Charles Darwin University

CDU eSpace
Institutional Repository

 
CDU Staff and Student only
 

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
Citation counts: Google Scholar Search Google Scholar
Attached Files (Some files may be inaccessible until you login with your CDU eSpace credentials)
Name Description MIMEType Size Downloads
Download this reading Thesis_CDU_60246_Camilleri_C.pdf PDF version generated by student application/pdf 3.09MB 35
Reading the attached file works best in Firefox, Chrome and IE 9 or later.

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
Subjects ENGINEERING
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
microstructure
bend test
hardness


© copyright

Every reasonable effort has been made to ensure that permission has been obtained for items included in CDU eSpace. If you believe that your rights have been infringed by this repository, please contact digitisation@cdu.edu.au.

 
Versions
Version Filter Type
Access Statistics: 17 Abstract Views, 35 File Downloads  -  Detailed Statistics
Created: Mon, 13 Feb 2017, 14:41:43 CST by Jessie Ng