The Effect of Main Factors on Forces during FSJ Processing of AA2024 Aluminum
An attempt is made here to measure the forces of three directions, under conditions of different feed speeds, different tilt angles of tool and without or with the pin on the tool, by using octagonal ring dynamometer in the AA2024 aluminum FSJ (Friction Stir Joining) process, and investigate how four main factors influence forces in the FSJ process. It is found that, high feed speed lead to small feed force and small lateral force, but high feed speed leads to large feed force in the stable joining stage of process. As the rotational speed increasing, the time of axial force drop from the maximum to the minimum required increased in the push-up process. In the stable joining stage, the rotational speed has little effect on the feed force; large rotational speed leads to small lateral force and axial force. The maximum axial force increases as the tilt angle of tool increases at the downward movement stage. At the moment of start feeding, as tilt angle of tool increases, the amplitudes of the axial force increasing become large. In the stable joining stage, with the increase of tilt angle of tool, the axial force is increased, the lateral force is decreased, and the feed force almost unchanged. The tool with pin will decrease axial force in the downward movement stage. The feed force and lateral force will increase, but the axial force will reduced in the stable joining stage by using the tool with pin compare to by using the tool without pin.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1127852Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 680
 Thomas WM. Friction stir butt welding. International patent PCT/GB92/02203, 1991.
 R.S. Mishra, Z.Y. Ma. Friction stir welding and processing (J). Materials Science and Engineering
 Yongfang Deng, Dunwen Zuo, Bo Song. Friction stir welding eccentric extrusion flow model (J). Transactions of the China Welding Institution, 2013, 12(34): 41-45.
 G.R. Cui, Z.Y. Ma, S.X. Li. The origin of non-uniform microstructure and its effects on the mechanical properties of a friction stir processed Al-Mg alloy (J). Acta Materialia, 2009, 57(19): 5718-5729.
 T.R. McNelley, S. Swaminathan, J.Q. Su. Recrystallization mechanisms during friction stir welding/processing of alumimum alloys (J). Scripta Materialia, 2008, 58(5):349-354.
 C.D. Sorensen, A. Stahl. Experimental Measurements of Load Distributions on Friction Stir Weld Pin Tools (J). Metallurgical and Materials Transactions B, 2007, 38(3): 451-459.
 K. Kumar, S.V. Kailas. On the role of axial load and the effect of interface position on the tensile strength of a friction stir welded aluminium alloy (J). Materials and Design, 2008, 29(4): 791-797.
 K. Elangovan, V. Balasubramanian, M. Valliappan. Influences of tool pin profile and axial force on the formation of friction stir processing zone in AA6061 aluminium alloy (J). Int J Adv Manuf Technol, 2008, 38(3): 285-295.
 R. Crawford, G.E. Cook, A.M. Straussl, D.A. Hartman, M.A. Stremler. Experimental defect analysis and force prediction simulation of high weld pitch friction stir welding (J). Science and Technology of Welding and Joining, 2006, 11(6): 657-665.
 Xijing Wang, Zhongke Wang, Daobin Han, Changqing Zhang. Measurements and analysis of onward force on stir-pin in FSW process (J). Transactions of the China Welding Institution, 2010, 31(4): 1-4.
 Xijing Wang, Ruijie Guo, Shujin Chen, Rong A. Calculating and measuring of heating power of friction stir welding (J). Transactions of the China Welding Institution, 2004, 25(4): 93-95.
 A. Arora, T. Debroy, H.K.D.H. Bhadeshia. Back-of-the-envelope calculations in friction stir welding – Velocities, peak temperature, torque, and hardness (J). Acta Materialia, 2011, 59(5): 2020-2028.
 G. Buffa, J.Hua, R. Shivpuri, L.Fratini. A continuum based fem model for friction stir welding – model development (J). Materials Science and Engineering A, 2006, 419(1-2): 389-396.