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Meeting 2023 TMS Annual Meeting & Exhibition
Symposium Friction Stir Welding and Processing XII
Presentation Title Simulation and Realization of Friction Stir Welding of Aluminum Joints Using Additively Manufactured Ceramic Bobbin Tools
Author(s) Toni Sprigode, Andreas Gester, Guntram Wagner, Murat Demirtas, Nadja Kratz, Anna Foit, Gerald Ochse, Angelika Brückner-Foit, Adrian Rienäcker, Marcus Emmel
On-Site Speaker (Planned) Toni Sprigode
Abstract Scope A huge disadvantage of conventional friction stir welding (FSW) tools is that if the welding depth is insufficient, root defects can occur, which have a negative effect on the joint strength and especially on the fatigue behavior. Bobbin tools are used to counteract this weak point. These special tools have an additional second shoulder at the welding probe, which enables welding over the entire thickness of the workpiece. The possibility of producing tools from ceramic materials by means of additive manufacturing allows direct adaptation to the respective welding task. In this investigation, aluminum joints were produced by FSW using additive manufactured ceramic bobbin tools. Thereby, the running-in process in particular proved to be a critical stress for the ceramic tools. As a consequence, the process was investigated through simulation including shape optimization of the tool. This contributed to improve the joint formation in the simulation as well as the process.
Proceedings Inclusion? Planned:
Keywords Aluminum,

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

2D Axisymmetric Modeling of RFSSW Repair and Experimental Validation
3D Modeling and Experimental Validation of Linear Friction Welding Process
A Coupled SPH-FEM Framework to Predict Residual Stresses during Friction Stir Processing
A Feasibility Study on Friction Screw Extrusion Additive Manufacturing of AA6060
Advancement of US Navy Sustainment Capabilities Through Solid-State Additive Manufacturing (FSW/FSAM)
Advances in Steel FSW
Analysis of Torque Data from Friction Stir Welds in Aluminum Alloys
Assessing Manufacturability of the Oxide Dispersion Strengthened (ODS) 14YWT Alloy Fuel Cladding Tube using SolidStirTM Technology
Assessing the Performance of Liquid Cooled Plates for Inverter Stacks Produced by CoreFlow
Closed-loop PID Temperature Control of Additive Friction Stir Deposition
Copper-aluminum Hybrid Induction Motor Rotors Using Friction Stir Welding
Dissimilar Copper and Aluminium Joining Using a Solid-state Friction-stir Welding Process
Effect of Friction Stir Processing on the Microstructure and Mechanical Properties of Thick Al-6061 Alloy
Effect of Locally Beta-transformed Area on Fatigue Crack Propagation Resistance in a FSWed Ti-6Al-4V
Effect of Microstructure on Mechanical Properties of Friction Stir Processed Al Alloy
Effect of Welding Parameters on Microstructure and Mechanical Properties of Friction Stir Lap Welds of an Ultrahigh Strength Steel
Embedded Anchoring of Multi-material Assemblies by Friction Riveting Process
Enhanced Tensile and Tear Toughness Properties of Thin-wall Vacuum-assisted High-pressure Die-cast Aural-5 Alloy by Friction Stir Processing
Fabrication and Characterization of Mono and Hybrid Composites Using Friction Stir Processing with Soda-lime Glass and Polymer Reinforcements
Friction Extrusion of Thermoplastics: Manufacturing and Recycling
Friction Stir Welding of Nickel-based Superalloys
Friction Stir Welding of Steel with Steel Tool
Friction Stir Welding of Thick Steel Plate by Silicon Nitride Tool
Friction Stir Welding Operating Window for Aluminum Alloy Obtained by Temperature Measurement
Friction Stir Welding to Seal 5 cm Thick Copper Canisters Containing Sweden´s Nuclear Waste
Fundamental Study of Material Properties of Aluminum Additively Manufactured via Multi-layer Friction Surfacing
Graphite-Reinforced 6201 Aluminum Alloy Fabricated by In-situ Friction Stir Processing: Process, Microstructure and Mechanical/Electrical Properties
High Speed Butt Joining of 1" Thick 2139-T8
Hybrid FSW Tools for Electromobile Applications
In-Situ Friction Stir Forging: An Innovative and Alternative Approach towards Gear Fabrication
Investigation of Shear Deformation Introduction n Friction Extrusion from Al-Cu Alloy
Joining Cast Mg AZ91 and Wrought Al 6082 through Friction Stir Welding
Joining of High Strength Low Ductility AA7055 by Friction Self-piercing Rivet
Linking Tool Features to Process Forces
Material Flow Visualization and Comparison in Different Aluminum Alloys during Friction Stir Welding using High-Speed X-ray Imaging
Measurement of Heat Transfer Coefficient between a Friction Stir Welding Tool and Workpiece during Plunge Using a 3ω Sensor
Mechanism of Joint Formation in Dissimilar Friction Stir Welding of Aluminum to Steel
Microstructure and Hardness of Al2050 Parts Made by Additive Friction Stir Deposition
Neutron/X-ray Testing on Al6061 Prepared by Solid-state Friction Stir Additive Manufacturing
Next Generation Tooling for Friction Stir Technologies
Numerical Simulation of the FSSW Process for Aluminum Alloys 5082-O, 6082-T6 and 7075-T6
Post-Irradiation Examination of High-dose Ion Irradiated Friction Stir Welding (FSW) MA956 ODS Alloy
Production Evaluation of Refill Friction Stir Spot Welding
Recent Progress in Additive Friction Stir Deposition: from Process Fundamentals to Niche Applications
Repair of Railroad Rail via Additive Friction Stir Deposition
Robust Temperature Control for Shear Assisted Processing and Extrusion (ShAPE)
Simulation and Realization of Friction Stir Welding of Aluminum Joints Using Additively Manufactured Ceramic Bobbin Tools
Smoothed Particle Hydrodynamics Model for Friction Stir Processing of 316 L Stainless Steel: Process Modeling and Microstructure Evolution Analysis
Submerged Bobbin Tool (SBT) Tunneling Technology
Surface Alloying Due to WC Tool Wear during FSP and Its Effects on the Microstructure and Mechanical Properties of Topmost Steel Layer
Temperature Matching of Friction Stir Welding: 3D Simulation
The Effect of Additional Impulses on Microstructure and Mechanical Performance of Impulse Friction Stir Welded AA7075-T6 Joints
The Influence of Flow Stress Data and Friction Models on 2D and 3D Simulations of Friction Stir Welding in AA 2219-T76
The Performance of a Force-based General Defect Detection Method Outside of Calibration
The Role of Fracture Properties on Lap Joint Strength of Friction Stir Welded AA 7055-T6 Sheets
Validation of Models for Predicting Bonding Behavior in Friction Stir Welding Processes

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