Skip to main content
SpringerLink
Log in

Influence of the Tool Shoulder Contact Conditions on the Material Flow During Friction Stir Welding

  • Published:
Metallurgical and Materials Transactions A Aims and scope Submit manuscript

Abstract

Friction stir welding (FSWing) is a solid-state joining process of special interest in joining alloys that are traditionally difficult to fusion weld. In order to optimize the process, various numeric modeling approaches have been pursued. Of importance to furthering modeling efforts is a better understanding of the contact conditions between the workpiece and the weld tool. Both theoretical and experimental studies indicate the contact conditions between the workpiece and weld tool are unknown, possibly varying during the FSW process. To provide insight into the contact conditions, this study characterizes the material flow in the FSW nugget by embedding a lead (Pb) wire that melted at the FSWing temperature of aluminum alloy 2195. The Pb trace provided evidence of changes in material flow characteristics which were attributed to changes in the contact conditions between the weld tool and workpiece, as driven by temperature, as the tool travels the length of a weld seam.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20

Similar content being viewed by others

References

  1. W.M. Thomas, E.D. Needham, M.G. Murch, P. Templesmith, and C.J. Dawes: International Patent Application No. PCT/GB92/02203 and GB Patent Application No. 9125978.9, 1991.

  2. A.C. Nunes, Jr.: Proc. Aluminum, TMS International, Materials Park, OH, 2001, pp. 235–48.

  3. J.A Schneider, A.C. Nunes, Jr.: Metall. Mater. Trans. B, 2004. vol. 35B, pp. 777-83.

    Article  Google Scholar 

  4. K. Colligan (1999) Weld. J. 78(7), pp. 229-37.

    Google Scholar 

  5. T.U. Seidel, A.P. Reynolds: Sci. Technol. Weld. Join., 2003, vol. 8, no. 3, pp. 175-83.

    Article  Google Scholar 

  6. M. Guerra, C. Schmidt, J.C. McClure, L.E. Murr, A.C. Nunes: Mater. Charact., 2003, vol. 49, pp. 95–101.

    Article  Google Scholar 

  7. Z.W. Chen, T. Pasang, Y. Qi: Mater. Sci. Eng. A, 2008, vol. 474, pp. 312–16.

    Article  Google Scholar 

  8. A.P. Reynolds: Scripta Mater., 2008, vol. 58, pp. 338–42.

    Article  Google Scholar 

  9. Y.H. Zhao, S.B. Lin, F.X. Qu, L. Wu: Mater. Sci. Technol., 2006, vol. 22, pp. 45–50.

    Article  Google Scholar 

  10. K. Kumar, S.V. Kailas: Mater. Sci. Eng. A, 2008, vol. 485, pp. 367–74.

    Article  Google Scholar 

  11. B. London, M. Mahoney, W. Bingel, M. Calabrese, R.H. Bossi, and D. Waldron: Friction Stir Welding Processing II, TMS International, Materials Park, OH, 2003, pp. 3–12.

  12. F. Gratecap, M. Girard, S. Marya, G. Racineux: Int. J. Mater. Form, 2011, vol. 5, pp. 99-107.

    Article  Google Scholar 

  13. K.N. Krishnan: Mater. Sci. Eng. A, 2002, vol. 327, pp. 246-51.

    Article  Google Scholar 

  14. R.M. Leal, C. Leitãoa, A. Loureiroa, D.M. Rodriguesa, P. Vilac: Mater. Sci. Eng. A, 2008, vol. 498, pp. 384–91.

    Article  Google Scholar 

  15. P.F. Mendez, K.E. Tello, T.J. Lienert: Acta Mater., 2010, vol. 58, pp. 6012-26.

    Article  Google Scholar 

  16. J.A. Schneider, R. Beshears, A.C. Nunes, Jr.: Mater. Sci. Eng. A, 2006, vol. 435-436, pp. 297-304.

    Article  Google Scholar 

  17. S. Xu, X. Deng: Acta Mater., 2008, vol. 56, pp. 1326–41.

    Article  Google Scholar 

  18. H. Zhang, S.B. Lin, L. Wu, J.C. Feng, S.L. Ma: Mater. Des., 2006, vol. 27, pp. 805–09.

    Article  Google Scholar 

  19. B. Yang, J. Yan, M.A. Sutton, A.P. Reynolds: Mater. Sci. Eng. A, 2004, vol. 364, pp. 55–65.

    Article  Google Scholar 

  20. Z.W. Chen, S. Cui: Scripta Mater., 2008, vol. 58, pp. 417–20.

    Article  Google Scholar 

  21. A. Scialpi, L.A.C. De Filippis, P. Cavaliere: Mater. Des., 2007, vol. 28, pp. 1124-29.

    Article  Google Scholar 

  22. H.N.B. Schmidt, T.L. Dickerson, J.H. Hattel: Acta Mater., 2006, vol. 54, pp. 1199–1209.

    Article  Google Scholar 

  23. S. Muthukumaran, S.K. Mukherjee: Sci. Technol. Weld. Join., 2006, vol. 11, pp. 337–40.

    Article  Google Scholar 

  24. S. Muthukumaran, S.K. Mukherjee: Int. J. Adv. Manuf. Technol., 2008, vol. 38, pp. 68–73.

    Article  Google Scholar 

  25. J.C. McClure, W. Tang, L.E. Murr, and X. Guo: Proc. 5th Int. Conf. Trends in Welding Res., Pine Mountain, GA, June 1998.

  26. Y.J. Chao, X. Qi, W. Tang: Trans. ASME, 2003, vol. 125, pp. 138-45.

    Google Scholar 

  27. O. Frigaard, O. Grong, O.T. Midling: Metall. Mater. Trans. A, 2011, vol. 32A, pp. 1189-1200.

    Google Scholar 

  28. P.Colegrove, M. Painter, D. Graham, and T. Miller: 2nd Int. Symp. FSWing, TWI, June 2000.

  29. P.A. Colegrove, H.R. Shercliff: Sci. Technol. Weld. Join., 2004, vol. 9, no. 6, pp. 483-92.

    Article  Google Scholar 

  30. P.A. Colegrove, H.R. Shercliff: J. Mater. Proc. Technol., 2005, vol. 169, pp. 320-27.

    Article  Google Scholar 

  31. H. Schmidt, J. Hattel: Model. Simul. Mater. Sci. Eng., 2005, vol. 13, pp. 77-93.

    Article  Google Scholar 

  32. B.C. Liechty, B.W. Webb, Int. J. Mach Tools Manuf., 2008, vol. 48, pp. 1474-85.

    Article  Google Scholar 

  33. H. Schmidt, J. Hattel, J. Wert: Model. Simul. Mater. Sci. Eng., 2004, vol. 12, pp. 143-57.

    Article  Google Scholar 

  34. M.Z.H. Khandkar, J.A. Khan, A.P. Reynolds: Sci. Technol. Weld. Join., 2003, vol. 8, no. 3, pp. 165-74.

    Article  Google Scholar 

  35. C.M. Chen, R. Kovacevic: Int. J. Mach. Tools. Manuf., 2003, vol. 43, pp. 1319-26.

    Article  Google Scholar 

  36. H. Schmidt, J. Hattel: Scripta Mater., 2008, vol. 58, pp. 332–37.

    Article  Google Scholar 

  37. J.A. Querin, J.A. Schneider: Weld. J. Supp., 2012, vol. 91, pp. 76s-82s.

    Google Scholar 

  38. J. Sanders: MSME Thesis, Mississippi State University, 2005.

  39. T.U. Seidel, A.P. Reynolds: Metall. Mater. Trans. A, 2001, vol. 32A, pp. 2879-84.

    Article  Google Scholar 

  40. H.A. Rubisoff, J.A. Schneider, and A.C. Nunes, Jr.: Friction Stir Welding & Processing-V, TMS International, Materials Park, OH, 2009.

  41. J.A. Schneider: Friction Stir Welding & Processing, chap. 3, ASM International, Materials Park, OH, 2007.

  42. W.G. Moffet: The Handbook of Binary Phase Diagrams, Genium, New York, 1984.

    Google Scholar 

  43. L.E. Murr, Y. Li, R.D. Flores, E.A. Trillo, J.C. McClure (1998) Mater. Res. Innovat., 2, pp. 150–63.

    Article  Google Scholar 

  44. W.J. Arbegast: Hot Deformation of Al Alloys, TMS Int., Materials Park, OH, 2003.

    Google Scholar 

  45. Y. Li, L.E. Murr, J.C. McClure: Scripta Mater., 1999, vol. 40, pp1041-46.

    Article  Google Scholar 

  46. M. Brendel and J.A. Schneider: Proc. 9th Int. FSWing Symp., TWI, May 2012.

  47. A.C. Nunes: Friction Stir Welding II, Proceedings MS&T, Columbus, OH, 2006, pp. 107–118.

  48. W. Tang, X. Gui, J.C. McClure, L.E. Murr, A.C. Nunes, Jr.: J. Mater. Proc. Manuf. Sci., 1998, vol. 7, no. 2, pp. 163-72.

    Article  Google Scholar 

  49. Y. Sato, M. Urata, H. Kokawa: Metall. Mater. Trans. A, 2002, vol. 33A, pp. 625-35.

    Article  Google Scholar 

  50. L.E. Murr, G. Liu, J.C. McClure: J. Mater. Sci., 1998, vol. 33, pp. 1243-51.

    Article  Google Scholar 

  51. T.W. Nelson, R.J. Steel, W.J. Arbegast: Sci. Technol. Weld. Join., 2003, vol. 8, pp. 283-88.

    Article  Google Scholar 

Download references

Acknowledgments

The authors [HRD, JAS] acknowledge the funding support provided by the NASA Faculty Fellowship Program and a NASA GSRP Fellowship [HRD].

Author information

Authors and Affiliations

  1. Center for Advanced Vehicular Systems, Mississippi State University, Mississippi State, MS, USA

    Haley R. Doude (Postdoctoral Associate)

  2. Mechanical Engineering Department, Mississippi State University, Mississippi State, MS, USA

    Judy A. Schneider (Professor)

  3. Marshall Space Flight Center (MSFC), National Aeronautics and Space Administration (NASA), Hunstville, AL, USA

    Arthur C. Nunes Jr. (Aerospace Engineer)

Authors
  1. Haley R. Doude
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Judy A. Schneider
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Arthur C. Nunes Jr.
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Haley R. Doude.

Additional information

Manuscript submitted September 7, 2013.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Doude, H.R., Schneider, J.A. & Nunes, A.C. Influence of the Tool Shoulder Contact Conditions on the Material Flow During Friction Stir Welding. Metall Mater Trans A 45, 4411–4422 (2014). https://doi.org/10.1007/s11661-014-2384-0

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11661-014-2384-0

Keywords

Search

Navigation