to develop a friction stir welding tool for non ferrous alloys

The current research investigates the effects that develop during various welding processes, welding difficulties, and selecting an energy-efficient, low metallurgical distortion, and high mechanical properties driven approach. Because of the metallurgical, environmental, and mechanical strength pro

Project Title

to develop a friction stir welding tool for non ferrous alloys

Project Area of Specialization

Mechanical Engineering

Project Summary

The current research investigates the effects that develop during various welding processes, welding difficulties, and selecting an energy-efficient, low metallurgical distortion, and high mechanical properties driven approach. Because of the metallurgical, environmental, and mechanical strength problems associated with fusion welding, FSW welding has been used to replace it by using different types of tools. The technique is extremely beneficial because no cover gas or flux is utilized. Because no filler metal is used in the joining, any aluminum alloy may be connected without consideration about composition compatibility, which is a problem with fusion welding. Friction stir welding may be used to create butt joints, lap joints, T butt joints, and fillet joints, among other types of joints. FSW is performed on 3mm Aluminum sheet, Butt joint configuration was used. Our aim of work is to design a FSW tools which is used to join the aluminum due to this reason we have designed five different types of tools in which H13 tool steel materials with 27mm diameter rod is machined from CNC lathe. All five tools contain same shoulder diameter of 14mm with different pin profile that is cylindrical thread, tapered with thread, thread with 3 flats and MX-Triflute along with Scroll feature except Cylindrical with 3 flats.

Project Objectives

Aim of this project is that we are going to work on joining of aluminum alloys with friction stir welding to obtain a uniform weld and desired properties. For this purpose, we will design and manufacture four tools (fixed tool, adjustable tool, bobbin tool and MX triflute) through CNC lathe machine then perform vacuum hardening process on these tools to obtain a desired hardness. After performing all these process on tools we are going to perform a FSW process on milling machine then on the obtain weld joints we will perform characterization process The goal of weld characterization is to assess the ability of a weld to successfully perform its function, to thoroughly document a weld and to determine why a welding process is failed (in case of failure). The microstructure of the joints from FSW will examine using optical microscope. The welding zones which thermo-mechanically affected zone (TMAZ) in FSW cases and also heat affected zone(HAZ) and base metal (BM) will be examined under optical microscope and observing the changes in microstructure on the joint which occur after using different tools.

Project Implementation Method

In this project we have to design four tools which is Fixed tool, Adjustable tool, Bobbin tool, Advance MX Triflute pin. Each tools has its own shoulder and pin features. Selected tool material of these all four tools is H13 tool steel. H13 tool material will be processed in desired features through CNC lathe machine.Each tool contain scroll feature at the end of their shoulder. This scroll feature helps to improve the flow of material from the edges of the shoulder to the probe. This scroll feature will be manufactured by EDM machine.

Benefits of the Project

Metallurgical and environmental benefits of FSW is

• Solid phase process
• Workpiece distortion is minimal.
• Dimensional consistency and repeatability are excellent.
• No loss of alloying element
• In the joint area, excellent metallurgical characteristics
• Fine microstructure
• Replace any pieces that are connected byfasteners.
• There is no need for a shielding gas.
• There is no need to clean the surface.
• Consumable materials, such as carpets, wire, or any other gas, can be saved.
• Eliminate a grinding waste and the need for degreasing solutions

Technical Details of Final Deliverable

Due to the lower temperatures there is a reduction in shrinkage and distortion in the material being joined. No filler materials, flux or shielding gas requirement for aluminium alloys. FSW is environmentally friendly as it produces no fume, spatter, or UV radiation.

Final Deliverable of the Project

Hardware System

Core Industry

IT

Other Industries

Education

Core Technology

Others

Other Technologies

Clean Tech

Sustainable Development Goals

Affordable and Clean Energy, Industry, Innovation and Infrastructure, Sustainable Cities and Communities, Partnerships to achieve the Goal

Required Resources

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