Setting optimum process parameters is very critical in achieving a sound friction stir weld joint. Understanding the formation of defects and developing techniques to minimize them can help in improving the overall weld strength. The most common defects in friction stir welding (FSW) are tunnel defects, cavities, and excess flash formation, which are caused due to incorrect tool rotational or advancing speed. In this paper, the formation of these defects is explained with the help of an experimentally verified 3D finite element (FE) model. It was observed that the asymmetricity in temperature distribution varies for different types of defects formed during FSW. The location of the defect also changes based on the shoulder induced flow and pin induced flow during FSW. Besides formation of defects like excess flash, cavity defects, tunnel/wormhole defects, two types of groove like defects are also discussed in this paper. By studying the different types of defects formed, a methodology is proposed to recognize these defects and counter them by modifying the process parameters to achieve a sound joint for a displacement-based FSW process.
Skip Nav Destination
Article navigation
November 2017
Research-Article
Investigation on the Effects of Process Parameters on Defect Formation in Friction Stir Welded Samples Via Predictive Numerical Modeling and Experiments
Abhishek Ajri,
Abhishek Ajri
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
Purdue University,
West Lafayette, IN 47907
Search for other works by this author on:
Yung C. Shin
Yung C. Shin
Fellow ASME
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: shin@purdue.edu
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: shin@purdue.edu
Search for other works by this author on:
Abhishek Ajri
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
Purdue University,
West Lafayette, IN 47907
Yung C. Shin
Fellow ASME
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: shin@purdue.edu
School of Mechanical Engineering,
Purdue University,
West Lafayette, IN 47907
e-mail: shin@purdue.edu
1Corresponding author.
Manuscript received June 12, 2017; final manuscript received June 22, 2017; published online September 13, 2017. Assoc. Editor: Wayne Cai.
J. Manuf. Sci. Eng. Nov 2017, 139(11): 111009 (10 pages)
Published Online: September 13, 2017
Article history
Received:
June 12, 2017
Revised:
June 22, 2017
Citation
Ajri, A., and Shin, Y. C. (September 13, 2017). "Investigation on the Effects of Process Parameters on Defect Formation in Friction Stir Welded Samples Via Predictive Numerical Modeling and Experiments." ASME. J. Manuf. Sci. Eng. November 2017; 139(11): 111009. https://doi.org/10.1115/1.4037240
Download citation file:
Get Email Alerts
On-Orbit Processing and Hardware Performance of Microgravity Hydrothermal Synthesis for Graphene Aerogel
J. Manuf. Sci. Eng (December 2024)
A Review on Metallic Drilling Burrs: Geometry, Formation, and Effect on the Mechanical Strength of Metallic Assemblies
J. Manuf. Sci. Eng (April 2025)
Related Articles
Thermal Mechanical Modeling of the Plunge Stage During Friction-Stir Welding of Dissimilar Al 6061 to TRIP 780 Steel
J. Manuf. Sci. Eng (October,2015)
Modeling of Friction Self-Piercing Riveting of Aluminum to Magnesium
J. Manuf. Sci. Eng (June,2016)
Heat Transfer in Friction Stir Welding—Experimental and Numerical Studies
J. Manuf. Sci. Eng (February,2003)
Modeling of Temperature Distribution in Laser Welding of Lapped Martensitic Steel M1500 and Softening Estimation
J. Manuf. Sci. Eng (November,2016)
Related Proceedings Papers
Related Chapters
Concluding Remarks and Future Work
Ultrasonic Welding of Lithium-Ion Batteries
Experimental Investigation of Ventilated Supercavitation Under Unsteady Conditions
Proceedings of the 10th International Symposium on Cavitation (CAV2018)
Defining Joint Quality Using Weld Attributes
Ultrasonic Welding of Lithium-Ion Batteries