The aim of this article is study of tool plunge depth (TPD) effects on mechanical properties of friction stir welding of AA1100 aluminium alloy to A441 AISI steel. For this purpose the 0.1, 0.2, 0.4, and 0.6 mm TPD selected and other welding parameters kept constant. The results shows that the frictional heat increases and stir zone grain size decreases with increasing TPD at both base metals. At higher TPD, the material press out from shoulder and base metals interface. The highest tensile strength allocated to the joint which welded whit 0.2 mm plunge depth. This joint had appropriate joint efficacy, material flow and microhardness compare other joints. پرونده مقاله

In this paper, welding feasibility between AA1100, AA5050 and AA6082 aluminum alloys and A441 AISI steel by friction stir welding has been studied. Mathematical analysis of the heat generation during process showed that the maximum temperature produced in AA6082 aluminum alloy and A441 AISI joint but heat distribution in AA1100 aluminum alloy was higher than the other alloys. The investigation on joints windows concluded that the connecting link between AA1100 and A441 AISI steel was without any defect. Because of improper heat production and distribution in other joints, small tunnel was formed in the joints lower zones. Due to the softness of aluminums rather than steels, in tensile tests all joints were broken from the aluminum base metals. Strongest weld belonged to AA5050 aluminum alloy and A441 AISI steel joint that was about 84% of the aluminum base metal strength. Maximum joint efficacy based on A441 AISI has its place to AA6082 to A441 weld. Microhardness tests shows that welding line between AA1100 aluminum alloy and A441 AISI steel is harder that other joints. پرونده مقاله

In this article effects of friction stir welding (FSW) tool rotational and traverse speeds were studied on heat generation and temperature distribution in welding zone of AA1100 aluminum alloy and A441 AISI joint. Computational fluid dynamics method was used to simulate the process with commercial CFD Fluent 6.4 package. To enhance the accuracy of simulation in this Study, the welding line that is located work-pieces interface, defined with pseudo melt behavior around the FSW pin tool. Simulation results showed that with increase of FSW tool rotational speed, the generated heat became more and dimensions of the stir zone will be bigger. The calculation result also shows that the maximum temperature was occurred on the advancing side. The computed results demonstrated that with increasing tool linear speeds the heat generation experienced growth down trend. With increasing traveling speeds the time to reach maximum temperature in stir zone growth but the tool rotational speed dose not effect on time to reach maximum temperature. The model outcomes show that more than 85% total heat was produced by tool shoulder and the maximum heat with selected parameters in this study was 935 kelvin degrees. The computed results shows that the maximum value of strain rate achieved was 29 S-1 for A441 AISI side and 42 S-1 at AA1100 side. پرونده مقاله