The effect of tool geometry on welding joint quality for aluminum 1100

Friction stir welding (Fsw) uses anon consumable tool to generate friction heat in the abutting surface, the welding parameter such as rotational speed, welding speed, tool tilt angle and tool pin profile play a major role to produce best quality joint.
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The effect of tool geometry on welding joint quality for aluminum 1100International Journal of Mechanical Engineering and Technology (IJMET)Volume 10, Issue 03, March 2019, pp. 1982-1993, Article ID: IJMET_10_03_200Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=3ISSN Print: 0976-6340 and ISSN Online: 0976-6359© IAEME Publication Scopus Indexed THE EFFECT OF TOOL GEOMETRY ON WELDING JOINT QUALITY FOR ALUMINUM 1100 Noori Hasson Mohammed Al- Saadi* Assistant Professor, Research Filed: Applied Mechanics, Civil Engineering Department, Dijlah University College, Baghdad, Iraq ABSTRACT Friction stir welding (Fsw) uses anon consumable tool to generate friction heat in the abutting surface, the welding parameter such as rotational speed, welding speed, tool tilt angle and tool pin profile play a major role to produce best quality joint. in this project we select two tool geometries square and triangle and constant tilt angle 2° as well as to three rotational speed 800,1000,1200 rpm and constant welding speed 35mm/min.under the above parameters we peformed six specimens at different condition and two kinds of tool geometring (square,triangle) After the tensile test for all specimens it is clear to detect that the Square tool under 1200 rpm and welding speed 30mm/min produce the high tensile stress due to heat generation at this condition. Key words: Friction stir welding (Fsw), tool geometries Cite this Article: Noori Hasson Mohammed Al- Saadi, The Effect of Tool Geometry on Welding Joint Quality for Aluminum 1100, International Journal of Mechanical Engineering and Technology 10(3), 2019, pp. 1982–1993. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=31. INTRODUCTION1.1 General IntroductionWelding is a material joining process for a permanent combining of two (or more) parts thatinvolves melting and subsequent solidification of the material from two parts thus forming astrong joint between them. The assemblage of parts is called a weldment. There are two groups of welding processes according to the state of the base material duringthe welding process:  Fusion welding.  Solid-state welding.Fusion weldingIs by far the more important category. In fusion welding, the base material is heated to melt. The most important processes in this group fall in the following categories: http://www.iaeme.com/IJMET/index.asp 1982 editor@iaeme.com Noori Hasson Mohammed Al- Saadi  Oxyfuel gas welding: an oxy fuel gas produces a flame to melt the base material;  Arc welding: heating and melting of the material is accomplished by an electric arc between the electrode and base metal.  Brazing and soldering: which involves heating the joint to a definite temperature and using filler metal that melts at a temperature less than the base metal melting temperature. [1] Figure 1 Shows the represent welding process [2]1.2. Welding joint Types  Lap Joint: Lap welding joints are used most often to joint two pieces differing thicknesses together. Also considered a fillet type, the weld can be made on one or both sides. A Lap Joint is formed when 2 pieces are placed in an over lapping pattern on top of each other.  Edge Welding Joint: Edge welding Joints are often applied to sheet metal parts that have flanging edges or are placed at a location where a weld must be made to attach to adjacent pieces. Being a groove type weld, Edge Joints, the pieces are set side by side and welded on the same edge. For heavier applications filler metal is added to melt or fuse the the edge completely and to reinforce the plate.  Butt Joint: Being the universally accepted method for attaching a pipe to itself it’s also used for valves, flanges, fittings, and other equipment. A butt welding joint is also known as a square grove weld. It’s the easiest and probably the most common weld there is. It consists of two flat pieces that are side by side parallel. It’s a very affordable option1.3. Friction WeldingTraditionally, friction welding is carried out by moving one component relative to the otheralong a common interface, while applying a compressive force across the joint. The frictionheating generated at the interface softens both components, and when they become plasticizedthe interface material is extruded out of the edges of the joint so that clean material from eachcomponent is left along the original interface.[1] Friction welding is defined by the different authors by adopting various definitions offriction welding. The friction welding is a solid state welding process ...