Tool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steel
Abstract Friction stir welding (FSW) is known for its environmentally friendly characteristics and energy efficiency. The geometry of the tool holds significant importance in FSW, playing a crucial role in ensuring satisfactory welds. In the present work, optimization of tool geometry is carried out...
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| Format: | Article |
| Language: | English |
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Springer
2025-06-01
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| Series: | Discover Materials |
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| Online Access: | https://doi.org/10.1007/s43939-025-00292-w |
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| author | Anmol Bhatia Reeta Wattal Rajeev Kumar Anant Prakash Agrawal Saurabh Dewangan |
| author_facet | Anmol Bhatia Reeta Wattal Rajeev Kumar Anant Prakash Agrawal Saurabh Dewangan |
| author_sort | Anmol Bhatia |
| collection | DOAJ |
| description | Abstract Friction stir welding (FSW) is known for its environmentally friendly characteristics and energy efficiency. The geometry of the tool holds significant importance in FSW, playing a crucial role in ensuring satisfactory welds. In the present work, optimization of tool geometry is carried out for the FSW of 3 mm thick AISI 1018 carbon steel. A tungsten carbide tool containing 7 wt.% cobalt with a tapered pin profile—identified as the optimal configuration—was employed for the welding process. The FSW joint was subjected to microstructure examination and tensile testing for weld quality. The results revealed that optimized tool geometry enhanced the weld quality. The welded joints revealed an 18% increase in ultimate tensile strength (UTS) than the base metal (BM). Microstructural observations in the thermo-mechanically affected zone (TMAZ) and heat-affected zone (HAZ) were conducted using Scanning Electron Microscopy (SEM) and analyzed with ImageJ software. The present study demonstrated a significant increment in the ultimate tensile strength of the joint obtained by incorporating the optimized parameters, additionally, the microstructures were uniform throughout the TMAZ and HAZ. Fractography of the ruptured sample revealed a dimpled region indicating ductile failure. |
| format | Article |
| id | doaj-art-e353ad96b1fc4e87845bb545682d7098 |
| institution | OA Journals |
| issn | 2730-7727 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Springer |
| record_format | Article |
| series | Discover Materials |
| spelling | doaj-art-e353ad96b1fc4e87845bb545682d70982025-08-20T02:31:00ZengSpringerDiscover Materials2730-77272025-06-015111110.1007/s43939-025-00292-wTool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steelAnmol Bhatia0Reeta Wattal1Rajeev Kumar2Anant Prakash Agrawal3Saurabh Dewangan4Department of Multidisciplinary Engineering, The NorthCap UniversityDepartment of Mechanical Engineering, Delhi Technological UniversityDepartment of Mechanical Engineering, Noida Institute of Engineering and TechnologyDepartment of Mechanical Engineering, Noida Institute of Engineering and TechnologyDepartment of Mechanical Engineering, Manipal University JaipurAbstract Friction stir welding (FSW) is known for its environmentally friendly characteristics and energy efficiency. The geometry of the tool holds significant importance in FSW, playing a crucial role in ensuring satisfactory welds. In the present work, optimization of tool geometry is carried out for the FSW of 3 mm thick AISI 1018 carbon steel. A tungsten carbide tool containing 7 wt.% cobalt with a tapered pin profile—identified as the optimal configuration—was employed for the welding process. The FSW joint was subjected to microstructure examination and tensile testing for weld quality. The results revealed that optimized tool geometry enhanced the weld quality. The welded joints revealed an 18% increase in ultimate tensile strength (UTS) than the base metal (BM). Microstructural observations in the thermo-mechanically affected zone (TMAZ) and heat-affected zone (HAZ) were conducted using Scanning Electron Microscopy (SEM) and analyzed with ImageJ software. The present study demonstrated a significant increment in the ultimate tensile strength of the joint obtained by incorporating the optimized parameters, additionally, the microstructures were uniform throughout the TMAZ and HAZ. Fractography of the ruptured sample revealed a dimpled region indicating ductile failure.https://doi.org/10.1007/s43939-025-00292-wTool geometry optimizationTungsten carbideCarbon steelFriction stir-weldingMicrostructures |
| spellingShingle | Anmol Bhatia Reeta Wattal Rajeev Kumar Anant Prakash Agrawal Saurabh Dewangan Tool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steel Discover Materials Tool geometry optimization Tungsten carbide Carbon steel Friction stir-welding Microstructures |
| title | Tool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steel |
| title_full | Tool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steel |
| title_fullStr | Tool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steel |
| title_full_unstemmed | Tool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steel |
| title_short | Tool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steel |
| title_sort | tool geometry optimization for enhanced mechanical properties in friction stir welding of carbon steel |
| topic | Tool geometry optimization Tungsten carbide Carbon steel Friction stir-welding Microstructures |
| url | https://doi.org/10.1007/s43939-025-00292-w |
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