Pin geometry: Straight cylindrical -
I
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Padmanaban and Balasubramanian [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
N: 1600 |
|
Fig. I - A [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
PD: 6 |
V: 40 |
Crack defect formed due to Lack of vertical displacement of material. |
Z: 0.2 |
PL: 5.7 |
T: 00 |
F: 3 |
Elangovan and Balasubramanian [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
N: 1600 |
|
Fig. I - B [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
V: |
PD: 6 |
a) 22 |
(a, b) Tunnel defects and pin holes are formed in the weld root towards the retreating side of the weld joint due to improper stirring of the tool pin. (c) Large tunnel defect was formed due to insufficient heat input. |
b) 45 |
c) 75 |
PL: 5.7 |
Z: NA |
T: NA |
F: 12 |
Elangovan and Balasubramanian [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
N: |
|
Fig. I - C [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
a) 1500 |
PD: 6 |
b) 1600 |
(a, b) Tunnel defects are formed at the root of the weld joint due to insufficient heat input. (c) Pin holes due to improper flow of the plasticized material. |
c) 1700 |
V: 45 |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 12 |
Pin geometry: Tapered cylindrical -
II
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Padmanaban and Balasubramanian [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
N: 1600 |
|
Fig. II - A [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
PD: 6 (root) |
V: 40 |
A long crack formed due to the absence of vertical motion of the material. |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 3 |
Elangovan and Balasubramanian [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
N: 1600 |
|
Fig. II - B [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
V: |
PD: 6 |
a) 22 |
(a, b) Small pinholes are formed at the bottom of the weld joint because of insufficient flow of plasticized material. (c) Tunnel defect was formed due to low heat generation per unit weld length. |
b) 45 |
c) 75 |
PL: 5.7 |
Z: NA |
T: NA |
F: 12 |
Elangovan and Balasubramanian [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
N: |
|
Fig. II - C [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
a) 1500 |
PD: 6 |
b) 1600 |
(a, c) Tunnel defect due to insufficient heat input. (b) Pin holes are formed since there is absence of vertical flow of material. |
c) 1700 |
V: 45 |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 12 |
Pin geometry: Threaded cylindrical -
III
|
Padmanaban and Balasubramanian [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
N: 1600 |
|
Fig. III - A [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
PD: 6 |
V: 40 |
Defect-free joints are formed due to sufficient heat generation and proper mixing of materials. |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 3 |
Elangovan and Balasubramanian [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
N: 1600 |
|
Fig. III - B [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
V: |
PD: 6 |
a) 22 |
(a) Crack-like defect formed due to excess heat input results in turbulent material flow. (b) Defect-free joint due to sufficient heat input. (c) Tunnel defect formed at the middle of the stirred zone due to faster welding speed results in lower heat input. |
b) 45 |
c) 75 |
PL: 5.7 |
Z: NA |
T: NA |
F: 12 |
Elangovan and Balasubramanian [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
N: |
|
Fig. III - C [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
a) 1500 |
PD: 6 |
b) 1600 |
(a, b) No defect because the threaded pin profile generates sufficient heat input and enhances the downward movement of plasticized material. (c) Pin holes are formed because of excess turbulent flow of materials takes place at higher tool rotational speed. |
c) 1700 |
V: 45 |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 12 |
Pin geometry: Square -
IV
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Padmanaban and Balasubramanian [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
N: 1600 |
|
Fig. IV - A [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
PD: NA |
V: 40 |
Tunnel defect formed due to large amount of material sweep from the SZ. |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 3 |
Elangovan and Balasubramanian [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
N: 1600 |
|
Fig. IV - B [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
V: |
PD: NA |
a) 22 |
(a) Defect-free weld joint. A wider weld zone appeared due to excess heat input at a higher rotational speed. (b) Defect-free joint and adequate heat input. (c) Defect-free joint. A narrower weld zone appeared due to low heat input at lower tool rotational speed. |
b) 45 |
c) 75 |
PL: 5.7 |
Z: NA |
T: NA |
F: 12 |
Elangovan and Balasubramanian [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
N: |
|
Fig. IV - C [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
a) 1500 |
PD: NA |
b) 1600 |
(a) and (b) Defect-free joint. Adequate heat input and sufficient working of plasticized metal. (c) Defect-free joint. A wider weld zone appeared due to excess working of plasticized metal at higher tool rotational speed. |
c) 1700 |
V: 45 |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 12 |
Pin geometry: Traingular - V
|
Padmanaban and Balasubramanian [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
N: 1600 |
|
Fig. V - A [4747 Padmanaban G, Balasubramanian V. Selection of FSW tool pin profile, shoulder diameter and material for joining AZ31B magnesium alloy - An experimental approach. Materials & Design. 2009;30(7):2647-2656. http://dx.doi.org/10.1016/j.matdes.2008.10.021. http://dx.doi.org/10.1016/j.matdes.2008....
] |
PD: NA |
V: 40 |
A cavity at the weld root appeared due to insufficient heat input. |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 3 |
Elangovan and Balasubramanian [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
N: 1600 |
|
Fig. V - B [4646 Elangovan K, Balasubramanian V. Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. Journal of Materials Processing Technology. 2008;200(1-3):163-175. http://dx.doi.org/10.1016/j.jmatprotec.2007.09.019. http://dx.doi.org/10.1016/j.jmatprotec.2...
] |
V: |
PD: NA |
a) 22 |
(a) Formation of tunnel defect due to excess turbulence of the plasticized metal at higher tool rotational speed. (b) Defect-free joint. Adequate heat input and sufficient working of plasticized metal. (c) Abnormal stirring of the tool pin causes a bigger tunnel defect at the weld root towards the retreating side. |
b) 45 |
c) 75 |
PL: 5.7 |
Z: NA |
T: NA |
F: 12 |
Elangovan and Balasubramanian[4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
N: |
|
Fig. V - C [4545 Elangovan K, Balasubramanian V. Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy. Materials Science and Engineering: A. 2007;459(1-2):7-18. http://dx.doi.org/10.1016/j.msea.2006.12.124. http://dx.doi.org/10.1016/j.msea.2006.12...
] |
a) 1500 |
PD: NA |
b) 1600 |
(a) Pin holes are formed towards the retreating side due to insufficient heat input. (b) Defect-free joint. Adequate heat input and sufficient working of plasticized metal. (c) Defect-free joint. Adequate heat input and sufficient working of plasticized metal. |
c) 1700 |
V: 45 |
PL: 5.7 |
Z: 0.2 |
T: 00 |
F: 12 |