Welding initiation at the entry stage of Bobbin Friction Stir Welding (BFSW)

Mahrob, Noramilza (2017) Welding initiation at the entry stage of Bobbin Friction Stir Welding (BFSW). Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Bobbin Friction Stir Welding is a welding process that used rotational tool cross through the welding plate to form joining between two plates. The purpose of this research conducted was to find out the welding initiation strategy at the entry stages of Bobbin Friction Stir Welding (BFSW). The experiment conducted using CNC Milling machine. The parameter set used were type of entry, strategy approaches, rotational speed and travel speed by using Al-Alloy 5xxx series with dimension l 40mm x l 40mm x 6mm using fixed bobbin tool. The study conducted since good weld formation influenced by good weld initiation. Defects such as material ejection, flash formation, void and tunnel at the entry stages can be reduced by suggesting the entry method. In this study, two types of entry were used; edge entry and guided holes entry approached. The maximum value given by edge entry method was 12.794 mm2 of area deformation with 0.074% of material wasted and used 27 672. 75 J of energy to complete one cycle of welding process. The maximum temperature reached was 387°C. Fast Fourier Transform was used to analyse the frequency response of the machine used and analyse the formation of good and bad weld quality. For edge entry, the good weld quality were frequently produced. The minimum result obtained from hardness and tensile test were 28.24 HV and 33.2292 MPa. For guided holes, the maximum value of area deformation was 43.160 mm2 with 0.499% of material wasted and the maximum amount of energy consumption to complete a welding cycle was 57 960 J. The maximum temperature reached was 438°C and produced bad weld quality frequently in Fast Fourier Transform analysis. The minimum value reached in hardness test and tensile test were 26.5 HV and 12.5625 MPa. At the end of the study, the best tool entry method was suggested in order to obtained better weld quality.

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