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Design of tool parameters for friction stir welding

Camilleri, Callan (2016). Design of tool parameters for friction stir welding. Bachelor of Engineering (Honours) Thesis, Charles Darwin University.

Document type: Thesis
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Author Camilleri, Callan
Title Design of tool parameters for friction stir welding
Institution Charles Darwin University
Publication Date 2016-10
Thesis Type Bachelor of Engineering (Honours)
Supervisor Kannoorpatti, Krishnan
Thennadil, Suresh
0913 - Mechanical Engineering
Abstract This thesis report investigates how the parameters of friction stir welding tools affect the quality of welds. Specifically, the joining of 5 mm 6061-T6 aluminium alloy with four different tools was carried out and a relationship between tool parameters and weld quality was then determined. The four types of tools include; a flat shoulder with cylindrical threaded pin, flat shoulder with triangular pin, spiral shoulder with threaded triflute pin and concave shoulder with threaded pin. The design of the friction stir welding tools are based on literature reviewed. To analyse the quality of the welds microstructure, bend and hardness tests were conducted. The experimental setup consists of a milling machine with an adjustable spindle speed and transverse feed rate which was used to undertake friction stir welding. The welding parameters of spindle speed and transverse feed rate were kept constant throughout testing which allows only the tool geometry to affect the outcome of the welds.

Welds made with the triflute, cylindrical and concave tools were of a satisfactory condition whereas the triangular tool failed. Results from post weld analysis indicate that the triflute and concave tools have a coarse grain microstructure which leads to a lower hardness and a more ductile failure during the bend test. The cylindrical tool resulted in a fine grained microstructure and thus has a higher hardness and brittle failure. The triangular tool failed to produce a satisfactory weld due to failure in the pin which sheared off. Micro crack defects were found in all weld samples as well as a wormhole in welds made using the cylindrical tool and lack of root penetration with the triflute tool.
Keyword friction stir welding
aluminium alloy
tool pin profile
tool shoulder profile
bend test
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Created: Mon, 13 Feb 2017, 14:41:43 CST by Jessie Ng