By Jordan Brandes
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Extra resources for Contract Manufacturing and Packaging May-June 2011
Sample text
6 times the melt temperature of the material being deformed and for strain rates such that recovery processes occur substantially during deformation (Dieter 1988). The need for such temperatures is because the mechanical working of a metallic material at room temperature will lead to a magnitude of dislocations forming in which slip becomes progressively more difficult. Hence dislocations increase internal stress and strain hardening is said to take place. By further applying cold work to the material, this raises the level of internal stress until fracture eventually occurs.
This material is then forced to flow and form the so-called solid-state joint, sometimes referred to as the weld nugget or more consistently identified today as the stir zone. The combination of applied forces and resultant processing temperature derived from the interfacial conditions between the rotating and traversing tool with that of the workpiece material causes macroscopic shape change to take place. This occurs in and directly adjacent to the stir zone via grain boundary sliding aided through recovery and recrystallisation, processes (Jata and Semiatin 2000), and for the case of precipitation hardening and non-heat-treatable alloys at temperatures which ensure the dissolution of hardening particles (Shercliff et al.
Since FSW is a fully coupled thermomechanical process, the properties of the workpiece material as it reaches the welding tool may affect the process forces and heat input generated. If the travel speed is very slow, the base metal initial temper may not significantly affect the spindle torque, since there is time for alteration of the initial temper prior to coming into contact with the welding tool. However, when welding thin materials at high travel speed, it is likely 38 Friction stir welding that the initial temper will influence heat generation, friction coefficient, and contact forces.