract The potential of friction stir welding (FSW) has thoroughly been investigated by several authors, however their focus has primarily been on butt joints. T-joints are of paramount interest for transportation industries especially due to their capacity to straighten panels. Welding of T-joints is very challenging due to thin walls, poor location of the rib–web interface and the requirements for corner-fillets. This paper investigates FSW of T-joints of two popular aluminum alloys, i.e. 2024-T4 and 6082-T6, and the role played by the material characteristics on joining. First, an experimental study is carried out with specially designed fixture to determine the effect of process condi…
FEM based prediction of phase transformations during Friction Stir Welding of Ti6Al4V titanium alloy
2013
Abstract Friction Stir Welding (FSW) is a solid state welding process patented in 1991 by TWI; initially adopted to weld aluminum alloys, it is now being successfully used also for high resistant materials. Welding of titanium alloys by traditional fusion welding techniques presents several difficulties due to high material reactivity with oxygen, hydrogen, and nitrogen with consequent embrittlement of the joint. In this way FSW represents a cost effective and high quality solution. The final mechanical properties of the joints are strictly connected to the microstructural evolutions, in terms of phase change, occurring during the process. In the paper a 3D FEM model of the FSW welding proc…
Design of Numerical Simulations of Linear Friction Welding Processes: Issues and Difficulties
2015
In this paper, a critical analysis of the technical difficulties and numerical issues in running simulations of linear friction welding processes is carried out. The focus of the paper is the comparison of different modeling strategies of a numerical analysis for the LFW process of Ti-6Al-4V titanium alloy, for which the thermal aspect strongly influences the mechanical behavior due to the phase transformation, taking place over a definite range of temperature. A 3D simulation campaign, conducted using the FEA code DEFORMTM, was considered in order to show advantages and disadvantages of each approach, including the most critic limitations and complexity in a correct simulation design using…
Experimental and Numerical Study on Linear Friction Welding of AA2011 Aluminum Alloy
2014
Linear Friction Welding (LFW) is a solid-state joining process used for non-axisymmetric components. LFW involves joining of materials through the relative motion of two components undergoing an axial force. In the process, the heat source is given by the frictional forces work decaying into heat and determining a local softening of the material and eventually the needed bonding conditions. In the paper, an experimental and numerical campaign is proposed for AA2011 aluminum alloys welding. Different case studies are considered with fixed oscillation frequency and varying pressure at the interface between the specimens. Constant oscillation amplitude and specimens geometry is used. The calcu…
Investigations on the linear friction welding process through numerical simulations and experiments
2012
Abstract Linear Friction Welding (LFW) is a solid-state joining process applied to non-axisymmetric components. LFW involves joining of materials through the relative motion of two components undergoing an axial force. In such process the heat source is given by the frictional forces work decaying into heat determining a local softening of the material and eventually bonding conditions. In the paper the authors present a designed and assembled laboratory fixture for LFW operations and the results of an experimental and numerical campaign aimed to weld steel parts. The dedicated fixture permitted to highlight the effect of the most important process parameters. Process conditions allowing ef…
Friction Based Solid State Welding Processes
2012
In the last decade the industrial use of solid state welding processes based on frictional forces work decaying into heat is continuously increasing due to their strong advantages with respect to traditional fusion techniques. Several advances have been proposed by the scientific community regarding process mechanics, material flow and also the computer aided engineering of the operation with the aim to maximize the mechanical performances of the welded joints. In the paper Friction Stir Welding (FSW) and Linear Friction Welding (LFW) operations are considered and a review of the most relevant research issues and results is provided.
Material flow analysis in dissimilar friction stir welding of AA2024 and Ti6Al4V butt joints
2016
The complex material flow occurring during the weld of dissimilar AA2024 to Ti6Al4V butt and lap joints was highlighted through a dedicated numerical model able to take into account the effects of the different materials as well as the phase transformation of the used titanium alloy.
A novel linear friction welding based approach for sheet-bulk joining
2019
In the last decades, the development of new, flexible manufacturing processes caused the increase of the demands for highly customized complex functional parts in many industrial fields. The peculiar design of these components often overcome conventional sheet metal and bulk metal forming processes capabilities. In order to face this issue, new hybrid techniques, capable of exploit key advantages of different processes, have to be developed. In this paper, a novel approach based on the Linear Friction Welding process is proposed to obtain sheet-bulk joints. The feasibility of the technique on high specific strength alloys is investigated through an experimental campaign.In the last decades,…
A case study on the evaluation of friction stir welds by ultrasonic inspection technique
2015
Friction stir welding (FSW) is an innovative process that has been successfully used in joining aluminum alloys, normally difficult to weld. Important advantages over fusion welding are better retention of baseline material properties, lower residual stresses and excellent mechanical properties. Defects that occur in FSW joints are due to improper tooling or setup. Non-destructive techniques used to inspect FSW joints are X-rays, eddy current, conventional ultrasonic testing and dye penetrant proper only for surface breaking defects. Currently there is no non-destructive technique that can guarantee absence of flaws in friction welds during manufacturing. In this work, non-destructive remot…
Mappe di Lavorabilita’ per Giunti Misti di Alluminio Mediante Processo di Saldatura Linear Friction Welding
2014
Il Linear Friction Welding è un processo di saldatura allo stato solido in cui una parte fissa è forzata contro una parte che si muove con moto lineare alternato per generare calore attraverso l’attrito. Nel presente lavoro viene descritto lo studio effettuato per la realizzazione della giunzione mista mediante processo di Linear Friction Welding tra due leghe di alluminio che presentano proprietà meccaniche differenti, come la lega AA2011 e AA6082. Lo studio è stato condotto analizzando due differenti configurazioni determinate dalla posizione relativa delle leghe costituenti i provini da saldare. Per la realizzazione del processo è stata utilizzata una macchina prototipale dotata di senso…