Rahul Jain

Indian Institute of Technology Bhilai · Mechanical engineering

This study focuses into strategizing the usage of self-reacting bobbin tool friction stir welding (SRBT-FSW) to obtain consistent microstructural homogeneity along the thickness of AA6061 aluminium alloy (AA) thick plates during welding. The SRBT-FSW technology, distinguished by its dual-shoulder design, represents a significant step forward in FSW...

The pursuit of sustainable practices in manufacturing has sparked an increased interest in recycling and reusing materials to reduce waste and environmental effect. One interesting technique is incorporating recycled materials to develop advanced composite materials. In this study, we focus on utilizing recycled Inconel IN718 powders as reinforceme...

Friction Stir Additive Manufacturing (FSAM) is a solid-state joining process that operates below the material’s melting point, avoiding the drawbacks of fusion-based methods. In FSAM, inter-surface bonding is crucial for the build strength and is influenced by material flow at the interface. This study examines the influence of flat-faced (square)...

Internal defects such as voids/cavities significantly hamper the weld quality, resulting in lower weld efficiency and mechanical properties. Therefore, there is a scope for developing a relationship between quantum of defects and weld efficiency. This research uses a thermomechanical model based on coupled Eulerian-Lagrangian (CEL) to predict defec...

Tailor-welded blanks (TWB) facilitate strategic material placement, ensuring desired materials are positioned appropriately, while single-point incremental forming (SPIF) enables versatile shape manufacturing with minimal tooling. Despite both methods offering customization benefits, their combined potential remains largely unexplored. This study u...

Magnesium (Mg) and its alloys are one of the highly sought after structural material due to its lowest density among the structural material. Various attempts are being made by researchers to improve the mechanical performance of Mg alloys to widen their scope of application domains, especially in defence and biomedical sectors. On the development...

Predicting the failure location of welded specimens is of importance for various industrial applications. In friction stir welding, material flow and eventually defect have an effect on the failure location. In the current work, a three-dimensional coupled Eulerian Lagrangian (CEL) is developed to study the material flow and predict defects origina...

Grain size significantly affects joint strength and mechanical properties after friction stir welding (FSW). The tool pin shape/feature is an important factor influencing weld quality and microstructural features. The current work investigates the FSW of AA2024 with eccentric (distance between the axis of tool pin and shoulder) square tool pin and...

Achieving good weld quality is of prime objective of every industry. Therefore, it is essential to understand the underlying mechanism of defect formation and its impact on weld quality. In the current work, a simulation through a coupled Eulerian-Lagrangian model is carried out to investigate the influence of peak temperature developed at the stir...

The presentation briefs on the development of a novel Magnesium based surface composite using Ti particulate as reinforcement through Friction stir processing. Details on microstructural evolution and mechanical performance is narrated.

Drill tip wandering during the entrance in the workpiece is a significant issue in micro-drilling because it directly affects hole quality, drill bit and dynamic stability. Although radial force and radial torque significantly influence drill tip wandering, measuring these characteristics has always been challenging, particularly due to their extre...

This study aims to model temperature distribution in friction stir welding (FSW) using various backing plates and polygonal pin profiles since temperature significantly modifies the microstructure and texture of the weld zone affecting the weld quality such as weld strength, hardness, etc. The experimental results depict the importance of temperatu...

Friction Stir Welding is one of the advanced and efficient methods to join aluminium alloys. The efforts to increase its productivity may sometimes lead to defective welds. Because, the increased welding speed may result in lesser heat input, inferior material flow and voids. To overcome this, external heat assistance can be provided to the FSW ope...

A three-dimensional coupled thermomechanical model was generated on coupled Eulerian Lagrangian method to simulate friction stir welding of AA6061 and predict defect formation. The volume of fluid code is applied to predict the defects such as void, cavity and tunnel defect during welding. Mesh sensitivity analysis is done for different mesh sizes...

In recent times additive manufacturing (AM) has emerged as a crucial manufacturing process for custom-made metal workpieces. Wire Arc Additive Manufacturing (WAAM) is a rising technology that can cut back material usage and manufacturing time due to its higher deposition rate. This research aims to develop an efficient 3D thermal model to simulate...

One of the challenges during FSW of pipe is establishing sufficient contact between the tool shoulder and the pipes to be welded. With improper contact, the torque requirement increases, which thereby increases the power consumption. The present work focuses on the demonstration of a 3D thermo-mechanical model showing the influence of tool shoulder...

In the quest for weight reduction, automobile industries introduced the technology of tailor welded blanks (TWB) which offered utilization of material as per functional requirement. In general, friction stir welding (FSW) is mostly used for fabricating aluminum based TWBs as fusion welding of Al—alloys are problematic. Recently, single point increm...

Defective weld significantly hampers the quality of the weld and selection of optimum process parameter which produces defect-free weld is an experimental tedious task. A robust numerical model capable of predicting various types of defects is required to save cost and time. In the current work, a numerical model is developed based on coupled Euler...

In friction stir welding (FSW) the material is welded without melting the base material. Aerospace, automobile, shipbuilding and electronics are some of the industrial sectors which use FSW for manufacturing of components. It is primarily used because of higher weld efficiency as compared with fusion joining processes. In this book chapter, the fun...

The manuscript reports on detection of defect that arises during friction stir welding using continuous wavelet transform (CWT) on force signal. The vertical force during welding undergoes sudden change due to presence of defects. These localized defects are detected accurately with the help of continuous wavelet transform scalogram (CWT coefficien...

Tool pin geometry plays an important role in the weld strength of friction stir welding process. In the current work, a thermo-mechanical model is developed to study the effect of three different pin shapes, viz. cylindrical, square and triflat, during friction stir welding process. The developed model is validated with the temperature, force and s...

In the current research, a coupled Eulerian and Lagrangian method is used to model the friction stir welding process. Volume of fluid principle is used to predict the formation of defects during the process. Model is validated with experimentally observed spindle torque and axial force. Three different pin heights were simulated and pin height of 2...

Selection of tool geometry is an important aspect for an efficient friction stir welding (FSW), as it influences material flow, forces, and other output responses. In the present paper, a three-dimensional coupled thermo-mechanical model is proposed based on Lagrangian method to evaluate the performance of two different pin shapes, i.e., smooth con...

Friction stir welding (FSW) is a solid-state joining process and is efficient in welding aluminum alloys. Study on material flow mechanisms, forces and defect formation are important as it could help in proper selection of process parameter and pin design. Their experimental study is exhaustive due to lots of post-weld analyses. Numerical modeling...

Friction Stir Welding (FSW) is a relatively new technology in welding. The ultimate aim of any welding process is to achieve a defect-free weld. Several defects during FSW can be attributed to various factors and are required to be examined and eliminated if required. The exact severity of a surface defect in FSW cannot be determined by a 2D image,...

Friction stir welding (FSW) is a solid-state joining process and is performed in three stages, viz., plunging, dwelling, and welding. In the plunging stage, a nonconsumable rotating tool plunges onto the workpiece surface to generate heat. Further, during dwelling the tool rotates in its position to further increase the heat generation. Finally, th...

Simulation of friction stir welding (FSW) provides vital information related to temperature, forces, material flow, etc. and will reduce the experimental cost incurred. In the present study, a three dimensional thermo-mechanical model based on Lagrangian method is proposed to predict temperature, forces and material flow during FSW. Finie element m...

Material flow is an important aspect to achieve an efficient weld; and this paper focuses on the simulation of material flow in friction stir welding (FSW) process. A finite element model is developed based on the Lagrangian incremental method coupled with adaptive re-meshing technique to tackle mesh distortion. The model is validated with the expe...

A three dimensional coupled thermo-mechanical finite element model (FEM) is proposed to simulate a friction stir welding (FSW) process based on Lagrangian incremental technique. Since FSW is a large deformation process, workpiece is considered as a rigid visco-plastic material. The model has been developed for predicting forces, spindle torque, tem...

Friction Stir Welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Finite Element Method (FEM) is an important tool to predict state variables of the process but numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and workpiece and interdependency of displacement and...

Friction stir welding (FSW) is a new entrant in welding technology and getting a defect-free weld is the final objective. But different defects are generated due to various reasons and needs to be analyzed to eliminate them. The aim of the research work is to identify and classify different kinds of surface defects generally encountered during the...

In this research, dissimilar friction stir welding between aluminium (Al) and copper (Cu) is investigated. The experimental results indicate that high quality joints can be obtained by placing the Cu plate on the advancing side of the tool rotation. Further improvement of mechanical properties and defect free joints could be obtained under specific...

This article discusses on the detection of fault occurred during friction stir welding using discrete wavelet transform on force and torque signals. The work pieces used were AA1100 aluminum alloys of thickness 2.5 mm. The plates were 200 mm in length and 80 mm in width. Presence of defect in welding causes sudden change in force signals (Z-load),...

Friction Stir Welding (FSW) is a new solid-state welding technique which finds application in various industries. This chapter introduces the process, basic mechanism, application, and recent research developments. Research work in this book chapter is broadly divided in two parts: experimental-based, and finite element modeling (FEM)-based approac...

Friction Stir Welding (FSW) is a new solid-state welding technique which finds application in various industries. This chapter introduces the process, basic mechanism, application, and recent research developments. Research work in this book chapter is broadly divided in two parts: experimental-based, and finite element modeling (FEM)-based approac...

Friction stir welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and work piece and interdependency of displacement and temperature. In the present paper a three dimensional finite element model is proposed to stud...

Friction stir welding (FSW) is a solid state joining process developed especially to weld aluminum alloys which are considered as difficult to weld materials. Force generated in the process is critical for fixture design and quality of weld. Finite element simulation of FSW is complex due to non linear contact interaction between tool and work piec...

Friction stir welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and work piece and interdependency of displacement and temperature. In the present paper a three dimensional finite element model is proposed to stud...

Productivity is an important aspect of machining and process and cutting parameter directly affects that. This makes the study of process parameters very important. The paper, thus presents a finite element analysis of temperature distribution and cutting forces in orthogonal turning using ABAQUS/Explicit software. The study shows the variation of...