Effect of friction stir welding parameters of aluminum alloy tubes on succeeding rotary draw bending

الموضوعات : فصلنامه شبیه سازی و تحلیل تکنولوژی های نوین در مهندسی مکانیک

Alireza Soleymanipoor ¹ (Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran)
Hamid Montazerolghaem ² (Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran)
Mohsen Loh-mousavi ³ (Department of Mechanical Engineering, Khomeinishahr Branch, Islamic Azad University, Khomeinishahr, Isfahan 81857-93768, Iran)

تاريخ الإرسال : 09 الإثنين , جمادى الثانية, 1444 تاريخ التأكيد : 08 الخميس , رمضان, 1444 تاريخ الإصدار : 09 الأربعاء , شعبان, 1444

الکلمات المفتاحية: Friction Stir Welding, Rotary draw bending, tube manufacturing methods,

ملخص المقالة :

Thin-walled aluminum alloy tubes utilized for industrial applications like aviation and car manufacturing can be produced by various processes which are mainly divided into seamless and welded tubes. The utilization of welded tubes is desired to meet the increasing need for production efficiency and flexibility in design particularly when the shape cross section is asymmetrical. In this study, the possibility of attaining the defect-free and manufacturing of friction stir welded tube of AA 6061-T6 having a wall thickness of 2.5 mm was carried out and process parameters were optimized to get a visually defect-free welded tube. In the next step, the characterization of welded tubes using rotary draw bending of the welded tubes was done. With the increase in the welding speed, the average ovality in bent tubes was decreased and with the increase in the bending speed, the ovality was decreased in rotary draw bending of friction stir welded aluminum tubes.

المصادر:

 

[1] Katiyar, B. S., Panda, S. K. & Saha, P. (2020). Quasi-static crushing behavior of stretch formed domes of laser welded tailored blanks. Thin-Walled Structures 159 (2021) 107288.

[2] HIRSCH, J. (2014). Recent development in aluminum for automotive applications, Trans. Nonferrous Met. Soc. China 24(2014) 1995−2002.

[3] Hashmi, M. S. J. (2006). Aspects of tube and pipe manufacturing processes: Meter to nanometer diameter, Journal of Materials Processing Technology 179 (2006) 5–10.

[4] Trimble, D., Donnell, G. E. O & Monaghan, J. (2015). Characterisation of tool shape and rotational speed for increased speed during friction stir welding of AA2024-T3, Journal of Manufacturing Processes 17 (2015) 141–150.

[5] Kah, P., Rajan, R., Martikainen, J., & Suoranta, R. (2015). Investigation of weld defects in friction-stir welding and fusion welding of aluminum alloys, International Journal of Mechanical and Materials Engineering (2015) 10:26.

[6] Mishra, R. S., Mab, Z.Y. (2005). Friction stir welding and processing, Materials Science and Engineering R 50 (2005) 1–78.

[7] Sen, D., Pal, S. K.,  & Panda, S. K. (2021). Tubular Structures: Welding Difficulty and Potential of Friction Stir Welding, Springer Nature Switzerland AG 2021 J. P. Davim (ed.), Welding Technology, Materials Forming, Machining and Tribology.  https://doi.org/10.1007/978-3-030-63986-0_7.

[8] Khalfallah, A. (2014). Experimental and numerical assessment of mechanical properties of welded tubes for hydroforming, Material and Design, no. 56, pp. 782-790, 2014.

[9] Gianluca D’Urso, Longo, M. & Giardini, C. (2013). Mechanical and metallurgical analyses of longitudinally friction stir welded tubes: The effect of process parameters, Article in International Journal of Materials and Product Technology. DOI: 10.1504/IJMPT.2013.056301.

[10] Yuan, S. J., Hu, Z. L., & Wang, X. S. (2012). Evaluation of formability and mechanical characteristics of aluminum alloy friction stir welded tube produced by a novel process, Materials Science and Engineering A, no. 543, pp. 210-216, 2012.

[11] Yuan, S.J., Hu, Z. L., & Wang, X. S. (2012). Formability and microstructural stability of friction stir welded Al alloy tube during subsequent spinning and post weld heat treatment, Material Science and Engineering A, No. 558, pp. 586-591, 2012.

[12] Pang, Q., Hu, Z.L., Pan, X.& Zuo. X.Q. (2014). Deformation Characterization of Friction-Stir-Welded Tubes by Hydrualic Bulge Testing, The Minerals, Matals & Materials Society, Vol. 66, No. 10, pp.2137-2144, 2014.

[13] Kim, Y. G., Kim, I. J., Kim, Y.P., & Joo, S. M. (2016). A Feasibility Study on the Three-Dimensional Friction Stir Welding of Aluminum 5083-O Thin Plate, Materials Transactions, Vol. 57, No. 6 (2016) pp. 988 to 994 ©2016 The Japan Institute of Metals and Materials.

[14] Sen, D., Pal, S. K., & Panda S. K. (2022). Fabrication of longitudinal welded tube of aluminum alloy for structural application using friction stir welding process and its characterization, Archives of Civil and Mechanical Engineering (2022) 22:91.

[15] Gregory, M. (2003). Tube Forming Processes: A Comprehensive Guide, pp. 72-110, Dearborn, Michigan, Society of Manufacturing Engineers, 2003.

[16] Lazarescu, L. (2013). Effect of internal fluid pressure on quality of aluminum alloy tube in rotary draw bending, Int J Adv Technol, no. 64, pp. 85-91, 2013.

[17] Hasanpour, K., Barati, M., Azimi B., & Poursina, M. (2013).The effect of an isotropy on wrinkling of tube under rotary draw bending, Journal of Mechanical Science and Technology, Vol. 27, No. 3, pp. 783-792, 2013.

[18] Ren, N., Zhana, M., Yanga, H., Zhanga, Z.Y., Qina, Y.T., Jiangb, H.M., Diaob, K.S., & Chenb, X.P. (2012). Constraining effects of weld and heat-affected zone on deformation behaviors of welded tubes in numerical control bending process, Journal of Materials Processing Technology 212 (2012) 1106–1115.

[19] Zhan, M., Xing, L., Gao, P.F., & Ma, F. (2019) An analytical spring back model for bending of welded tube considering the weld characteristics, International Journal of Mechanical Sciences 150 (2019) 594–609.

[20] Liu, H., Liu, Y., & Du, X. (2020). Cross-sectional deformation of high strength steel rectangular welded tube in rotary draw bending with different constitutive relationships, The International Journal of Advanced Manufacturing Technology (2020) 107:4333–4344.

[21] Cheng, C., Pan, C., Bai, X., Liu, C., & Guo, X. (2022). Investigation on the influence of weld position on the deformation, behavior of welded tube during free bending process, The International Journal of Advanced Manufacturing Technology (2022) 120:2201–2215,

[22] Kim, Y. G., Fujii, H., Tsumura, T., Komazaki, T., & Nakata, K. (2006). three defect types in friction stir welding of aluminum die casting alloy, Materials Science and Engineering A 415 (2006) 250–254.

[23] Chen, Z., Li, S., Hiha. L. (2015). Microstructure, mechanical properties and corrosion of friction stir welded 6061 Aluminum Alloy, https://www.researchgate.net/publication/284219459

[24] Dong, P., Li, H., Sun D., Gong, W. & Liu, J. (2013). Effects of welding speed on the microstructure and hardness in friction stir welding joints of 6005A-T6 aluminum alloy, Materials and Design 45 (2013) 524–531.

[25] Jun, F., Lu, S., Chuang, L., Lu, C., & Deliang, Z,. (2019). Influences of mandrel types on forming quality of TA18 high strength tube in numerical control bending, IOP Conf. Series: Materials Science and Engineering 631 (2019) 032032, doi:10.1088/1757-899X/631/3/032032.

[26] Jun, F., Shiqiang, Lu., Chuang, L., Lu, C., and Deliang, Z,. & Jingbo, W., (2019). Mandrel role in numerical control rotary draw bending process of TA18 high strength titanium alloy tube, IOP Conf. Series: Materials Science and Engineering 631 (2019) 022065, doi:10.1088/1757-899X/631/2/022065.