Feasibility Study of Friction Stir Welding Application for Kevlar Material

Authors: Ahmet Taşan, Süha Tirkeş, Yavuz Öztürk, Zafer Bingül

Abstract:

Friction stir welding (FSW) is a joining process in the solid state, which eliminates problems associated with the material melting and solidification, such as cracks, residual stresses and distortions generated during conventional welding. Among the most important advantages of FSW are; easy automation, less distortion, lower residual stress and good mechanical properties in the joining region. FSW is a recent approach to metal joining and although originally intended for aluminum alloys, it is investigated in a variety of metallic materials. The basic concept of FSW is a rotating tool, made of non-consumable material, specially designed with a geometry consisting of a pin and a recess (shoulder). This tool is inserted as spinning on its axis at the adjoining edges of two sheets or plates to be joined and then it travels along the joining path line. The tool rotation axis defines an angle of inclination with which the components to be welded. This angle is used for receiving the material to be processed at the tool base and to promote the gradual forge effect imposed by the shoulder during the passage of the tool. This prevents the material plastic flow at the tool lateral, ensuring weld closure on the back of the pin. In this study, two 4 mm Kevlar^® plates which were produced with the Kevlar^® fabrics, are analyzed with COMSOL Multiphysics in order to investigate the weldability via FSW. Thereafter, some experimental investigation is done with an appropriate workbench in order to compare them with the analysis results.

Keywords: Analytical modeling, composite materials welding, friction stir welding, heat generation.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.3298910

References:

[1] K. Kumar, Satish V. Kailas, “The Role Of Friction Stir Welding Tool On Material Flow and Weld Formation”, Materials Science and Engineering A 485 (2008) 367–37.
[2] The ESAB Way, Friction Stir Welding.
[3] Rajiv S. Mishra, “Center for Friction Stir Processing, University Of Missouri”, Rolla Murray W. Mahoney, Rockwell Scientific Company B.
[4] Jeroen De Backer, Bert Verheyden, “Robotic Friction Stir Welding for Automotive and Aviation Applications”.
[5] R. Rai, A.De, H. K. D. H. Bhadeshia and T. DebRoy, “Review: Friction stir Welding Tools”.
[6] DPT Kevlar Technical Guide, Aramid Fiber.
[7] Rene Lohmann, Sales & Marketing Ballistics, Teijin Aramid GmbH, Techtextile Middle East Symposium, Dubai, 20 th February 2014.
[8] Kerem Altuğ GÜLER, “Uçak Yapımında Kullanılan Malzemeler Ve Özelliklerinin İncelenmesi (Bitirme Tezi)”, Yıldız Teknik Üniversitesi Kimya-Metalurji Fakültesi Metalurji Ve Malzeme Mühendisliği Bölümü.
[9] Vijay Shivaji Gadakha, Kumar Adepu, “Heat Generation Model For Taper Cylindrical Pin Profile In FSW”.
[10] Friction Stir Welding, Solved with COMSOL Multiphysics 4.1.
[11] Basil M. Darras, “Experimental And Analytical Study Of Friction Stir Processing, University of Kentucky”.
[12] S. Cui, Z.W. Chen, J.D. Robson, “A Model Relating Tool Torque and It’s Associated Power and Specific Energy To Rotation and Forward Speeds During Friction Stir Welding/Processing”, Department of Mechanical and Manufacturing Engineering, AUT University, NZ.
[13] James,R.S. 1990. “Aluminum-Lithium Alloys”, Metal Handbook Tenth Edition, Volume 2: Properties and Selection: “Nonferrous Alloys and Special-Purpose Materials”, ASM International: Metals Park, OH.178-199.
[14] Hill,R. 1956, “The Mathematical Theory of Plasticity”, Oxford at the Clarendon Press.
[15] M. A. Martinez, C. Navarro, R. CorteS, J. Rodriguez, V. Sanchez- Galvez, “Friction and Wear Behaviour of Kevlar Fabrics”, Department of Materials Science, E. T. S, Ingenieros de Caminos, Canales y Puertos, Polytechnic University of Madrid, Ciudad Universitaria s/n, 28040 Madrid, Spain.
[16] B. Saha Roy, T. Medhi, S. C. Saha, “Material Flow Modeling in Friction Stir Welding of AA6061-T6 Alloy and Study of the Effect of Process Parameters”, World Academy of Science, Engineering and Technology International Journal of Materials and Metallurgical Engineering Vol:9, No:6, 2015.
[17] Dr. Yong Gan, “Continuum Mechanics-Progress in Fundamentals and Engineering Applications”.
[18] James E. Mark, “Polymer Data Handbook”, University Of Cincinnati.
[19] Brett D. Sanborn, Tusit T. Weerasooriya, “Effect of Strain Rates and Pre-Twist on Tensile Strength of Kevlar KM2 Single Fiber”, Oak Ridge Institute for Science and Education, Weapons and Materials Research Directorate, ARL.
[20] Wagner et al, “United States Patent Application Publication”, Pub. No.: US 2006/0234572 A1.
[21] Diana Serbezeanu, Ana Maria Popa, Timea Stelzi, Ion Sava, Rene ´ M Rossi and Giuseppino Fortunato, “Preparation and characterization of thermally stable polyimide membranes by electrospinning for protective clothing applications”.