GTU - International Conference - GTU ICON 2019
PCE 102
A REVIEW ON RESIDUAL STRESS IN FRICTION STIR WELDING:
CAUSES, MEASURING TECHNIQUES, NATURE OF DISTRIBUTIONS,
CONSEQUENCES AND CONTROL
AE0257 AE0258
Samir K Raval K B Judal
Lecturer, Principal
K D polytechnic Patan GEC, Palanpur
[email protected] [email protected]
7575809673 9375844848
Abstract
Residual stresses are process-induced, locked-in stresses which are desirably or undesirably present in
components. They develop primarily due to non-uniform volumetric change in metallic components
irrespective of manufacturing methods and sometimes without external loading. Residual stresses in
welded joints primarily build up due to differential weld thermal cycle (i.e. heating, peak temperature and
cooling at the any moment during welding). It is more common in fusion welding with high magnitude
but usually believed to be less in solid state welding owing to lower peak temperature (below melting)
during joining. Friction Stir Welding (TWI, 1991) is rapidly blooming in the contemporary modern
engineering fields of aerospace, defense, marine, automotive, and railway industries as proven approach
of solid state joining. Residual stresses are also found in the friction stir welded plates due to thermal
loading and unloading, plastic deformation, and mechanical constraints imposed during welding. Over the
last few years, both experimental and numerical techniques have been conducted to study the residual
stress distribution during similar and dissimilar friction stir welding of aluminum and other alloys.
Research revealed that residual stresses are functions of peak temperature and flow stress distribution of
the various regions of the joints which may be influenced by process variants like properties of materials
being welded, welding speeds, feeds and tool geometry. Since unwanted stresses are not favorable to the
integrity, fatigue properties, soundness, dimensional stability, fracture toughness and service life of
fabricated articles, appraisal becomes imperative to tease out recent trends and progress in this field. The
present review gives comprehensive insight to this significant issue in view of; reasons for development,
various methods of evaluation and some common fashions of their distributions. Finally the outcomes due
to presence of stress have been elaborated and few novel approaches to restrain its development are
addressed.
Keywords: Friction Stir Welding (FSW), Aluminium alloys, Residual Stress, Neutron Diffraction, Hole-
drilling
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