TY - GEN
T1 - Reduction of Excessive Flash in Friction Stir Processing of AA1100
T2 - 4th International Conference on Mechanical, Manufacturing and Plant Engineering, ICMMPE 2018
AU - Marazani, Tawanda
AU - Akinlabi, Esther T.
AU - Madyira, Daniel M.
N1 - Publisher Copyright:
© 2020, Springer Nature Singapore Pte Ltd.
PY - 2020
Y1 - 2020
N2 - Friction stir processing (FSP) has proven to be a powerful emerging surface engineering technology for modifying metal surfaces and their bulk properties to desired forms. As a variant of friction stir welding (FSW), FSP borrows its principles of functionality from FSW. FSP technology is highly dependent on careful selection of process parameters. Its key parameters include tool rotational speed, traverse speed, tool tilt angles, axial force, tool and process design as well as base metal properties. Formation of excessive flash is a common FSP parametric challenge which needs to be studied. In this work, build-up of mass flash was experimentally observed and controlled by varying process tool tilt angle and the rotational during FSP of AA1100. The process was conducted using H13 tool steel cylindrical tool with a shoulder diameter of 21 mm with a 7 mm cylindrical threaded pin, at constant traverse speed of 20 mm/min at tilt angles varying from 0° to 3°, rotational speeds of 500 to 1500 rpm for unreinforced process and 2100–2800 rpm for reinforced process, at constant plunge depth of 0.2 mm, and traverse force of 11.2 kN. Results obtained from the physically examined FSP’ed samples show that excessive flash was generated for tilt angles from 0° to 2° as a result of limited under-shoulder space for flow of the plasticized material and the front tip of the tool digging into the base metal ejecting material from the processed zone. Massive flash reduction was observed at 2.5°. A further improvement of flash reduction was witnessed at 3° tilt angle but with reduced shoulder-to-base metal areal contact due to too much raised tool front.
AB - Friction stir processing (FSP) has proven to be a powerful emerging surface engineering technology for modifying metal surfaces and their bulk properties to desired forms. As a variant of friction stir welding (FSW), FSP borrows its principles of functionality from FSW. FSP technology is highly dependent on careful selection of process parameters. Its key parameters include tool rotational speed, traverse speed, tool tilt angles, axial force, tool and process design as well as base metal properties. Formation of excessive flash is a common FSP parametric challenge which needs to be studied. In this work, build-up of mass flash was experimentally observed and controlled by varying process tool tilt angle and the rotational during FSP of AA1100. The process was conducted using H13 tool steel cylindrical tool with a shoulder diameter of 21 mm with a 7 mm cylindrical threaded pin, at constant traverse speed of 20 mm/min at tilt angles varying from 0° to 3°, rotational speeds of 500 to 1500 rpm for unreinforced process and 2100–2800 rpm for reinforced process, at constant plunge depth of 0.2 mm, and traverse force of 11.2 kN. Results obtained from the physically examined FSP’ed samples show that excessive flash was generated for tilt angles from 0° to 2° as a result of limited under-shoulder space for flow of the plasticized material and the front tip of the tool digging into the base metal ejecting material from the processed zone. Massive flash reduction was observed at 2.5°. A further improvement of flash reduction was witnessed at 3° tilt angle but with reduced shoulder-to-base metal areal contact due to too much raised tool front.
KW - AA1100
KW - Excessive flash reduction
KW - Experimental study
KW - Friction stir processing
KW - Plasticized metal flow
UR - http://www.scopus.com/inward/record.url?scp=85075728127&partnerID=8YFLogxK
U2 - 10.1007/978-981-13-8297-0_32
DO - 10.1007/978-981-13-8297-0_32
M3 - Conference contribution
AN - SCOPUS:85075728127
SN - 9789811382963
T3 - Lecture Notes in Mechanical Engineering
SP - 299
EP - 308
BT - Advances in Material Sciences and Engineering, ICMMPE 2018
A2 - Awang, Mokhtar
A2 - Emamian, Seyed Sattar
A2 - Yusof, Farazila
PB - Springer Science and Business Media Deutschland GmbH
Y2 - 14 November 2018 through 15 November 2018
ER -