A three-dimensional numerical model is used to simulate the Friction Stir Welding (FSW) process using the computational fluid dynamics package ‘FLUENT’. Two mechanical models: the Couette and the Visco-Plastic fluid flow models for Al-6061-T6 were simulated. The simulation results are compared to experimental data for Al 6061-T6 welded at high rotational (1500–5000 rpm) and travel speeds rangin...

in the present research, friction stir welding (fsw) process was used for butt joining of pure copper plate to 316l stainless steel plate. mechanical properties and microstructural characteristics of the joint were evaluated by microhardness and tensile tests as well as optical and scanning electron microscope (sem). it was found that microstructure of the weld nugget (wn) has fine grains where...

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 us...

Friction Stir Welding (FSW) is a solid-state welding process, based on frictional and stirring phenomena, that offers many advantages with respect to the traditional welding methods. However, several parameters can affect the quality of the produced joints. In this work, an experimental approach has been used for studying and optimizing the FSW process, applied on 5754-H111 aluminum plates. In ...

Friction Stir Welding (FSW) is a solid-state joining process; i.e., no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFS...

abstract: friction stir welding, a solid state innovative joining technique, is widely being used for joining aluminium alloys for aerospace, marine automotive and many other applications of commercial importance. fsw trials were carried out using a vertical machining centre (vmc) on aa6061 alloy. the main objective of the present work was to evaluate the weld processing parameter of friction s...

This paper describes a technique for determining the position of the friction stir welding (FSW) tool with respect to the weld seam during welding. This technique is proposed for online misalignment detection or as a position estimator for in-process tracking of the weld seam for FSW.

The current paper presents a robust optimum design of friction stir welding (FSW) lap joint AA1100 aluminum alloy sheets using Monte Carlo simulation, NSGA-II and neural network. First, to find the relation between the inputs and outputs a perceptron neural network model was obtained. In this way, results of thirty friction stir welding tests are used for training and testing the neural network...

In the friction stir welding (FSW) process, heat is generated by friction between the tool and the workpiece. This heat flows into the workpiece as well as the tool. The amount of heat conducted into the workpiece determines the quality of the weld, residual stress and distortion of the workpiece. The amount of the heat that flows to the tool dictates the life of the tool and the capability of ...

The relevance, importance and presence of industrial robots in manufacturing have increased over the years, with applications in diverse new and nontraditional manufacturing processes. This paper presents the complete concept and design of a novel friction stir welding (FSW) robotic platform for welding polymeric materials. It was conceived to have a number of advantages over common FSW machine...