Tensile and wear behaviour of friction stir welded AA5052 and AA6101-T6 aluminium alloys: effect of welding parameters

2020 ◽  
Vol 117 (4) ◽  
pp. 405 ◽  
Author(s):  
G. Kasirajan ◽  
Sathish Rengarajan ◽  
R. Ashok kumar ◽  
G.R. Raghav ◽  
V.S. Rao ◽  
...  
Keyword(s):  
Strain Hardening ◽  
Aluminium Alloys ◽  
Signal To Noise Ratio ◽  
High Strength ◽  
High Heat ◽  
Wear Behaviour ◽  
Welding Parameters ◽  
Wear Properties ◽  
Friction Stir ◽  
Four Levels

To improve the performance and effectiveness of cost, constructing lightweight structure is the important factor for automobile, naval and aerospace industries. AA5052 and AA6101-T6 aluminium alloys are widely applied in transport industries, due to their lightweight and high strength and hence, joining of these two are unavoidable. Friction stir welding is an unconventional welding method, which is developed for constructing lightweight structures. This work describes the detailed study of friction stir welded dissimilar AA5052 and AA6101-T6 alloys. AA5052 and AA6101-T6 plates are welded with rotation rates of 765–1400 rpm and offset distances at advancing side of 0–2 mm. For this purpose, four levels of welding parameters based on Taguchi L16 orthogonal array are chosen. To determine the optimum combinational levels and identify the effect of above-mentioned parameters on tensile and wear properties, Signal to Noise ratio and ANOVA respectively are used. From the results, it is observed that the combination of 1 mm offset distance at advancing side and 1400 rpm rotating speed produces better tensile and wear properties, which is due to high heat generation, sufficient flow of materials and balanced precipitation and strain hardening effects. On the other hand, the combination of 2 mm tool offset at advancing side and 765 rpm rotational rate exhibits poor properties, which is associated with low heat input, defects formation, precipitate coarsening and lesser strain hardening effects.

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

Friction Stir Welding of Elements Made of Cast Aluminium Alloys

2014 ◽  
Vol 59 (1) ◽  
pp. 385-392
Author(s):  
B. Rams ◽  
A. Pietras ◽  
K. Mroczka
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Aluminium Alloys ◽  
Welding Parameters ◽  
Process Conditions ◽  
Friction Stir ◽  
Seam Weld ◽  
Cast Aluminium ◽  
Weld Structure ◽  
Welding Stability

Abstract The article presents application of FSW method for joining elements made of cast aluminium alloys which are hardly weldable with other known welding techniques. Research’s results of plasticizing process of aluminium and moulding of seam weld during different FSW process’ conditions were also presented. Influence of welding parameters, shape and dimensions of tool on weld structure, welding stability and quality was examined. Application of FSW method was exemplified on welding of hemispheres for valves made of cast aluminium alloy EN AC-43200.

Effect of hybrid reinforcement at stirred zone of dissimilar aluminium alloys during friction stir welding

2019 ◽  
Vol 116 (6) ◽  
pp. 631 ◽  
Author(s):  
R. Ashok kumar ◽  
G.R. Raghav ◽  
K.J. Nagarajan ◽  
Sathish Rengarajan ◽  
P. Suganthi ◽  
...  
Keyword(s):  
Silicon Carbide ◽  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Groove Depth ◽  
Weld Nugget ◽  
Wear Properties ◽  
Friction Stir ◽  
Alumina Particles ◽  
Silicon Carbide Particles ◽  
Carbide Particles

The main objective of this work is to modify the mechanical as well as surface properties of weld nugget by the reinforcement of hybrid ceramic particles (alumina and silicon carbide). This is accomplished by combining friction stir welding (FSW) and friction stir processing (FSP) on dissimilar AA6101-T6 and AA1350 aluminium alloys. For this purpose, various levels of mixing proportions of Al2O3 & SiC particles are used with constant groove depth and width i.e. constant groove dimension. To evaluate the quality of joints, tensile, bending, micro-hardness, wear and microstructural studies are carried out. Among these, reinforcement of 100% alumina particles exhibits better mechanical and wear properties. On the other hand, reinforcement of 100% silicon carbide particles produces poor mechanical and wear properties. And also increment in percentage of reinforcement of alumina particles improves the mechanical and wear properties of weld nugget, when compared to increment in percentage of reinforcement of silicon carbide particles.

scholarly journals Influence of lubrication, tool steel composition, and topography on the high temperature tribological behaviour of aluminium

Friction ◽  
2020 ◽  
Vol 9 (1) ◽  
pp. 155-168
Author(s):  
Justine Decrozant-Triquenaux ◽  
Leonardo Pelcastre ◽  
Braham Prakash ◽  
Jens Hardell
Keyword(s):  
High Temperature ◽  
Tool Steel ◽  
Aluminium Alloys ◽  
Friction And Wear ◽  
Weight Ratio ◽  
High Strength ◽  
Wear Behaviour ◽  
Tribological Behaviour ◽  
Material Transfer ◽  
The Stability

Abstract The use of high strength aluminium alloys, such as 6XXX and 7XXX series, is continuously increasing for automotive applications in view of their good strength-to-weight ratio. Their formability at room temperature is limited and they are thus often formed at high temperatures to enable production of complex geometries. Critical challenges during hot forming of aluminium are the occurrence of severe adhesion and material transfer onto the forming tools. This negatively affects the tool life and the quality of the produced parts. In general, the main mechanisms involved in the occurrence of material transfer of aluminium alloys at high temperature are still not clearly understood. Therefore, this study is focussed on understanding of the friction and wear behaviour during interaction of Al6016 alloy and three different tool steels in as-received and polished state. The tribotests were carried out under dry and lubricated conditions, with two distinct lubricants, using a reciprocating friction and wear tester. The worn surfaces were analysed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). The results showed a high dependence of friction and wear behaviour on the tool steel roughness as well as on the stability of the lubricant films. Tribolayers were found to develop in the contact zone and their capacity to improve the tribological behaviour is seen to be drastically impacted by the surface roughness of the tool steel. When the tribolayers failed, severe adhesion took place and led to high and unstable friction as well as material transfer to the tool steel.

Sign in / Sign up

Export Citation Format

Share Document