Abstract

An attempt has been made to study the effect of counter rotating twin tool on the commercially pure
aluminium alloy using friction stir welding. Further a comparative study is made between twin tool
(TT) and single tool using double pass (ST-D).Twin tool helps in generating high heat caused
intense plastic deformation in the processed !one. Defect free !one not only depends on the
rotational speed but also on the combined effect of welding speed and rpm. "igher hardness profile
is observed with highest welding and rotational speed (#$%% rpm with &' mm(min).)oints fabricated
at higher rpm and higher welding speed are found to be free from defects. Further '#.* mm(min
welding speeds is the critical point where a sudden change in mechanical properties was observed.
S+, results confirm the e-istence of ductile failure with microscopic voids of different shape and
si!es.
.eywords/ Friction stir welding0 counter rotating twin tool0
1ntroduction
+specially for aluminium alloy0 Friction stir welding is an improved techni2ue of 3oining compared
to fusion welding process. 1t is a solid state techni2ue where the temperature is reached below
melting point of the welding material0 invented by The 4elding 1nstitute0 in #55# (,ishra and ,a0
6%%*) and (7andan et al.0 6%%$).The process is advanced in 3oining materials which are difficult to
weld0 re2uire no filler and shielding gas0 need less s8illed wor8ers.
"owever0 careful selection of welding process parameters (such as weld speed0 rotation
speed0 plunge depth or plunge force0 tool geometry) which are comple-0 is beneficial for preventing
the formation of defective weld (9eal and 9oureiro0 6%%:).
Furthermore0 some degradation in mechanical properties has been observed when there is a
deviation in the welding condition. Though it is a reliable techni2ue for 3oining0 complete
elimination of defect is not possible. So a lot of researchers focussed to repair the defective portion
by using multi-pass FS4(FS using the nominal process parameters. That means0 by using the re-
welding techni2ue0 defective portion of the weld is being repaired (;rown et al.0 6%%5). <ecent
literature reports several e-amples related to multi-pass FS(FS4.
(;rown et al.0 6%%5) performed five overlapping passes and found that there is no need of any
ad3ustment for multi-pass welding. Further there is a significant reduction in feed force when
welding is done over the previous weld. "owever grain si!e0 hardness and temperature during
welding is unaffected with number of passes. Again there is a gradual reduction of residual stress
with increasing pass number.
(7ata8a et al.0 6%%&) reported an advancement of the mechanical properties in aluminium die
casting alloy using multi-pass FS compared to the as-cast base metals. As compared to base metal0
hardness increased by 6%"=and the tensile strength of the multi-pass specimens were significantly
increased to about #.> times of as-cast base metal. The main reason for improvement of mechanical
properties is due to the removal of cold fla8e0 uniform distribution of the silicon particles over the
aluminium matri- which refines the grain. ?n the other hand (,a et al.0 6%%&) reported that there is
no effect of overlapping passes on si!e0 aspect ratio or distribution of the Si particle while
performed five-pass with *%@ overlap FS on cast A'&*.
(9eal and 9ouriero 6%%$) investigated the effect of overlapping FS4 passes using two Al alloys
(AA*%$'-? and AA &%&'-T&).They found that the 2uality and strength of the welded 3oint is not
only dependent on the weld parameters0 but also on the type of material and its heat treatment
conditions. 9astly they found that weld polishing improved the mechanical efficiency of the welded
3oint.
As FS is one of the most promising techni2ues for grain refinement0 removing flaws0 defectsA
many researchers used multi-pass FS to improve the properties of as-cast material. ()ohannes and
,ishra 6%%>) used to demonstrate the effectiveness of multiple passes to create large area of super
plastic materials with properties. They conclude that for achieving the super plastic deformation
grain boundary sliding (B;S) is the most important mechanism. Similarly (,a et al.0 6%%5) noted
that two pass FS shows enhanced super plastic elongation compared to single pass. Further the
temperature in central !one of second pass and transitional !one is more than the single pass.
(Sure8ha et al. 6%%$) reported that multi-pass FS showed better corrosion resistance compared to
the base metal.
Csing cast Al alloy0 ()ana et al.0 6%#%) reported that multiple passes helped in removal of abnormal
grain growth (ABB) occurred during single pass runs. They also e-amined and found that higher
rotational speed was found to be beneficial for controlling the ABB. (;armou! and Bivi0 6%##)
used ,FS to improve metallurgical and mechanical properties of cu(sic metal matri- composites.
<esult shows Sic particle dispersed and fragmented to smaller si!e due to severe stirring action in
the nugget !one of the copper matri-. 1t also created strong interfacial bonding by removing the
porosity content.
,ulti-pass overlapping FS (,? FS) has been applied by (7i et al.0 6%##) to transform the
coarse as-cast 7ab alloy base metal to get defect free material with fine microstructure0 which was
feasible to modify the large si!ed plates. Similar type of study had been conducted by (1!adi and
Berich0 6%#6) to study the effect of multi-pass FS on distribution and stability of carbon nano-tube
and to fabricate A9 *%*5 and ,4D7Ts metal matri- composite (,,D).
To avoid the use of multi-pass FS4(FS0 the two-tool-FS4 concept is being developed at T41 in
several variations (Thomas0 #555). ?ne of those techni2ues is named as Tandem twin-stir techni2ue
(Thomas et al.0 6%%*). Tandem Twin-Stir uses two FS4 tools (with or without counter rotation)
positioned one in front of the other.
The aim of this investigation to determine the effect of two contra rotating FS4 tool (Tandem
Twin-stir) on the friction stir processing(welding region of commercially pure aluminium alloys.
6. +-perimental wor8
1n order to demonstrate the characteristics of twin tool0 a self designed twin tool setup is designed0
fabricated and used for friction stir welding is shown in Fig #. The twin tool system is composed of
two tools which are rotating in opposite direction to each other. The primary tool is mounted on the
main spindle shaft. Therefore0 the main tool rotates at the same rotational speed and in the same
direction as the spindle during the welding process. The secondary tool is connected with the
primary tool with the help of gear assembly. The power transmission from the primary to secondary
tool is similar to the transmission of power from driver to driven gear0 So that the rotation of the
secondary tool is 3ust opposite to the primary tool.
Fig.#/ Twin tool attachment
Friction stir welding using twin tool and single tool with double pass were produced in 6.* mm
thic8 plate of commercially pure ##%% aluminium alloy. 1n both the cases welds made with
complete overlapping passes. ;oth the plates were clamped using specially designed E-ture as
shown in Fig 6. The nominal chemical composition of the plate is shown in Table #.The FS4
carried out at 8nee type vertical milling machine (;F40 =F'.*)0 which has wide range of rotational
speed (:* to #$%% rpm) and welding speed(feed rate (#& to $%% mm(min).
Fig.6/ Specially designed Fi-ture
Table #.
Dhemical composition of the wor8 piece material
Dhemical composition (weight @) of wor8 piece material
Si Fe Du ,n ,g Fn Ti Ba 7a ?thers
<emainder
Aluminium
%.>%** .$'# .%%*%* %.%#' %.%%:&* %.%%'# %.%%:$ %.%##$ %.%%6:*
,a-.
%.%*@
5$.>
A non-consumable tool made of stainless steel SS'#& with #& mm shoulder diameter0 a cylindrical
pin of * mm diameter and 6 mm length was used for welding. ;y using four rotational speeds (5%%0
##6%0 #:%%0 #$%% rpm) and three welding speeds (#&0 '#.*0&' mm(min)0 total #6 e-periments were
performed using twin tool and single tool with double pass. Therefore0 total 6: e-periments have
been carried out at this stage. The coupled plate with simultaneous double pass using the twin tool
setup is shown in Fig '.
Fig.'/ Schematic diagram of welded plate using twin tool setup
To e-amine the superficial defects macroscopic analysis was done using 9eica S&D Trinocular
stereo !oom microscope with 9eica G4in-=' image analysis software. Specimen for
metallographic analysis are sectioned comprising of welded !one0 heat affected !one0 thermo-
mechanical !one and unaffected base metal region. Samples are polished with a set of emery papers
with different grades. Further diamond paste is used for final polishing in variable speed grinder
polishing machine. .ellers reagent was used to e-amine the macroscopic view. The ;uhlerHs
=ic8ers hardness indentation machine with 6%% gmf with #* sec dwell time was used to get the
hardness profile of the welded sample on a cross section normal to the welding direction. To
evaluate the tensile strength of the welded samples0 specimens were cut using electro discharge
machine transverse to the direction of the weld line. The tensile test was carried out at normal room
temperature using 17ST<?7-$$&6 machine with a ram speed of #mm(min. Fig : shows the
dimension of the tensile test specimen. The fractured tensile surfaces were studied using scanning
electron microscope ()?+9-)S, *$%%) to analyse the failure patterns.
Fig. :/ Shape of the tensile test samples
'. <+SC9TS
'.# ,acrostructural analysis
orosity0 solidification crac8ing0 inclusions are some of the defects in fusion welding process
which degrades the 2uality of the weld and the property of the 3oint. ,ainly these types of
defects are not generated in case of friction stir welding0 in which there is no melting of metal
occurs. )oining ta8es place due to the stirring action of metal and heat generation by friction.
"owever due to improper selection of process parameters defects li8e pinhole0 tunnels0 piping
defect0 8issing bond0 crac8s are generated in the friction stir welded 3oints. Stereo !oom
microscope with magnification of #%I was used to analyse the 2uality of the welded region.
,acrostructure of the welded regions are shown in Fig * using twin tool attachment with
different rotational and welding speed. At higher rpm and high welding speed 3oints using twin
tool shows defect free welds. "ence formation of defect free weld is both dependent on the
rotational speed and welding speed.
900-16 1120-16
1400-16 1800-16 900-31.5 1120-31.5
1400-31.5
1800-31.5 900-63
1120-63 1400-63
1800-63
Fig.*/ ,acrographs of welded samples using twin tool
'.6 "ardness Testing
Fig * shows the hardness profiles of the welds made with twin tool as well as single tool with
double pass. 4elds made with twin tool shows higher value of hardness compared to the two pass
FS4 3oints for most of the welding parameters. This is due to the hardening effect caused by
intense plastic deformation in the processed !one. As materials in the nugget !one are sub3ect to two
stirring actions so materials undergo severe plastic deformation due to which it gains a higher
cooling rate as compared to single pass material. 4ith subse2uent processing of one tool over the
other intense plastic deformation is occurred by which hardness caused due to second pass is more
than the first pass. Similarly in case of two pass using single tool0 the material is sub3ected to two
stir effects but there is a time delay in between the two passes. Therefore0 cooling rate is somewhat
less as compared to twin tool passes. From the Fig * (l)0 it is revealed that welds made with twin
tool shows higher hardness value compared to single tool with double pass corresponding to #$%%
rpm with &' mm(min welding speed. Further from Fig * (a-l) it is observed that at high rotational
speed of #$%% rpm with all constant welding speed0 twin tool gives the higher value of hardness
profile in comparison to two pass using single tool. Fig > (a-d) shows the effect of welding speed on
average micro hardness of welded samples at constant rpm. 1t can be seen that '#.* mm (min is the
critical welding speed where there is drastic change in the average micro hardness of a particular
sample with a definite welding parameter. So harness value is not only depends on the rotational
speed or welding speed it depends on the revolutionary pitch i.e. (welding speed(rotational speed)
in mm per rev.
-10 -5 0 5 10
20
25
30
35
40
45
50
55
60
H
a
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s
s

(
H
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)
Distance from weld centre (mm)
900-16()
900-16(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
30
35
40
45
50
55
H
a
r
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s
s

(
H
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Distance from weld centre (mm)
1120-16()
1120-16(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
15
20
25
30
35
40
45
50
H
a
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s

(
H
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Distance from weld centre (mm)
1400-16()
1400-16(!-D")
-12 -10 -8 -6 -4 -2 0 2 4 6 8 10 12
20
25
30
35
40
45
50
55
60

H
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s

(
H
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Distance from weld centre (mm)
1800-16()
1800-16(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
20
25
30
35
40
45
50
55
60
H
a
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s
s

(
H
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Distance from weld center (mm)
900-31.5()
900-31.5 (!-D")
-10 -5 0 5 10
20
25
30
35
40
45
50
H
a
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(
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Distance from weld centre (mm)
1120-31.5()
1120-31.5(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
10
15
20
25
30
35
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45
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H
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(
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Distance from weld centre (mm)
1800-31.5()
1800-31.5(!-D")
-10 -8 -6 -4 -2 0 2 4 6 8 10
30
35
40
45
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55
H
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(
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Distance from weld centre (mm)
1400-31.5()
1400-31.5(!-D")
-10 -5 0 5 10
25
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H
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Distance from t#e weld center (mm)
900-63()
900-63(!-D")
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30
35
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45
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H
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(
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Distance from weld centre(mm)
1120-63()
1120-63(!-D")
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30
35
40
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H
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1400-63()
1400-63(!-D")
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30
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H
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(
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Distance from weld centre (mm)
1800-63()
1800-63(!-D")
Fig.* (a-l)/ +ffect of TT0 ST-S0 and ST-D on the nugget !one hardness
900-16 1120-16 1400-16 1800-16
35
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sam$le $arameter

!-D"
%eldin& s$eed 16mm'min(const.)
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30
35
40
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%eldin& s$eed 31.5 mm'min(const.)
H
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!am$le $arameter

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900-63 1120-63 1400-63 1800-63
30
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%eldin& s$eed 63 mm'min(const.)
H
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!am$le $arameter

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Fig.& (a-c)/ +ffect of rotational speed on average micro hardness of FS4 !one using TT J
ST-D
900-16 900-31.5 900-63
35
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(otational s$eed 900 (const.)
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Fig.> (a-d)/ +ffect of welding speed on average micro hardness of FS4 !one using TT J ST-
D
'.' Tensile testing
Fig $ (a-l) shows all the comparative graphs corresponding to yield strength0 ultimate tensile
strength0 percentage of elongation and 3oint efficiency of the welded 3oints using twin tool
and single tool with double pass. 1t is seen that there is no significant variation in the yield
strength of the 3oints fabricated using twin tool and double pass.
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Fig.$ (a-l)/ +ffect of TT and ST-D on KS0 CTS0 @ age of elongation and 3oint efficiency of
the welded samples
Fig 5 shows the effect of rotational speed on yield strength at constant welding speed. 1t is
seen that at a constant welding speed #$%% rpm shows higher yield strength in all the cases
using single tool with double pass. Similarly from Fig.#% at a constant rotational speed &'
mm(min welding speed results higher yield strength using single tool with double pass. ;ut
the variation in yield strength using both twin tool and single tool with double pass at higher
rpm (#$%% rpm) and at higher welding speed (&' mm(min) is almost negligible. Further from
the comparative graphs it is observed that '#.* mm(min welding speeds is the critical point
where there is a sudden change in the mechanical strength for all the cases. This similar
scenario is observed in case of ultimate strength0 percentage of elongation and 3oint efficiency
also.
900-16 1120-16 1400-16 1800-16
35
40
45
50
)
!

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5
"
a
!am$le $arameter

!-D"
%eldin& s$eed816 mm'min(const.)

900-31.5 1120-31.5 1400-31.5 1800-31.5
30
35
40
45
50
55
60
%eldin& s$eed831.5 mm'min(const.)
)
!

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5
"
a
!am$le $arameter

!-D"
900-63 1120-63 1400-63 1800-63
38
40
42
44
46
48
50
%eldin& s$eed863 mm'min(const.)
)
!

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"
a
!am$le "arameter

!-D"
Fig. 5 (a-c)/ +ffect of rotational speed on yield strength of welded 3oints using TT J ST-D
900-16 900-31.5 900-63
35
40
45
50
55
60
(otational s$eed8900 r$m(const.)
)
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"
a
!am$le $arameter

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1120-16 1120-31.5 1120-63
25
30
35
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55
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(otational s$eed81120 r$m(const.)
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a
!am$le $arameter

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1400-16 1400-31.5 1400-63
35
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45
50
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(otational s$eed81400 r$m(const.)
)
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a
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1800-16 1800-31.5 1800-63
30
35
40
45
(otational s$eed81800 r$m(const.)
)
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"
a
!am$le $arameter

!-D"
Fig.#% (a-d)/ +ffect of welding speed on yield strength of welded 3oints using TT J ST-D
900-16 1120-16 1400-16 1800-16
40
50
60
90
80
90
100
110
120
%eldin& s$eed16 mm'min (const.)
*

!

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n

5
"
a
!am$le $arameter

!-D"

900-31.5 1120-31.5 1400-31.5 1800-31.5
40
50
60
90
80
90
100
110
120
%eldin& s$eed 31.5 mm'min (const.)
*

!

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5
"
a
!am$le $arameter

!-D"
900-63 1120-63 1400-63 1800-63
90
95
80
85
90
95
100
%eldin& s$eed863 mm'min (const.)
*

!

i
n

5
"
a
!am$le $arameter

!-D"
Fig.## (a-c)/ +ffect of rotational speed on CTS of welded 3oints using TT J ST-D
900-16 900-31.5 900-63
40
50
60
90
80
90
100
110
120
(otational s$eed8900 r$m (const.)
*

!

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5
"
a
!am$le $arameter

!-D"

1120-16 1120-31.5 1120-63
40
50
60
90
80
90
100
110
120
(otational s$eed81120 r$m (const.)
*

!

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5
"
a
!am$le $arameter

!-D"
1400-16 1400-31.5 1400-63
60
90
80
90
100
110
120
(otational s$eed81400 r$m (const.)
*

!

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5
"
a
!am$le $arameter

!-D"

1800-16 1800-31.5 1800-63
60
90
80
90
100
110
120
(otational s$eed81800 r$m (const.)
*

!

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5
"
a
!am$le $arameter

!-D"
Fig.#6 (a-d)/ +ffect of welding speed on CTS of welded 3oints using TT J ST-D
900-16 1120-16 1400-16 1800-16
0
5
10
15
20
25
30
35
40
%eldin& s$eed816mm'min (const.)
+

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!-D"

900-31.5 1120-31.5 1400-31.5 1800-31.5
0
5
10
15
20
25
30
35
40
%eldin& s$eed831.5 mm'min (const.)
+

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!-D"
900-63 1120-63 1400-63 1800-63
10
15
20
25
30
35
%eldin& s$eed863 mm'min (const.)
+

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!-D"
Fig.#' (a-c)/ +ffect of rotational speed on @age of elongation of welded 3oints using TT J
ST-D
900-16 900-31.5 900-63
5
10
15
20
25
30
35
40
45
(otational s$eed8900 r$m (const.)
+

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1120-16 1120-31.5 1120-63
0
5
10
15
20
25
30
35
40
45
(otational s$eed81120 r$m (const.)
+

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!-D"
1400-16 1400-31.5 1400-63
5
10
15
20
25
30
35
40
45
(otational s$eed81400 r$m (const.)
+

1
3

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1800-16 1800-31.5 1800-63
20
22
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26
28
30
(otational s$eed81800 r$m (const.)
+

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!-D"
Fig#: (a-d)/ +ffect of welding speed on @age of elongation of welded 3oints using TT J ST-
D
900-16 1120-16 1400-16 1800-16
30
40
50
60
90
80
90
100
%eldin& s$eed816 mm'min (const.)
0
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900-31.5 1120-31.5 1400-31.5 1800-31.5
20
30
40
50
60
90
80
90
100
%eldin& s$eed831.5 mm'min (const.)
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900-63 1120-63 1400-63 1800-63
60
65
90
95
80
85
90
95
100
%eldin& s$eed863 mm'min (const.)
0
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Fig.#* (a-c)/ +ffect of rotational speed on 3oint efficiency of welded 3oints using TT J ST-D
900-16 900-31.5 900-63
30
40
50
60
90
80
90
100
(otational s$eed8900 r$m (const.)
0
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1120-16 1120-31.5 1120-63
20
30
40
50
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90
80
90
100
(otational s$eed81120 r$m (const.)
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1400-16 1400-31.5 1400-63
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60
90
80
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100
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0
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1800-16 1800-31.5 1800-63
50
60
90
80
90
100
(otational s$eed81800 r$m (const.)
0
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;

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+

a
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!-D"
Fig.#& (a-d)/ +ffect of welding speed on 3oint efficiency of welded 3oints using TT J ST-D
!-D"
900-16
1120-16
1400-16
1800-16
900-31.5
1120-
31.5
1400-
31.5
1800-
31.5
900-63
1120-63
1400-63
1800-63
Fig.#>/ Appearance of the test pieces after tensile tests
Fig.#> shows the photographs of the test pieces after tensile testing using twin tool and single
tool with double pass. From the figure it is seen that the fractured position in the weld reflects
the location of minimum hardness !one. This implies that the 3oint strength can be correlated
with the micro hardness property.
'.: Fractography
The fractured surface of the welded plate under tension is shown in the Table ' for twin tool
and single tool with double passes. The presence of microscopic voids of different si!e and
shape confirms the e-istence of ductile failure using scanning electron microscope. The
fractured surfaces of the tensile sample were populated with a large number of fine dimples
revealing failure due to ductile behaviour. This type of situation arises due to optimal material
mi-ing with grain refinement. ?n the contrary due to comple- process parameter a less
ductile failure occur resulted in a less ductile failure or combination of ductile with brittle
fracture or cleavage type. At 5%% rpm and #& mm per min welding speed the welded
specimen shows different nature of fractured surface. Csing twin tool welded specimen is
fractured at the base metal !one but using single tool with double pass the specimen brea8s at
the weld !one region which shows partly ductile and partly brittle fracture. Similarly with
twin tool the specimen brea8s at the mid-!one of the weld region with #:%% rpm and #& mm
per min welding speed. The fractured surface shows a combination of ductile and cleavage
type fracture. Therefore when the specimen brea8s at the weld !one or nearby !one the
fractured surface is the combination of ductile and brittle fracture due to high heat generation
in that !one which causes intense plastic deformation.
Table 6.
1mages of the fractured surface.
"<(<5,,( !-D"
900-16
1400-16
1800-31.5
900-63
1400-63
Donclusions
1n this investigation an attempt has been made to study the effect of twin tool and single tool
with double pass on the formation of friction stir welding !one in a commercially pure
aluminium alloy with different rotational speed and welding speed. From this0 the following
conclusions are derived/
#. Formation of defect free weld is a function of both rotational speed and welding
speed. )oints fabricated at #$%% rpm and &' mm(min welding speed shows the highest
hardness profile compared to the other welded 3oints.
6. Further from the comparative graphs it is observed that '#.* mm(min welding speeds
is the critical point where there is a sudden change in the mechanical strength (yield
strength0 ultimate tensile strength0 percentage of elongation and 3oint efficiency) for
all the cases.
'. From the S+, analysis it is observed that the presence of microscopic voids of
different si!e and shape confirms the e-istence of ductile failure.
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;rown0 <.0 Tang0 4.0 <eynolds0 A..0 6%%5.,ulti-pass friction stir welding in alloy >%*%-
T>:*#/ +ffects on weld response variables and on weld properties. ,ater Sci +ng A0 *#'-
*#:0 ##*-#6#.
1!adi0 ".0 Berlich0 A..0 6%#6. Distribution and stability of carbon nanotubes during multi-
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)ana0 S.0 ,ishra0 <.S.0 ;aumann0 ).A.0 Brant0 B.0 6%#%. +ffect of process parameters on
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9eal0 <.0 9oureiro0 A.0 6%%:.Defects formation in friction stir welding of aluminium alloys.
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#&6'-#&6&.
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,ater sci. +ng A0 :'>0 6>:-6$%.
7i0 D.<.0 Iue0 .0 ,a0 F.K.0 6%##.+ffect of ,ultiple-ass Friction Stir rocessing
?verlapping on ,icrostructure and ,echanical roperties of As-Dast 7iAl ;ron!e. ,etall
,ater Trans A0 :6($)0 6#6*-6#'*.
Sure8ha0 ..0 ,urty0 ;.S.0 <ao0 ...0 6%%$.,icrostructural Dharacteri!ation and corrosion
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:%*>-:%&$.
Thomas0 4.,.0 Staines0 D.).0 4atts0 +.<.0 7orris0 1.,.0 6%%*. The simultaneous use of two or
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