Simulation of heat transfer and analysis of impact of tool pin geometry and tool speed during friction stir welding of A
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DOI 10.1007/s12206-020-0916-7
Journal of Mechanical Science and Technology 34 (10) 2020 Original Article DOI 10.1007/s12206-020-0916-7 Keywords: · AZ80A Mg alloy · Friction stir welding · Mechanical process model · Peak temperature · Tool pin geometry · Tool speed
Simulation of heat transfer and analysis of impact of tool pin geometry and tool speed during friction stir welding of AZ80A Mg alloy plates S. D. Dhanesh Babu1, P. Sevvel2 and R. Senthil Kumar2 1
Correspondence to: P. Sevvel [email protected]
Department of Mechanical Engineering, St. Joseph College of Engineering, Sripeumbudur 602 117, 2 India, Department of Mechanical Engineering, S.A. Engineering College, Chennai 600 077, India
Abstract
Citation: Babu, S. D. D., Sevvel, P., Kumar, R. S. (2020). Simulation of heat transfer and analysis of impact of tool pin geometry and tool speed during friction stir welding of AZ80A Mg alloy plates. Journal of Mechanical Science and Technology 34 (10) (2020) ?~?. http://doi.org/10.1007/s12206-020-0916-7
Received March 25th, 2020 Revised
June 21st, 2020
Accepted July 21st, 2020
Peak temperature arising during the joining of metals by friction stir welding (FSW) needs to be investigated along with other process parameters of FSW to understand their inevitable impact on joint quality. This investigational and experimental analysis aims to determine the impact of pin geometry and its rotational speed by formulating thermic mechanical process-based models to anticipate peak temperature and to compare it with actual values. Three distinctive pin geometries rotated at three speeds were used while other parameters were unchanged. The fitness and suitability of the model were verified by comparing the anticipated values with the experimental values. Macrographic and micrographic observations revealed that flawless joints with improved mechanical properties were fabricated at a peak temperature of 616 K (80 % melting temperature) when a taper cylindrical pin with a rotational speed of 818 rpm was employed. In addition, SEM analysis of the fractured specimen confirmed that failure of the defect free weldment occurred in brittle mode, indicating that preferred fusion of grains and their constituents occurred during the joining process.
† Recommended by Editor Hyung Wook Park
1. Introduction
© The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature 2020
In this modern era, Mg alloys, especially low-density alloys (e.g., AZ80A), are widely used in various automobile and aerospace applications, including parts for gearboxes of helicopters, frames of bicycles, struts of landing gear, and hubs of rotors, because of their unique strength (specific strength) and rigidities, attractive capacities of damping, and stable dimension before and after machining [1, 2]. Most components of Mg alloys are obtained through casting techniques, and some components are formed through other techniques, such as plastic forming. With the increasing applicability of Mg alloys for various industr
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