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    Heat Input and Temperature Distribution in Friction Stir Welding PDF

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    ILL Number: 71600418 {A AA Shipping Method: Ariel Yes No Cond Borrower: SUC. cai #: LSA no call# In Process: 20101129 Charge: Lending String: *MYG,JHE,JHE,LHL,WTU hccee osoeM : Upadhy Patron: Upadhyay, Piyush; Graduate re Document Services ‘Thomas Cooper Library 1822 Greene Street University of South Carolina Journal Title: Journal of materials processing & manufacturing science. Volume: Issue: MonthvYear: 1998 Pages: 163-172 Shipping Address: fed declied Fax: 803 777-9503 Article Title: W. Tang, X. Guo, J.C. McClure, LE, Email Address: uscill@gwm.sc.edu Murr, A. Nunes; Heat Input and Temperature Distribution in Friction Stir Welding g @ nS a S z= z & 3 = Request Type: Article Borrowing Notes: Document Type: _ MIT Libraries Document Services/ Interlibrary Loan OCLe# 25517123 \ go wt Imprint: Lancaster, Pa. ; Technomic Pub. Co., c19 2 Von ee Ariel Address: 129.252.80.49 {A "US Copyright Notice’** ‘The copyright law ofthe United States (Title 17, United States Code) governs the making of reproductions of copyrighted material, Under certain conditions spectied in the law, libraries are authorized to furnish a reproduction. One of these specified conditions is that the reproduction is not to be “used for any purpose ether than private study, scholarship, or research. Ifa user makes a request for, or later uses, a reproduction for purposes in excess of “Yair use,” that user may be lable for copyright infringement. This institution reserves the right to refuse to accept a copying order ints judgment, fulliment ofthe order would involve violation of Copyright Law. Heat Input and Temperature Distribution in Friction Stir Welding W. TANG, X. GUO, J.C. MeCLURE! and L. E MURR ‘Metalorgical ond Motevcls Engineering Department Universiy of Texas a E Paso 1 Paso, 1X 79968 USA ‘A. NUNES NASA ‘Marshall Space Flight Center Huntsvila, labora USA Abstract: In his paper the het input und temperate distebution during fiction stir welding is n- ‘vestigated. The temperatures at iffeent positions inthe specimen thickness direction and perpen- Aiclar the pin toot travel direction were reconded during welding under various welding condi- tons. It was found that the highest temperature in the welding seam i less that 087. For the conditions usd in his work, the temperature does not change appreciably in the specimen thickness ‘ireton. The temperature distribution perpendicular to the weld is nearly isothermal under the pin tool shoulder Furthermore, increasing welding pressure and pin tol rotational speed inreases the peak welding temperature. Finally. itis shown that the shoulder of the pn tool plays avery impertant ‘le inthe welding process. INTRODUCTION ALUMINUM is usually welded by fusion methods such as TIG and plasma welding. The main Jifficulties when fusion welding methods are applied to aluminum alloys ate, first, the adher- ent refractory aluminum oxide film, which is sometimes not removed completely and is en- trained in the weld pool during the welding process, and second hot cracking and porosity that takes place during the melting and solidification process. Welding methods and parame- ters must be chosen very carefully to avoid these defects, Special methods such as variable polarity plasma and careful shielding must be used to break the aluminum oxide film and pre- vent new oxide film growth, Friction stir welding isa newly developed solid state welding method (1]. Solid state weld- ing (as opposed to fusion welding) methods are widely used in industry to avoid welding defects which always occur when molten metal sofidifies, or to weld materials with a very high melting temperature, Traditional friction welding is usually performed on small axisymmetric parts, which can be rotated and pushed against each other to form a joint [2]. Friction stir welding on the other hand can be applied to various types of joints like butt joints, lap joints, T butt joints, and fillet joints [3] In friction stir welding, the melting and solidification process does not occur, so there will be no shrinkage or hot cracking, Shielding gas is not needed since temperature is Tow. Other advantages of friction stir welding are presented elsewhere [3,4]. Previous work on Gfietion stir welding has discussed the method itself and the microstructure of the welded joint [5-8], but the heat input and temperature distribution in the friction stir welded joints have never been presented before. This paper reports temperature isotherms and shows the effect of increas- {ng pin tool pressure and rotational speed on the temperature distribution, ‘Auth to whom corespondence should he aresed Journal of Materials Processing & Manufacturing Science, Vol. 7~October 1998 163 152.065698102 0163-10 $10.000 (0 1999 Technamie Publishing Co ne. 164 \W. TANG, X, GUO, J.C. MeCLURE, L.E. MURR and A. NUNES: Nib Figure 1. Scheretic of in too. WELDING PROCESS AND WELDING PARAMETERS Experiments were performed on 6061 T6 aluminum. Most welds were bead on plate to pet ‘mit temperature measurement on the centerline of the weld. The specimen size was 12 inches (304 mm) by 4 inches (101 mm) and 0.25 inches (6.4 mm) thick. Welds were made on Gorton “Mastermil milling machine. The pin tool was made up of a screw nib and a shoulder made of tool steel as shown in Figure I During the welding process, the aluminum plate was clamped against the work table with a steel backup plate, the rotational speed of the pin tool ranged from 300 pm to 1200 rpm, and the travel speed was 2 mm/s, The downward pressure between the shoulder and the workpiece was controlled manually by raising the work table, to which the welded specimen is clamped, against the pin tool and judging the amount of material forced up at the edge of weld during welding. As ‘check on the consistency of the pressure used, the thickness variations of twenty random speci- mens were measured and found to be nearly equal (0 the thickness variations in the original plates. At the start of the weld, the average reduction of the thickness was about 3%. ‘TEMPERATURE MEASUREMENT Temperatures during the friction stir welding process were measured by 30 gauge type K ‘thermocouples imbedded in a series of small holes (0.92 mm diameter) at different distances {rom the weld seam drilled into the back surface of the workpiece. The holes were 4 inches from {the start ofthe weld to allow equilibrium to develop. It was found thatthe existence ofthese holes does not affect the temperature field during the welding process [9]. Three depths of holes (1.59 ‘mm, 3.18 mm and 4,76 mm) are used to measure the temperature field at one quarter, one half, and three quarters ofthe plate thickness, The thermocouples were inserted and secured tothe bot- tom of the hole from the back side of the specimen. Thermally conducting paste was packed in the holes to seat the thermocouples. The temperature was recorded digitally using a National In- struments SCXI-1000 amplifier and Labview. Temperatures were sampled at 60 Hz so that sev~ eral samples were taken per revolution ofthe nib. Digital signal smoothing was used as necessary to remove noise. RESULTS AND DISCUSSION Weld Temperature History A cross section ofa friction str weld is shown in Figure 2 and a typical welding temperature history at different positions from the weld center is shown in Figure 3. Itis seen that the welding temperature, including the peak temperature at the weld center, which is about 450°C, is below the melting temperature ofthe 6061 aluminum, which is 582°C [10]. The specimen after welding Heat Input and Temperature Distribution in Friction Stir Welding 165 eee shows that the weld center thermocouple was not destroyed by the pin tool but did change posi- tion slightly due to workpiece plastic flow, Microstructures ofthe welded joint also showed that thore was no melting during the welding process. As expected, the friction stir welding process solid state welding process, and welding defects such as porosity and hot cracking are avoided, ‘Atthe same time, withthe stir and deformation process, the grain size of the welded zone is nota- bly smaller and more equiaxed than that of the parent aluminum as a result of dynamic recrystallization [5,7,8] Figures 4(a) and 4(b) show for comparison the original workpiece grain structures in con- trast tothe recrystallized grain structure in the weld center, respectively as observed by optical ‘metallography. Figures 4(c) and 4(d) show these corresponding microstructures as observed in the transmission electron microscope. The initial workpiece microstructure (Figure 4(c)} is char- acterized by dense dislocation cells and tangles while the recrystallized grains within the weld zone (Figure 4(d)] contain a considerably reduced dislocation density and distributed precipita- tion similar to the original material. In addition, Murr et al. [8] have previously shown a wide variation in precipitation phenomena near the edges of the weld zone (Figure 2) and within a transition region which extends from about & to 15 mm on either side ofthe weld center line. This variation includes Guiniet-Preston-like precipitates atthe furthest distance, Widmanstatten ar- [Pormmaremm | |°° Temperature in celsius 3 ‘Temperatureusion temperature Time in second Figure 2, Typcol temperature-time dota fore weld mode ot 400 rpm ond 2 mm/sec travel speed. Curves repro. Sant the fomporatre history ot different dlstarces from weld centering 16 \W, TANG, X.QUO,1.C. MeCLURE. LE. MURR and A. NUNES Figure 4. Comperison f intl 6061-7 aluminum workpiace and weld zone microstructures. (a) ntl goin Sincture observed by ight metalogrophy. fb] Typical weld tone grain srctoreebserved by ght mictoscopy. (el TEM moge showng dislocation sructrein (od TEM image showing coresponding micros homogeneously dsinbutedpraciatotes. Magnifcations in (a) ond (b) are some, Magri rein (b} Note in and () ore Heat Input and Temperature Distribution in Friction Stir Welding 167 rays of plate-like precipitates, and the more homogeneous precipitate particles in the weld zone are shown in Figure 4(d). These variations in precipitation microstructures were attributed 10 temperature variations or temperature field distributions, In this case, when the temperature in- creases and decreases continuously, the homogeneous precipitate, Widmanstatten arrays of plate-like precipitates, and the Guinier Preston-like precipitates occur in regions where the peak temperatures were 450°C, 398°C, and 363°C, respectively ‘TEMPERATURE FIELD DISTRIBUTION From the temperature recorded during the welding process, the welding temperature disti- bution at different points away from the welding centerline and welding top surface could be de- termined. The peak temperature distribution at 00 rpm rotational speed is shown in Figure 5 for different depths below the top surface ofthe workpiece, The region near the nib is nearly isother- ‘mal suggesting that plastic deformation occurs away from the nib. From Figure 5 itis clear that the peak temperature gradient inthe thickness direction of the welded joint is not large, and the fact thatthe grain sizes throughout the weld zone do not change appreciably from those shown in Figure 4(b) supports this conclusion. Welds made with a smaller shoulder radius to workpiece thickness ratio may show some gradient, however. Lower thermal conductivity materials than aluminum may also show some gradient ‘A contraction ofthe isotherms with depth can be seen in Figure 6 due to the heat sinking of the backup plate below the workpiece and due to the greater distance from the shoul-

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