Tool design and process analysis of bobbing tool friction stir welding for thin-walled extrude profile of 6061-T6 aluminum alloy

ZHANG Yingchuan; MA Guodong; DAI Peng; WANG Jingshui; JIN Wei

doi:10.12073/j.hjxb.20210512001

TRANSACTIONS OF THE CHINA WELDING INSTITUTION > 2022 > 43(6): 88-95. > DOI: 10.12073/j.hjxb.20210512001

ZHANG Yingchuan, MA Guodong, DAI Peng, WANG Jingshui, JIN Wei. Tool design and process analysis of bobbing tool friction stir welding for thin-walled extrude profile of 6061-T6 aluminum alloy[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2022, 43(6): 88-95. DOI: 10.12073/j.hjxb.20210512001

Citation:

PDF (2519 KB)

Tool design and process analysis of bobbing tool friction stir welding for thin-walled extrude profile of 6061-T6 aluminum alloy

ZHANG Yingchuan^{1, 2,},
MA Guodong^{1, 2},
DAI Peng¹,
WANG Jingshui¹,
JIN Wei^{1, 2, ,}

1.
Beijing Zhongheng Electro-Mechanical Technology Co., Ltd., Beijing, 100091, China
2.
Locomotive & Car Research Institute, China Academy of Railway Sciences Co., Ltd., Beijing, 100081, China

More Information

Received Date: May 20, 2021
Available Online: May 29, 2022

Graphical Abstract

Abstract

Abstract

An engineering model between characteristic value of welding tool and specimen thickness was established based on heat input theoretical analysis of bobbing tool friction stir welding. According to this model, a welding tool was designed and optimized, which was used for join 2.5 mm thin-walled extrude profile of 6061-T6 aluminum alloy. Friction stir welding parameters were optimized as well. When the rotation speed of the tool was 1 000 r/min and welding speed was 600 mm/min, the joint obtained a maximum mechanical properties. The front side joint had a tensile strength of 231 MPa, 77% of the base material, and a bend angle of 180°, while the back side joint had a tensile strength of 226 MPa, 76% of the base material, and a bend angle of 180°.
- bobbing tool friction stir welding,
- 6061-T6 aluminum alloy,
- thin-walled cavity extrude profile,
- welding tool design

FullText(HTML)

References (30)

References

张鑫, 张洁利, 韩冬等. 搅拌摩擦焊技术研究现状及发展展望[J]. 热加工工艺, 2018, 47(23): 1 − 5.

Zhang Xin, Zhang Jieli, Han Dong et al. Research status and developing prospect of friction stir welding[J]. Hot Working Technology, 2018, 47(23): 1 − 5.

张华, 林三宝, 吴林等. 搅拌摩擦焊研究进展及前景展望[J]. 焊接学报, 2003, 24(3): 91 − 96. doi: 10.3321/j.issn:0253-360X.2003.03.025

Zhang Hua, Lin San-Bao, Wu Lin, et al. Current progress and prospect of friction stir welding[J]. Transactions of the China Welding Institution, 2003, 24(3): 91 − 96. doi: 10.3321/j.issn:0253-360X.2003.03.025

董春林, 栾国红, 关桥. 搅拌摩擦焊在航空航天工业的应用发展现状与前景[J]. 焊接, 2008(11): 25 − 31. doi: 10.3969/j.issn.1001-1382.2008.11.009

Dong Chunlin, Luan Guohong, Guan Qiao. Prospects of application and development of friction stir welding in aerospace and aviation industry[J]. Welding & Joining, 2008(11): 25 − 31. doi: 10.3969/j.issn.1001-1382.2008.11.009

温林秀, 赵运强, 董春林, 等. 1561铝合金搅拌摩擦焊接过程压力特征及接头组织性能分析[J]. 焊接学报, 2019, 40(12): 91 − 96.

Wen Linxiu, Zhao Yunqiang, Dong Chunlin, et al. Analysis on characteristics of welding pressure, microstructures and mechanical properties of friction stir welded 1561 aluminum alloy[J]. Transactions of the China Welding Institution, 2019, 40(12): 91 − 96.

荆忠亮, 赵彤涌, 宋志强. 船舶结构的搅拌摩擦焊技术[J]. 舰船科学技术, 2015(4): 117 − 120. doi: 10.3404/j.issn.1672-7649.2015.04.024

Jing Zhongliang, Zhao Tongyong, Song Zhiqiang. Friction stir welding technology research in chip structure[J]. Ship Science and Technology, 2015(4): 117 − 120. doi: 10.3404/j.issn.1672-7649.2015.04.024

相倩, 吕念春, 薛鹏, 等. 铝-钢异种金属搅拌摩擦焊研究现状及展望[J]. 机械工程学报, 2017, 53(20): 28 − 37. doi: 10.3901/JME.2017.20.028

Xiang Qian, Lv Nianchun, Xue Peng, et al. Research status and prospect on friction stir welded dissimilar al-steel joints[J]. Journal of Mechanical Engineering, 2017, 53(20): 28 − 37. doi: 10.3901/JME.2017.20.028

杜文普, 钮旭晶, 郁志凯, 等. 6005A-T6铝合金型材搅拌摩擦焊与MIG焊的数值分析[J]. 焊接技术, 2019, 48(3): 16 − 20.

Du Wenpu, Niu Xujing, Yu Zhikai, et al. Numerical analysis of friction stir welding and MIG welding of 6005A-T6 aluminum alloy[J]. Welding Technology, 2019, 48(3): 16 − 20.

钮旭晶, 侯振国, 鲁二敬, 等. 标动铝合金底板双轴肩搅拌摩擦焊的数值仿真[J]. 轨道交通装备与技术, 2019(6): 26 − 30.

Niu Xujing, Hou Zhenguo, Lu Erjing, et al. Numerical simulation of FSW with double probes for base board of standard EMU[J]. Rail transportation Equipment and Technology, 2019(6): 26 − 30.

闫占奇. 轨道交通车辆铝合金地板FSW与MIG焊残余应力对比分析[J]. 城市轨道交通研究, 2018, 21(2): 64 − 66.

Yan Zhanqi. Comparative analysis of residual stress distribution on railway vehicle floor with FSW and MIG welding[J]. Urban Mass Transit, 2018, 21(2): 64 − 66.

廖蕴博. 双轴肩搅拌摩擦焊工艺研究[D]. 兰州: 兰州理工大学, 2017.

Liao Yunbo. Study on BT-FSW process of aluminum alloy[D]. Lanzhou: Lanzhou University of Technology, 2017.

郝云飞, 魏瑞刚, 周庆, 等. 焊接热输入对铝合金双轴肩搅拌摩擦焊缝形貌与接头性能的影响[J]. 焊接学报, 2018, 39(2): 84 − 88.

Hao Yunfei, Wei Ruigang, Zhou Qing, et al. Effect of heat input on weld morphology and tensile properties of bobbin friction stir welded joints[J]. Transactions of the China Welding Institution, 2018, 39(2): 84 − 88.

吉华, 邓运来, 邓建峰, 等. 焊接速度对6005A-T6铝合金双轴肩搅拌摩擦焊接头力学性能的影响[J]. 焊接学报, 2019, 40(5): 24 − 29. doi: 10.12073/j.hjxb.2019400122

Ji Hua, Deng Yunlai, Deng Jianfeng, et al. Effect of welding speed on mechanical properties of bobbin tool friction stir welded 6005A-T6 aluminum alloy joints[J]. Transactions of the China Welding Institution, 2019, 40(5): 24 − 29. doi: 10.12073/j.hjxb.2019400122

周利, 刘朝磊, 王计, 等. 双轴肩搅拌摩擦焊技术研究现状[J]. 焊接, 2015(6): 14 − 18. doi: 10.3969/j.issn.1001-1382.2015.06.006

Zhou Li, Liu Chaolei, Wang Ji, et al. Development of bobbin tool friction stir welding[J]. Welding & Joining, 2015(6): 14 − 18. doi: 10.3969/j.issn.1001-1382.2015.06.006

夏佩云, 尹玉环, 赵慧慧, 等. 厚板双轴肩搅拌摩擦焊温度场及流场数值模拟[J]. 电焊机, 2018, 48(3): 294 − 299.

Xia Peiyun, Yin Yuhuan, Zhao Huihui, et al. Nummerical simulation of temperature and flow for bobbin tool friction stir welding of thick plates[J]. Electric Welding Machine, 2018, 48(3): 294 − 299.

李敬勇, 周小平, 董春林, 等. 6082铝合金双轴肩搅拌摩擦焊试板温度场研究[J]. 航空材料学报, 2013, 33(5): 36 − 40.

Li Jingyong, Zhou Xiaoping, Dong Chunlin, et al. Temperature field in 6082 aluminum alloy samples bobbin tool friction stir welded[J]. Journal of Aeronautical Materials, 2013, 33(5): 36 − 40.

刘琪, 董仕节, 官旭, 等. 搅拌摩擦焊温度场数值模型的研究进展[J]. 材料导报, 2015, 29(21): 118 − 125.

Liu Qi, Dong Shijie, Guan Xu, et al. A review of numerical model for temperature field in friction stir welding process[J]. Materials Reports, 2015, 29(21): 118 − 125.

王希靖, 郭瑞杰, 陈书锦, 等. 搅拌摩擦焊摩擦功率的计算与检测[J]. 焊接学报, 2004, 25(4): 93 − 95. doi: 10.3321/j.issn:0253-360X.2004.04.024

Wang Xijing, Guo Ruijie, Chen Shujin, et al. Calculating and measuring of heating power of friction stir welding[J]. Transactions of the China Welding Institution, 2004, 25(4): 93 − 95. doi: 10.3321/j.issn:0253-360X.2004.04.024

Mendez P F, Tello K E, Lienert T J. Scaling of coupled heat transfer and plastic deformation around the pin in friction stir welding[J]. Acta Meterialia, 2010, 58(18): 6012 − 6026. doi: 10.1016/j.actamat.2010.07.019

Schmidt H, Hattel J. Modelling heat flow around tool Probe in friction stir welding[J]. Science Technology of Welding and Joining, 2005, 10(2): 176 − 186. doi: 10.1179/174329305X36070

Diogo Mariano Neto, Pedro Neto. Numerical modeling of friction stir welding process: A literature review[J]. The International Journal of Advanced Manufacturing Technology, 2013, 65: 115 − 126. doi: 10.1007/s00170-012-4154-8

冀海贵. 铝合金双轴肩搅拌摩擦焊搅拌头设计、接头组织和性能研究[D]. 南昌: 南昌航空大学, 2017.

Ji Haigui. Study on the tool design, joint microstructure and propertise of bobbin tool friction stir welded aluminum alloy[D]. Nanchang: Nanchang Hangkong University, 2017.

刘朝磊. 6061铝合金双轴肩搅拌摩擦焊工艺及机理研究[D]. 哈尔滨: 哈尔滨工业大学, 2015.

Liu Chaolei. Research on process and mechanism ofselr-reacting friction stir welding for 6061 aluminum alloy[D]. Harbin: Harbin Institute of Technology, 2015.

张春波, 周军, 张汇文, 等. 6061-T6铝合金双轴肩搅拌摩擦焊接头组织与力学性能[J]. 电焊机, 2015, 45(1): 120 − 124.

Zhang Chunbo, Zhou Jun, Zhang Huiwen, et al. Microstructure and mechanical properties of bobbin tool friction stir welding of 6061-T6 aluminium alloy[J]. Electric Welding Machine, 2015, 45(1): 120 − 124.

王鹏浩, 陈书锦, 李浩, 等. 不同轴肩组合对双轴肩搅拌摩擦焊接质量的影响[J]. 电焊机, 2015, 45(10): 23 − 29.

Wang Penghao, Chen Shujin, Li Hao, et al. Effect of different shoulder combination on quality of bobbin tool friction stir welding[J]. Electric Welding Machine, 2015, 45(10): 23 − 29.

Hou J C, Liu H J, Zhao Y Q. Influences of rotation speed on microstructures and mechanical properties of 6061-T6 aluminum alloy joints fabricated by self-reacting friction stir welding tool[J]. The International Journal of Advanced Manufacturing Technology, 2014, 73: 1073 − 1079. doi: 10.1007/s00170-014-5857-9

Liu H J, Hou J C, Guo H. Effect of welding speed on microstructure and mechanical properties of self-reacting friction stir welded 6061-T6 aluminum alloy[J]. Materials and Design, 2013, 50: 872 − 878. doi: 10.1016/j.matdes.2013.03.105

Piyush Singh, Pankaj Biswas, Sachin D. Kore. Finite element Method and experimental study of self-reacting friction stir welding of aluminium alloy AA6061-T6[J]. Simulations for Design and Manufacturing, 2018: 79 − 102.

Zhou L, Li G H, Liu C L, et al. Effect of rotation speed on microstructure and mechanical properties of self-reacting friction stir welded Al-Mg-Si alloy[J]. The International Journal of Advanced Manufacturing Technology, 2017, 89: 3509 − 3516. doi: 10.1007/s00170-016-9318-5

Yanga C, Nia D R, Xue P, et al. A comparative research on bobbin tool and conventional friction stir welding of Al-Mg-Si alloy plates[J]. Materials Characterization, 2018, 145: 20 − 28. doi: 10.1016/j.matchar.2018.08.027

Luis Trueba Jr, Monica A Torres, Lucie B Johannes, et al. Process optimization in the self-reacting friction stir welding of aluminum 6061-T6[J]. International Journal of Material Forming, 2018, 11: 559 − 570. doi: 10.1007/s12289-017-1365-4

[1]	CAO Runping, HAN Yongquan, LIU Xiaohu, HONG Haitao, HAN Jiao. Effect of rare earth Ce on arc and droplet transfer behavior[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2025, 46(1): 95-102. DOI: 10.12073/j.hjxb.20231109001
[2]	HU Qingsong, YAN Zhaoyang, ZHANG Pengtian, CHEN Shujun. Arc behavior and droplet transfer in self-adaptive shunt alternating arc WAAM[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2024, 45(2): 41-46. DOI: 10.12073/j.hjxb.20230309003
[3]	YANG Yicheng, DU Bing, HUANG Jihua, HUANG Ruisheng, CHEN Jian, XU Fujia. Mechanism of wire and arc interaction in hollow tungsten arc welding with coaxial filler wire[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2022, 43(4): 94-99. DOI: 10.12073/j.hjxb.20210913001
[4]	ZHOU Xiaochen1, LI Huan1, SONG Chunguang2, ZHANG Yuchang3. Study on characteristics of droplet transfer for pulsed TOPTIG[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2017, 38(7): 45-48. DOI: 10.12073/j.hjxb.20150609001
[5]	ZHU Xiaoyang, LI Huan, HUANG Chaoqun, YANG Ke, NI Yanbing, WANG Guodong. Analysis of droplet transfer and weld appearance in pulsed wire feeding MIG welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2016, 37(10): 59-63.
[6]	XIE Shengmian, WU Kaiyuan, WEN Yuanmei, GE Weiqing, HUANG Shisheng. Effects of pulse frequency on TCGMAW droplet transfer modes[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2012, (3): 69-72.
[7]	LI Fang, HUA Xueming, WANG Weibin, WU Yixiong. Modeling of droplet transfer electrical characteristics in pulsed gas melted arc welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2009, (7): 97-100.
[8]	LIU Gang, FENG Yun, LI Jun-yue, FAN Rong-huan. Arc spectrum signals of droplet spray transfer in MIG welding[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2004, (1): 40-44.
[9]	YANG Yun-qiang, ZHANG Xiao-qi, LI Jun-yue, LI Huan. Selection of droplet transfer specific spectrum window[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2003, (1): 14-18.
[10]	YANG Yun-qiang, LI Jun-yue, HU Sheng-gang, LIU Gang, LI Huan. The Characteristic Spectral Information of Droplet Transfer in Pulsed MIG Welding and It's Applications[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2001, (4): 36-38.

Cited By

Get Citation

PDF

XML

Article views (300) PDF downloads (29)

Turn off MathJax

Article Contents

Abstract

References

Tool design and process analysis of bobbing tool friction stir welding for thin-walled extrude profile of 6061-T6 aluminum alloy

Abstract

References

Related Articles

Catalog

Tool design and process analysis of bobbing tool friction stir welding for thin-walled extrude profile of 6061-T6 aluminum alloy

Abstract

References

Related Articles

Catalog

Export File

Citation

Format

Content