Characteristics of potential sources - vertical force, torque and current on penetration depth for quality assessment in friction stir welding of AA 6061 pipes

Ahmed M. El-Kassas, Ibraheem Sabry, Abdel Hamid I. Mourad, Dinu Thomas Thekkuden

Research output: Contribution to journalArticlepeer-review

21 Citations (Scopus)

Abstract

Friction stir welding of the pipes or curved bodies in aerospace components is tedious due to complex geometry, and hence, research articles related to it are rare. Primarily, this research has investigated the nature of vertical welding force, torque and current on the weld quality during the friction stir welding of Aluminium 6061 (AA 6061) pipe at different penetration depths – 1.4 mm, 1.54 mm, 1.66 mm, 1.7 mm, 1.9 mm and 2 mm. The feed rate and rotational speed have been set at 1 mm/s and 1800 rpm respectively. The weld quality has been evaluated using visual inspection and tensile test. From the results, penetration depths from 1.7 mm to 2 mm have been suitable for producing quality welds on a specimen with 2 mm thickness, which resulted in fewer shoulder marks, and percentage reduction of strength lower than 25.61% compared to the base metal. Friction stir welding using penetration depth of 1.4 mm has resulted in a weld, with excess shoulder marks and 43.84% of reduction in strength, which is not acceptable. In addition, the range of penetration depths (1.7 mm to 2 mm) for which the force remains constant is recommended for producing quality welds. While torque and power have increased linearly with the penetration depth, the distribution of the current has remained the same for different penetration depths. However, the current consumption has varied significantly in each one of the friction stir welding stages clearly distinguishing the tool penetration, the dwell time, the traverse tool movement and the tool pull out. The experimentation has been successful in laying the foundation for the process parameters signifying the importance of penetration depth.

Original languageEnglish
Pages (from-to)195-204
Number of pages10
JournalInternational Review of Aerospace Engineering
Volume12
Issue number4
DOIs
Publication statusPublished - Aug 2019

Keywords

  • AA 6061 Pipe
  • Current consumption
  • Friction Stir Welding (FSW)
  • Penetration depth
  • Torque
  • Vertical force

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Aerospace Engineering
  • Fluid Flow and Transfer Processes
  • Electrical and Electronic Engineering

Fingerprint

Dive into the research topics of 'Characteristics of potential sources - vertical force, torque and current on penetration depth for quality assessment in friction stir welding of AA 6061 pipes'. Together they form a unique fingerprint.

Cite this