A Numerical Study on the Effect of Tool Speeds on Temperatures and Material Flow Behaviour in Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets.

A three-dimensional (3D) numerical model was created to simulate and analyze the effect of tool rotational speeds (RS) and plunge rate (PR) on refill friction stir spot welding (refill FSSW) of AA7075-T6 sheets. The numerical model was validated by comparing the temperatures recorded at a subset of locations with those recorded at the exact locations in prior experimental studies from the literature. The peak temperature at the weld center obtained from the numerical model differed by an error of 2.

A Comprehensive Review of Friction Stir Additive Manufacturing (FSAM) of Non-Ferrous Alloys.

Additive manufacturing is a key component of the fourth industrial revolution (IR4.0) that has received increased attention over the last three decades. Metal additive manufacturing is broadly classified into two types: melting-based additive manufacturing and solid-state additive manufacturing.

Experimental and Numerical Analysis of Refill Friction Stir Spot Welding of Thin AA7075-T6 Sheets.

The refill friction stir spot welding (refill FSSW) process is a solid-state joining process to produce welds without a keyhole in spot joint configuration. This study presents a thermo-mechanical model of refill FSSW, validated on experimental thermal cycles for thin aluminium sheets of AA7075-T6. The temperatures in the weld centre and outside the welding zone at selected points were recorded using K-type thermocouples for more accurate validation of the thermo-mechanical model.

Double Pulse Resistance Spot Welding of Dual Phase Steel: Parametric Study on Microstructure, Failure Mode and Low Dynamic Tensile Shear Properties.

Resistance spot welding (RSW) of dual phase (DP) steels is a challenging task due to formation of brittle martensitic structure in the fusion zone (FZ), resulting in a low energy capacity of the joint during high-rate loading. In the present study, in situ postweld heat treatment (PWHT) was carried out by employing a double pulse welding scheme with the aim of improving the mechanical performance of DP590 steel resistance spot weld joint. Taguchi method was used to optimize in situ PWHT parameters to obtain maximum peak load and failure energy.

Effect of Tilt Angle and Pin Depth on Dissimilar Friction Stir Lap Welded Joints of Aluminum and Steel Alloys.

Automobile, aerospace, and shipbuilding industries are looking for lightweight materials for cost effective manufacturing which demands the welding of dissimilar alloy materials. In this study, the effect of tool rotational speed, welding speed, tilt angle, and pin depth on the weld joint were investigated. Aluminum 5052 and 304 stainless-steel alloys were joined by friction stir welding in a lap configuration.