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Search results for: UNDERWATER FRICTION STIR WELDING
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Thermo-Mechanical Simulation of Underwater Friction Stir Welding of Low Carbon Steel
PublicationThis article investigates the flow of materials and weld formation during underwater friction stir welding (UFSW) of low carbon steel. A thermo-mechanical model is used to understand the relation between frictional heat phenomena during the welding and weld properties. To better understand the effects of the water environment, the simulation and experimental results were compared with the sample prepared by the traditional friction...
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Effect of underwater friction stir welding parameters on AA5754 alloy joints: experimental studies
PublicationThe water as a welding environment may generate serious technological and metallurgical problems but in certain cases, the physicochemical properties of water can be used effectively, e.g., to impart the specific properties of welded materials. The purpose of the work was verification of effectiveness of the water cooling of aluminium alloy AA5754 for various sets of technological parameters of underwater friction stir welding...
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Investigation of Mechanical and Microstructural Properties of Welded Specimens of AA6061-T6 Alloy with Friction Stir Welding and Parallel Friction Stir Welding Methods
PublicationThe present study investigates the effect of two parameters of process type and tool offset on tensile, microhardness, and microstructure properties of AA6061-T6 aluminum alloy joints. Three methods of Friction Stir Welding (FSW), Advancing Parallel-Friction Stir Welding (AP-FSW), and Retreating Parallel-Friction Stir Welding (RP-FSW) were used. In addition, four modes of 0.5, 1, 1.5, and 2 mm of tool offset were used in two welding...
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Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review
PublicationThe use of the friction stir welding (FSW) process as a relatively new solid-state welding technology in the aerospace industry has pushed forward several developments in different related aspects of this strategic industry. In terms of the FSW process itself, due to the geometric limitations involved in the conventional FSW process, many variants have been required over time to suit the different types of geometries and structures,...
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Influence of friction stir welding technological parameters on the properties of the joints of selected aluminum alloys
PublicationThe purpose of this dissertation was to determine the effect of friction stir welding technological parameters on the properties of selected aluminum alloy joints, with consideration of the residual stresses and dislocation density in the joints. The goal of the present work was also to produce defect-free joints with high mechanical and electrochemical properties. In the dissertation, similar welds of AA6082 alloy and dissimilar...
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Induction Assisted Hybrid Friction Stir Welding of Dissimilar Materials AA5052 Aluminium Alloy and X12Cr13 Stainless Steel
PublicationThis research aimed to study the induction in-situ heated hybrid friction stir welding (IAFSW) method to join AA5052 aluminium alloy with X12Cr13 stainless steel (SS) to enhance joint strength. The potency of this method on the mechanical properties and microstructural characterizations were also investigated. The results show that the transverse tensile strength gained was 94% of the AA5052 base metal that is 229.5 MPa. This superior...
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Pin Angle Thermal Effects on Friction Stir Welding of AA5058 Aluminum Alloy: CFD Simulation and Experimental Validation
PublicationThe friction stir welding (FSW) of tool pin geometry plays a critical role in the final properties of the produced joint. The tool pin geometry directly affects the generation of heat and the flow of internal materials during the FSW process. The effects of the FSW tool pin angle on heat generation and internal flow have not been quantitatively investigated in detail. In this manuscript, a validated Computational Fluid Dynamic...
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Artificial neural network based fatigue life assessment of friction stir welding AA2024-T351 aluminum alloy and multi-objective optimization of welding parameters
PublicationIn this paper, the fracture behavior and fatigue crack growth rate of the 2024-T351 aluminum alloy has been investigated. At first, the 2024-T351 aluminum alloys have been welded using friction stir welding procedure and the fracture toughness and fatigue crack growth rate of the CT specimens have been studied experimentally based on ASTM standards. After that, in order to predict fatigue crack growth rate and fracture toughness,...
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Temperature Evolution, Material Flow, and Resulting Mechanical Properties as a Function of Tool Geometry during Friction Stir Welding of AA6082
PublicationThe friction stir welding process was simulated for joining AA6082 aluminum alloy with the use of the computational fluid dynamics method. Two different tool geometries were used—a tapered cylindrical pin (simple pin) and a hexagonal pin with grooves (complex pin). The analysis of the simulations performed was discussed in terms of temperature evolution during the process, total heat input, residual stresses and material flow....
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Review on friction stir welding of dissimilar magnesium and aluminum alloys: Scientometric analysis and strategies for achieving high-quality joints
PublicationMagnesium and aluminum alloys continually attract interest as lightweight structural materials for transport applications. However, joining these dissimilar alloys is very challenging. The main obstacle that hinders progress in dissimilar Mg-Al joining is the formation of brittle intermetallic compounds (IMCs). As a solid-state joining technique, FSW is an excellent candidate to attenuate the deleterious IMC effects in dissimilar...
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Wpływ warunków zgrzewania metodą Friction Stir Welding na własności mechaniczne i jakość złączy ze stopu aluminium
PublicationW prezentacji przedstawiono wyniki badań nad wpływem warunków zgrzewania metodą FSW na jakość połączeń ze stopów aluminium.
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Wpływ warunków zgrzewania metodą Friction Stir Welding na własności mechaniczne i jakość złączy ze stopu aluminium
PublicationCelem niniejszych badań było porównanie wpływu kształtu narzędzia na złącze oraz uzyskanie wartości parametrów zgrzewania tarciowego z przemieszaniem (FSW) zapewniających najlepszą możliwą jakość złącza. Zastosowanym materiałem był stop aluminium EN AW-3004 (AlMn1Mg1). Według najlepszej wiedzy autorów dotychczas nie przedstawiono żadnych badań tego stopu w kwestii zgrzewania FSW. Złącza pięcioczołowe wykonano samodzielnie opracowanym...
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Investigation of the Effects of Tool Positioning Factors on Peak Temperature in Dissimilar Friction Stir Welding of AA6061-T6 and AA7075-T6 Aluminum Alloys
PublicationAmong the emerging new welding techniques, friction stir welding (FSW) is used frequently for welding high-strength aluminum alloys that are difficult to weld by conventional fusion-welding techniques. This paper investigated the effects of tool-positioning factors on the maximum temperature generated in the dissimilar FSW joint of AA6061-T6 and AA7075-T6 aluminum alloys. Three factors of plunge depth, tool offset, and tilt angle...
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Effects of polymer sealant interlayer on quality of EN AW-2024-T3 aluminum alloy lap joint prepared by friction stir welding
PublicationThis study investigates the influence of polymer interlayers on the mechanical properties and fracture behavior of friction stir welded EN AW-2024-T3 aluminum alloy joints. Aqualock AL 6002 (Adhesive_1) and 3M Adhesion Promoter 86A (Adhesive_2) were selected as polymeric sealants for EN AW-2024-T3 aluminum alloy interfaces. Force analysis revealed that the choice of polymer interlayer significantly affects the axial force during...
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Zgrzewanie tarciowe z mieszaniem wewnętrznym zgrzeiny stopów aluminium AW7075-T651 i AW6082-T6 = Friction stir welding of aluminium alloys AW-7075-t651 and AW-6082-t6
PublicationW pracy przedstawione są wyniki badań nad złączami doczołowymi zgrzewanymi przy użyciu technologii Friction Stir Welding (FSW), wykonanymi z wysokowytrzymałego stopu Al-Zn (AW-7075-T651) oraz stopu Al-Mg2Si (AW-6082-T6) o wysokiej odporności na korozję. Stop AW-7075-T651 okazał się bardziej podatny na obniżenie własności mechanicznych w odniesieniu do materiału rodzimego. Złącza ze stopu AW-6082-T6 wykazały się lepszą plastycznością....
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Jacek Tomków dr hab. inż.
PeopleEducation:1. 2018 - Ph.D. of Technical Sciencesin field of Materials Engineeringthesis: Influence of underwater welding conditions on cold cracking of high strength low alloy steel 2. 2012 - Master of Science Engineer, Gdansk University of Technologyin the field of: Mechanical Engineeringwith specialization in: Manufacturing Engineering and Computer Aided Manufacturing Processesthesis: Non-destructive testing of welding joints...
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Assessment of Corrosive Behaviour and Microstructure Characterization of Hybrid Friction Stir Welded Martensitic Stainless Steel
PublicationThis study examined the effect of induction heating on the microstructure and corrosion characteristics of hybrid friction stir welded AISI 410 stainless steel. Five joints have been produced with different friction stir welding parameters like welding speed, spindle speed, plunge depth, and induction power. Their microstructures were evaluated using a scanning electron microscope, and chemical composition was examined using...
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Effect of Processing Parameters on Strength and Corrosion Resistance of Friction Stir-Welded AA6082
PublicationThe friction stir welding method is increasingly attracting interest in the railway sector due to its environmental friendliness, low cost, and ease of producing high-quality joints. Using aluminum alloys reduces the weight of structures, increasing their payload and reducing fuel consumption and running costs. The following paper presents studies on the microstructure, strength, and corrosion resistance of AA6082 aluminum alloy...
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Corrosion Properties of Dissimilar AA6082/AA6060 Friction Stir Welded Butt Joints in Different NaCl Concentrations
PublicationA solid-state friction stir welding method which is increasingly used in the marine and shipbuilding industry, has been developed to produce welds with high mechanical properties. In seawater, the oxide layer of aluminium is attacked by Cl− ions resulting in its disruption and formation of pitting corrosion. It is particularly important to determine the electrochemical properties of the produced welds and to evaluate the efect...
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Manufacturing Parameters, Materials, and Welds Properties of Butt Friction Stir Welded Joints–Overview
PublicationThe modern and eco-friendly friction stir welding (FSW) method allows the combination of even such materials that are considered to be non-weldable. The development of FSW technology in recent years has allowed a rapid increase in the understanding of the mechanism of this process and made it possible to perform the first welding trials of modern polymeric and composite materials, the joining of which was previously a challenge....
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Effect of Porosity on the Thermo-Mechanical Behavior of Friction-Stir-Welded Spark-Plasma-Sintered Aluminum Matrix Composites with Bimodal Micro- and Nano-Sized Reinforcing Al2O3 Particles
PublicationThe thermo-mechanical behavior of nanosized Al2O3 particles reinforcing aluminum was analyzed in the present paper. The material was prepared by spark plasma sintering and friction stir welding. The thermal stresses affecting the composite behavior during welding were modeled through COMSOL MultiPhysics, and the results were validated by the analyses of the composites’ mechanical properties. The spark-plasma-sintered materials...
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Effect of processing parameters on the cyclic behaviour of aluminium friction stir welded to spark plasma sintered aluminium matrix composites with bimodal micro-and nano-sized reinforcing alumina particles
PublicationUnderstanding the cyclic behaviour of Alumina reinforced Aluminium composites (Al-A2O3) was of critical importance, for their further application in the different industrial sectors. The present study is focussing on the cyclic behaviour of the Al-Alumina nanocomposite produced through the combination of spark plasma sintering (SPS) method and friction stir welding (FSW). The added Alumina with total content of 10% is the combination...
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The Influence of Tool Shape and Process Parameters on the Mechanical Properties of AW-3004 Aluminium Alloy Friction Stir Welded Joints
PublicationThe purpose of the following study was to compare the effect of the shape of a tool onthe joint and to obtain the values of Friction Stir Welding (FSW) parameters that provide the bestpossible joint quality. The material used was an aluminium alloy, EN AW-3004 (AlMn1Mg1). To theauthors’ best knowledge, no investigations of this alloy during FSW have been presented earlier. Fivebutt joints were made with a self-developed, cylindrical,...
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Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation
PublicationThis article studied the effects of pin angle on heat generation and temperature distribution during friction stir welding (FSW) of AA1100 aluminum alloy and St-14 low carbon steel. A validated computational fluid dynamics (CFD) model was implemented to simulate the FSW process. Scanning electron microscopy (SEM) was employed in order to investigate internal materials’ flow. Simulation results revealed that the mechanical work...
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Analysis of Residual Stresses and Dislocation Density of AA6082 Butt Welds Produced by Friction Sir Welding
PublicationThe Friction Stir Welding (FSW) method was employed to join AA6082 sheets. The welds were produced with different tool traverse speed (200 and 250 mm/min), rotational speed (1000 and 1250 RPM) and tool tilt angle (0 and 2 deg). Based on the analysis of XRD patterns, the total precipitation volume fractions in the nugget zones and the base material were calculated. The FSW process resulted in a reduction in the fraction of precipitates...
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Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6
PublicationFriction Stir Welding (FSW) is a solid-state bonding technique. There are many direct and indirect factors affecting the mechanical and microstructural properties of the FSW joints. Tool offset, tilt angle, and plunge depth are determinative tool positioning in the FSW process. Investigating the effect of these factors simultaneously with other parameters such as process speeds (rotational speed and translational speed) and tool...
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Influence of the Tool Rotational Speed on Physical and Chemical Properties of Dissimilar Friction-Stir-Welded AA5083/AA6060 Joints
PublicationAluminum alloys have been successfully used in the railroad and automotive industries because of their potential to significantly reduce component weights, and their good mechanical and anti-corrosion properties. Problems with joining aluminum alloys are characterized by low weldability, which influences the need for studies focused on unconventional methods. The environmentally friendly and low-cost friction-stir-welding method...
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Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation
PublicationOne of the main challenging issues in friction stir welding (FSW) of stiffened structures is maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD) method can help understand TPD effects on FSW...
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Assessment of FSW Welds Made of Aluminum Alloy AW7075-T651.
PublicationThis paper summarizes the results of experimental studies in which the aluminum alloy AW7075-T651 was friction stir welded (FSW) using various combinations of process parameters (rotational - R and travel speed - T). Mechanical properties of the test welds were assessed by using static tensile test and Vickers hardness measurement. The temperature of the welded plates was monitored during welding by means of thermocouples placed...
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Underwater Welding of Duplex Stainless Steel
PublicationThe present work was conducted to assess the weldability of duplex stainless steel at underwater conditions. Interest of underwater welding of this steel grade is connected with necessity of preparing welding repair technologies for subsea pipelines widely used in offshore oil and gas industry. The GMA local cavity welding method was used in the investigations. Welded beads were performed underwater at 0.5 m depth and in the air....
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The Effects of Pin Profile on HDPE Thermomechanical Phenomena during FSW
PublicationFriction stir welding (FSW) of polymeric materials has recently attracted significant attention. Herein, we present the effect of the tool pin profile on the FSW of high-density polyethylene (HDPE) joints through joint experimental analysis and thermomechanical simulations. For analysis of pin profile effects on the thermomechanical properties of HDPE joints, frustum (FPT), cubic (CPT), and triangular (TPT) pin shapes were selected...
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Development of a Friction Welding System for CNC Lathes
PublicationDedicated friction welding machines are sturdy in order to handle large process forces but expensive. Thus, it is proposed to equip two axis CNC lathes with an add-on direct drive friction welding system as an affordable solution for occasional use. The first part to be welded is clamped on the lathe chuck, whilst the second part is clamped on a dedicated chuck on the tailstock. The latter is programmed to follow three phases:...
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Role of bead sequence in underwater welding
PublicationThis paper presents examinations of the role of the bead sequence in underwater welding. Two specimens of wet welded layers made by covered electrodes with the use of normalized S355G10+N steel were welded by a reasonable bead sequence. For each specimen, metallographic macro- and micro-scopic tests were done. Then, Vickers HV10 hardness measurements were conducted for each pad weld in the welded layer. The results show that welding...
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Dissimilar underwater wet welding of HSLA steels
PublicationThe high-strength low-alloy S460ML and S460N steels were chosen for underwater wet welding of dissimilar T-joints using covered electrodes. For improving the quality of joints, the temper bead welding (TBW) method was used. The application of TBW in pad welding conditions has been investigated earlier but the possibility of usage of this technique in welded joints was not analyzed. The main aim of the study was to check the influence...
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Underwater Local Cavity Welding of S460N Steel
PublicationIn this paper, a comparison of the mechanical properties of high-strength low-alloy S460Nsteel welded joints is presented. The welded joints were made by the gas metal arc welding (GMAW)process in the air environment and water, by the local cavity welding method. Welded joints were testedfollowing the EN ISO 15614-1:2017 standard. After welding, the non-destructive—visual, penetrant,radiographic, and ultrasonic (phased array) tests...
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Bead-on-Plate Underwater Wet Welding on S700MC Steel
PublicationThe participation of high strength steels in marine and offshore structures is increasing, which makes it necessary to develop recommendations for underwater repair welding works. The article presents the results of bead-on-plate welded specimens made of S700MC high strength steel in underwater wet welding conditions by covered elec- trodes. Three specimens with heat input values in the range 0.91-1.05 kJ/mm were made. The specimens...
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Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6)
PublicationIn this study, the effects of the traverse and rotational velocities of the noncontact shoulder tool on the heat generation and heated flux during the friction stir joining of high-density polyamide 6 (PA6) polymer were investigated. The computational fluid dynamics (CFD) method was employed to simulate the thermomechanical phenomena during the friction stir joining (FSJ) process of PA6. A developed model was used to consider the...
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Underwater wet welding of S1300 ultra-high strength steel
PublicationMarine Structures Volume 81, January 2022, 103120 Underwater wet welding of S1300 ultra-high strength steel Author links open overlay panelJacekTomkówGrzegorzRogalski https://doi.org/10.1016/j.marstruc.2021.103120 Get rights and content Under a Creative Commons licenseopen access Highlights • Technological method of S1300 steel underwater weldability improving was proposed. • Number of cracks and hardness of welded joints was...
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Underwater Wet Repair Welding of API 5L X65M Pipeline Steel
PublicationThis paper presents results of the research of effect of polymer insulation of pipeline made of API 5L X65M steel as well as underwater wet welding parameters on properties of joints made by covered electrodes. Effect of heat input on structure and hardness of joints during repair of underwater pipeline was analyzed. Welding defects like microcracks, micro-lacks of fusion, slag inclusions, as well as HAZ hardness increase over...
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Effect of underwater wet welding conditions on the diffusible hydrogen content in deposited metal
PublicationIn the study mercury displacement method was used for determination of diffusible hydrogen amount in deposited metal obtained during underwater wet welding with covered electrodes in laboratory conditions according to a two-level full factorial design for three factors. The factors and their levels were chosen among conditions and parameters of welding in accordance with the results of own preliminary studies. A statistical analysis...
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THE EFFECT OF WET UNDERWATER WELDING ON COLD CRACKING SUSCEPTIBILITY OF DUPLEX STAINLESS STEEL
PublicationABSTRACT The present work was conducted to assess the weldability of duplex stainless steel in underwater conditions. Metal manual arc welding (MMA) with the use of coated electrodes was used in the investigations. Tekken weldability tests were performed underwater at 0.5 m depth and in the air. Nondestructive tests, metallographic examinations of welds, ferrite content assessment in microstructure and hardness test were performed....
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Underwater welding - a review
PublicationW artykule przedstawiono stan obecny oraz perspektywy rozwoju technik spawania pod wodą. Przeanalizowano najważniejsze problemy spawania w środowisku wodnym. Przedstawiono najważniejsze kierunki badań spawania podwodnego podejmowane w Katedrze Technologii Materiałów Maszynowych i Spawalnictwa Politechniki Gdańskiej
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Bead-on-plate welding on S235JR steel by underwater local dry chamber process
PublicationThe article presents the results of the effect of parameters of underwater local dry chamber welding on the properties of padding welds. The effect of heat input and the type of shielding gas on the structure and hardness of welds was established. the functions for estimating the maximum hardness of the heat affected zone have been also elaborated.
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Determination of t8/5 cooling times for underwater local dry welding of steel
PublicationKnowledge of thermal history is the basic condition for studying the structure - properties of welded joints. The determinant of thermal history is the thermal cycle, whose in-situ measurements are still a big challenge. Water as the welding environment complicates this issue even more. The article presents a method to determine an equation for calculating t8/5 cooling times for underwater gas metal arc welding of unalloyed steels...
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Effect of underwater local cavity welding method conditions on diffusible hydrogen content in deposited metal
PublicationOne of the methods with great potential for applications in underwater repairs is local cavity welding. In local cavity method, cooling conditions and diffusible hydrogen amount in weld metal are nearly the same as those existed during welding in the air. This paper presents the results of literature survey and preliminary tests of the effect of local cavity welding conditions on diffusible hydrogen amount in a deposited metal....
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Diffusible hydrogen management in underwater wet self-shielded flux cored arc welding
PublicationThis article reports the effect of underwater wet welding parameters and conditions on the diffusible hydrogen content in deposited metal for welding with a self-shielded flux cored wire. The diffusible hydrogen content in deposited metal was determined using the glycerin method according to the Plackett-Burman design determining the significance of the effect of the stick out length, welding current, arc voltage, travel speed...
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Operational Performance and Weld Bead Characteristics of Experimental Tubular-Wires for Underwater Welding
PublicationAiming to evaluate new formulations and their operational behavior underwater, two experimental tubular wires with different chemical compositions in their internal flux were initially manufactured, employing a pilot machine and a unique manufacturing process. Weld beads were deposited on a plate placed in a flat position inside a tank using a mechanized system and the IMC 300 welding power source. The work was done at a depth...
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Investigation on polypropylene friction stir joint: effects of tool tilt angle on heat flux, material flow and defect formation
PublicationTool tilt angle (TTA) is a critical factor that can control material flow in polymeric materials' friction stir joining (FSJ). This study selected a TTA range between 0° to 4° for FSJ of polypropylene (PP) polymer sheet. A modified computational fluid dynamic (CFD) technique was implemented to gain a deep understanding of the effects of TTA during FSJ of PP. The PP joint's internal flow, defect formation, heat generation, and tensile...
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Friction stir welds (FSW) of aluminium alloy AW6082-T6
PublicationW pracy przedstawiono badania właściwości mechanicznych złącz stopu aluminium AW6082-T6 wykonanych metodą tarciowego zgrzewania z wymieszaniem zgrzeiny. Złącza wykonano z różnymi parametrami procesu technologicznego. Wykazano, że wytrzymałość złącz jest proporcjonalna do prędkości zgrzewania oraz, że spadek twardości SWC jest większy po stronie ''advancing'' złącz.
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Mechanical and structural behavior of high-strength low-alloy steel pad welded by underwater wet welding conditions
PublicationThe aim of the paper was to determine the metallurgical and mechanical behaviors of a high-strength low-alloy (HSLA) steel pad-welded specimen used in the structures of industrial and naval parts. Then to predict the metallurgical consequences (nature of the phases present) and the mechanical properties (hardness and impact strength) of the pad-welded steel obtained by underwater wet welding with different heat input values. The...