I'm doing a friction stir welding experiment which needs to join two dissimilar material which are aluminium 6061 and 7075. so i had to design 6 tools with different profiles. so, i plan on designing taper tool pins but the problem is i'm not sure about the angle i have to used? did anyone has any suggestion on this problem?
Hi
based on researches the best ratio for D/d = 3. for example if the tool shoulder has 18 mm diameter it would be better to use a pin with 6 mm diameter. but in your case the sheet thickness(2 mm) is too low, so if you use a pin with large diameter(d > 3 mm) the excessive heat produced by tool will affected the weld nugget zone and the mechanical properties of the joint as well. if it is possible do not use taper pin profile because in process of welding AL alloys, the AL particles will stick around the pin and the pin will be shaped as a curve and can not stir the materials from the advanced to retreat side, so the best suggestion is to use a taper pin profile with thread on it. in my experimental work the angle for taper pin was 32 degree.
good luck !
thanks! that help me a lot! i also think the same. i will try to research more about this matter.
Please refer to my paper on the topic. It is available at:
https://www.researchgate.net/publication/281556538_Effect_of_Shoulder_Diameter_to_Pin_Diameter_%28Dd%29_Ratio_on_Tensile_Strength_of_Friction_Stir_Welded_6063_Aluminium_Alloy?ev=prf_pub
Article Effect of Shoulder Diameter to Pin Diameter (D/d) Ratio on T...
Dear Amirah,
When joining a dissimilar Aluminium combination such as 6065 to 7075, you might want to keep your D/d ratio as low as possible for sheet thicknesses of 2mm. You could probably start off with 2.5 and work your way down to 1.5 preferably. There are videos on youtube that you show the use of such ratios on sheet metal thicknesses of 2mm and lower.
Regards,
Samir
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