Dissertation (Ph.D.)--Auburn University, 2009. / Abstract. Vita. Includes bibliographic references (p.107-111).

Thesis (Ph. D. in Electrical Engineering)--Vanderbilt University, May 2009. / Title from title screen. Includes bibliographical references.

Friction Stir Processing (FSP) of aluminium alloys has been used to modify and improve the microstructure and relevant properties of fusion welded aluminium alloys. The effect of FSP on MIG-Laser Hybrid (MLH) welded aluminium alloy 6082-T6 mechanical and microstructural properties has been studied in this research. The FSP process was used on 6mm thick aluminium alloy plates and a tool was designed specifically for FSP, and the effect of varying speeds was analysed before the final FSP welds were made. The effect of FSP was analysed by optical microscopy, tensile, microhardness and fatigue testing. The aim of the study was to determine whether the FSP process has a beneficial influence on the mechanical properties and metallurgical integrity of MIG-Laser Hybrid welded 6082-T6 aluminium alloy with varying gap tolerances. Three welding processes were compared, namely combined Friction Stir Processing on MIG-Laser hybrid process (FSP-MLH), MLH and Friction Stir Welding (FSW) as part of the analysis. (FSP was carried out on MLH components when it was found that FSP is not an entirely complete welding process but rather a finishing process per se.) The aim of this dissertation is to investigate the effects of the FSP process on the weld quality of MLH welded joints and also to compare this to individual processes like FSW and MLH. This investigation was undertaken in order to gain an understanding of the effect of these processes on fatigue performance and microhardness distribution on aluminium alloy 6082-T6 weld joints.

This Master Thesis was performed in terms of robotic three dimensional friction stir welding with T-butt joint. Friction stir welding (FSW) is a solid state welding method that achieves the weld temperature by friction of a rotating non-consumable tool with the workpiece. Science and technology fast developing requires for higher seam quality and more complex welding joint geometry like 3D welds. In order to acquire high productivity, capacity and flexibility with acceptable cost, robotic FSW solution have been proposed. Instead of the standard FSW machine, using a robot to perform complicated welds such as, three-dimensional. In this report, a solution for weld a 3D T-butt joint, which located in an aluminium cylinder with 1.5 mm thickness using a robot, was developed. Moreover, two new paths were investigated in order to avoid the use of two welds to perform this type of joint. The paths were tested on 2D and on 3D (with a 5050 curvature radius) geometries. Both paths had good results. What is more, the parameter developing methods of FSW process, which is composed of necessary parameter setting, positional compensation was introduced. Specially,the study demonstrates how complicate geometry can be welded using a robot. Also,it shows that TWT temperature control is able to acquire high quality 3D welds. In addition, an analysis of the 2D welding and 3D welding was performed, which exposed that, keeping exactly the same welding conditions, higher lateral forces on the tool were found during 3D welding. Basis on the special case in this paper, when the tool goes like "climbing" the sample, the suffering force of tool decreasing with increasing the height(Z position); nevertheless, when the tool goes like "downhill", the suffering force of tool decreasing with decreasing the height (Z position). What is more, in 2D weld, increasing the downforce (Fz) results increasing the lateral forces which can be Fx and/or Fy. Finally, the future works suggestions were presented in terms of (1) performing the new paths into a real cylinder, (2) performing tensile test on the paths and comparing it with conventional path which weld twice, (3) researching how the downforce (Fz) influence the Fx and Fy during welding of different 3D geometries, (4) how the cooling rate of backing bar influence the seam quality when it is use the same welding parameters and (5) the effect of performing welds in the same welding temperature achieved with different combination of the tool rotational speed and downforce on the material properties

Dissimilar metals joining have been used in many industry fields for various applications due to their technique and beneficial advantages, such as aluminum-steel and magnesium-steel joints for reducing automobile weight, aluminum-copper joint for reducing material cost in electrical components, steel-copper joints for usage in nuclear power plant, etc. The challenges in achieving dissimilar joints are as below. (1) Big difference in physical properties such as melting point and coefficient of thermal expansion led to residual stress and defects. (2) The miscibility issues resulted in either brittle intermetallic compound layer at the welded interface for miscible combinations (such as, aluminum-steel, aluminum-copper, aluminum-titanium, etc.) or no metallurgical bonding for immiscible combinations (such as magnesium-copper, steel-copper, etc.). For metallurgical miscible combinations, brittle intermetallic compounds formed at the welded interface created the crack initiation and propagation path during deformational tests. (3) Stress concentration appeared at the welded interface region during tensile testing due to mismatch in elastic properties of dissimilar materials. In this study, different combinations of dissimilar metals were joined with friction stir welding. Lap welding of 6022-T4 aluminum alloy/galvanized mild steel sheets and 6022-T4 aluminum alloy/DP600 steel sheets were achieved via friction stir scribe technology. The interlocking feature determining the fracture mode and join strength was optimized. Reaction layer (intermetallic compounds layer) between the dissimilar metals were investigated. Butt welding of 5083-H116 aluminum alloy/HSLA-65 steel, 2024-T4 aluminum alloy/316 stainless steel, AZ31/316 stainless steel, WE43/316 stainless steel and 110 copper/316 stainless steel were obtained by friction stir welding. The critical issues in dissimilar metals butt joining were summarized and analyzed in this study including IMC and stress concentration.

Thesis (Ph. D.)--West Virginia University, 2007. / Title from document title page. Document formatted into pages; contains xii, 135 p. : ill. (some col.). Includes abstract. Includes bibliographical references (p. 106-112).

The study of defect formation and identification is important to the further application of friction stir welding in industry. To better understand the topic, a systematic study was undertaken to describe material flow effects on the formation of defects, to list the various types of defects encountered across a parameter window, and to identify features in the weld force data that can then be used to recognize defects within the weld without destructive testing. Tracer studies were used to determine the impact of the material flow on defect formation with a determination that proper shoulder contact is necessary to obtain sufficient material flow to fully consolidate the weld. A series of welds across a range of rotational speeds was used to identify mechanisms that led to variations in the mechanical properties of the welded panels. A balance between the x- and yorces on the tool is needed to produce robust welds that were defect free. UMF was shown to identify regions of changing material flow conditions; however, the identification of intermittent defects was not as successful.

Process forces arising during Friction Stir Welding (FSW) have become of interest to investigators interested in obtaining weld quality information from recorded weld data. Successful analysis of process forces require the separation of force signals stemming from material flow mechanisms within the weld from signals influenced by the FSW machine. Three modes of FSW control were characterized for system response: Servo Position (SPC), Electronic Deflection Compensation (EDC), and Constant Load Control (CLC). The gain value of the feedback loops associated with EDC and CLC modes were altered and characterized. SPC mode response to vertical changes in the tool position was also characterized. Machine-specific force signatures associated with the motor transmission assembly and spindle resonance were also identified. Characterization of the influence of machine control modes and other machinespecific frequencies on process force signals will allow future investigators to identify segments of welds during which machine actions influenced recorded force data.

In this paper, Friction Stir Welding(FSW) experiments are conducted using similar and dissimilar metals of 6061-T6 Aluminum alloy, AZ-31 Magnesium alloy, JISC-1100 pure copper as specimens. Thermalcouples of type D are used to measure temperature history at different postions of workpiece duing Fsw. Form the temperature history, the preheating temperature and the tool rotation and tool moving speed can be found for a successful welding process. The experimental results show that the temperature ranges for the tool starting to move after preheating are 250-2500C, 200-2500C and 300-3500C for silimar metals of Al alloy, Mg alloy and pure copper and that for of dissimilar of Al alloy and Mg alloy is 200-2500C. Vickers hardness test and tensile test of the welded products are also conducted. The hardness testing results show that the vickers hardness of similar Al alloy, Mg alloy and pure copper sheets beforing weldig are about, 102, 70 and 105HV, respectively. The hardness of the nugget region of similar Al alloy, Mg alloy and pure copper sheets after welding are about 60, 62 and 65 HV, respectively and that for dissimilar of Al alloy and Mg alloy sheets is 138HV. The tensile testing results shows that for similar of Al alloy, Mg alloy and pure copper sheets beforing weldig are about, 320, 300 and 280MPa, respectively. The tensile strenghts of similar Al alloy, Mg alloy and pure copper sheets after welding, are about 160, 250 and 200 MPa, respectively, and that for dissimilar Al and Mg alloys is 100 MPa. The above experimental results can provide information for Fsw of Al, Mg alloys and pure copper. Keywords¡GFriction Stir Welding¡Fthermalcouple¡Ftemperature career

Friction Stir Welding(FSW) experiments are conducted using 6061-T6 aluminum as specimens. The temperatures at different distances from the center of the joint are measured. Curve fitting analyses are used to predict the temperature distribution and calculate the central temperature of the joint, proceeding by measuring temperature. A second order curve is found to better fit the experiment values by the least square method.