I have tried several ranges of welding speed (18 mm/mim-50mm/min) and rotational speed (560 rpm-1100 rpm), different type of tool (h13. hss s600) with different pin profile (square, triangular ) and none of the FSWed joints are defectless.
It depends on what kinds of defects you observed. Apart from tool rpm, welding speed and shoulder diameter; you try to vary tool tilt angle and plunge depth as well. Tool tilt affects the forging action and plunge depth affects the flash/crater formation.
hi mohammad,
the statement said by Arshad is correct one.. because tool parameters( tool shoulder dia, tool pin dia, tool tilt angle,tool pin profile) play vital role in FSW process.. for example if the ratio of shoulder dia and pin dia is not correct ratio means skimming of metal layers and void fformation (tunnel like) in weld bead.. increase in tool tilt angle reduces the forging action and decrease the temperature... it leads to improper plastic deformation in weld zone and failure of joints...
It depends on the location of sheets to be welded. Aluminium alloy place on the advancing side.
Al-Mg dissimilar joint is difficult to produce without defects using FSW. There is a great mismatch between AA7075 and AZ31. The plasticization behavior of both are different. Try using a tool with larger dimensions say shoulder diameter equal to 4 to 4.5 times thickness of the plate and offset the tool towards aluminum. Nevertheless, the welding window will be narrower. Hence, finding the optimized parameters will be critical.
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