Friction Stir Welding of T-Joints in Dissimilar Aluminium Alloys

2008 ◽  
Author(s):  
S. M. O. Tavares ◽  
P. C. M. Azevedo ◽  
B. Emi´lio ◽  
V. Richter-Trummer ◽  
M. A. V. Figueiredo ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Weld Zone ◽  
T Joints ◽  
Friction Stir ◽  
Base Materials ◽  
Feasible Alternative ◽  
Series Alloy ◽  
Full Benefit ◽  
Welding Processes

The T-joint is a common joint type frequently used in transport industries because of the importance of increasing the inertia and strength of thin skins and shells without significant weight increase. This shape can be obtained by different processes as extruding, riveting, welding or others. However, the low weldability of some aluminum alloys, when using traditional welding processes, is an obstacle to the possible full benefit of such reinforced structures. The friction stir welding (FSW) process is suitable to join most aluminum alloys and should be considered as a feasible alternative to the other processes used to produce this type of geometry. This paper reports the results obtained concerning FSW T-joints with a new configuration. These joints simulate a typical reinforcement composed by two materials in order to optimize the damage tolerance. The skin is made of a 6xxx series alloy, and the reinforcement is made of a 7xxx series alloy. Mechanical properties were obtained and micro-structural analyses of the weld zone were performed, and the results were compared with those obtained in base materials and butt joints.

Evaluation of dissimilar joints properties of 5083-H12 and 6061-T6 aluminum alloys produced by tungsten inert gas and friction stir welding

2015 ◽  
Vol 231 (3) ◽  
pp. 297-308 ◽  
Author(s):  
Morteza Ghaffarpour ◽  
Mohammad Kazemi ◽  
Mohammad Javad Mohammadi Sefat ◽  
Ahmad Aziz ◽  
Kamran Dehghani
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Traverse Speed ◽  
Inert Gas ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
The Difference ◽  
Welding Processes

In the present study, friction stir welding (FSW) and tungsten inert gas (TIG) techniques were used to join the dissimilar aluminum alloys of 5083-H12 and 6061-T6. The laboratory tests were designed using design of experiment (DOE) method. Variables for the FSW process were the rotational speed, traverse speed, shoulder diameter, and pin diameter. They changed in ranges of 700–2500 r/min, 25–400 mm/min, 10–14 mm, and 2–4 mm, respectively. In the case of TIG process, the variables were current intensity, traverse speed, and tilt angle. These parameters varied from 80 to 90 A, 200 to 400 mm/min, and 3° to 12°, respectively. The optimum amounts of parameters were obtained using response surface methodology (RSM). The RSM-based model was developed to predict ultimate tensile strength (UTS) of the welds produced. In FSW, the difference between predicted and measured UTS was about 1.28% and in TIG it was 1.78%. The good agreement between experimental and predicted results indicates the high accuracy of the developed model. Mechanical properties and also the microstructure of the welds were compared after optimizing both welding processes using RSM. The results showed that the welds produced by FSW indicated a considerably higher quality and also improved mechanical properties compared to TIG. Properties of the joints obtained by FSW in single-sided joints were more desirable. In the double-sided welds obtained by FSW these differences were of an even higher significance.

Solid State Welding Process for Aerospace Components

2015 ◽  
Vol 1119 ◽  
pp. 597-600
Author(s):  
Hyun Ho Jung ◽  
Ye Rim Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo ◽  
Kyung Ju Min ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Structural Integrity ◽  
Welding Process ◽  
Diffusion Welding ◽  
Intimate Contact ◽  
Friction Stir ◽  
Base Materials ◽  
Welding Processes ◽  
And Diffusion

Since solid state welded joint is formed from an intimate contact between two metals at temperatures below the melting point of the base materials, the structural integrity of welding depends on time, temperature, and pressure. This paper provides some of examples of friction stir welding and diffusion welding process for aerospace components. Friction stir welding process of AA2195 was developed in order to study possible application for a large fuel tank. Massive diffusion welding of multiple titanium sheets was performed and successful results were obtained. Diffusion welding of dissimilar metals of copper and stainless steel was necessary to manufacture a scaled combustion chamber. Diffusion welding of copper and steel was performed and it is shown that the optimum condition of diffusion welding is 7MPa at 890°C, for one hour. It is shown that solid state welding processes can be successfully applied to fabricate lightweight aerospace parts.

Microstructure and Mechanical Properties of Friction Stir Welded AA2195-T0

2016 ◽  
Vol 857 ◽  
pp. 266-270 ◽  
Author(s):  
Ho Sung Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo ◽  
Kyung Ju Min
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Weld Zone ◽  
Microscopic Analysis ◽  
Butt Joint ◽  
Fusion Welding ◽  
Electron Microscopic ◽  
Friction Stir ◽  
Microstructure And Mechanical Properties

Aluminum-copper-lithium alloy is a light weight metal that has been used as substitute for conventional aerospace aluminum alloys. With addition of Li element, it has lower density but higher strength. However these aluminum alloys are hard to weld by conventional fusion welding, since they often produce porosities and cracking in the weld zone. It is known that solid state welding like friction stir welding is appropriate for joining of this alloy. In this study, friction stir welding was performed on AA2195 sheets, in butt joint configuration in order to understand effects of process parameters on microstructure and mechanical properties in the weld zone. The results include the microstructural change after friction stir welding with electron microscopic analysis of precipitates.

Properties of Friction-Stir Welded Aluminum Alloys 6111 and 5083

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
W. Gan ◽  
K. Okamoto ◽  
S. Hirano ◽  
K. Chung ◽  
C. Kim ◽  
...  
Keyword(s):  
Aluminum Alloys ◽  
Weld Zone ◽  
Base Material ◽  
Natural Aging ◽  
Tensile Tests ◽  
Travel Speed ◽  
Minimum Phase ◽  
Friction Stir ◽  
Base Materials ◽  
Fsw Parameters

Friction-stir welding (FSW) promises joints with low porosity, fine microstructures, minimum phase transformation, and low oxidation compared with conventional welding techniques. It is capable of joining combinations of alloys not amenable to conventional welding. Certain combinations of FSW parameters were used to create FSWs of aluminum alloys 5083-H18 and 6111-T4, and the physical weld defects were measured. The mechanical behavior of FSW welds made under the most favorable choice of parameters was determined using tensile tests and hardness measurements and was correlated to the microstructures of the weld and base material. Stir zones (SZs) in the 5083 specimens were much softer than the strain-hardened base materials. SZs in the 6111 material are approximately as hard as the base material. Natural aging of 6111 FSW specimens occurred in some parts of the heat-affected zone and produced hardening for up to 12weeks after welding. Annealing of 5083 FSW specimens produced abnormal grain growth (AGG) for welds produced under certain welding conditions and in certain parts of the weld zone. AGG is more severe for low-heat conditions, i.e., higher tool travel speed but lower rotational speed. The conditions for most favorable FSW are presented, as well as the expected microstructures and mechanical properties, along with the weld conditions that promote AGG.

Advances and Potentials in Friction Stir Welding of Aluminum Alloys

2016 ◽  
Vol 710 ◽  
pp. 137-142 ◽  
Author(s):  
Jean Pierre Bergmann ◽  
Michael Grätzel ◽  
René Schürer ◽  
Anna Regensburg ◽  
Markus Weigl
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Fusion Welding ◽  
Product Development Process ◽  
Cast Aluminum ◽  
Friction Stir ◽  
Cast Aluminum Alloys ◽  
Electrical Components ◽  
Welding Processes

Within the last decade, Friction Stir Welding (FSW) has increasingly been gaining relevance for joining nonferrous metals, especially aluminum alloys. Possible applications range from the aerospace and automotive sector up to manufacturing electrical components. Compared to conventional fusion welding processes, FSW offers numerous advantages, as it for example does not require shielding gas or filler material. However, FSW is still not applied or taken into account during the product development process in proportion to its potential. This is mainly caused by the lack of data in order to evaluate the process economically and differentiate it to other processes like arc and laser welding, also regarding technological factors. Therefore, this investigation focusses on the possibilities and limits when joining wrought and cast aluminum alloys, like EN AW-6082 T6, EN AW-7075 T651 and AlSi11Mg0,3, respectively, by FSW compared to MIG. The weld quality of the samples is characterized by tensile testing, hardness measurements and microstructure analysis. Furthermore, an approach to reduce the process forces by using FSW tools with reduced diameters and respectively adjusted process parameters is presented.

Joining of AA2014 and AA5059 dissimilar aluminium alloys by Friction Stir Welding

2019 ◽  
Vol 1 (97) ◽  
pp. 15-20
Author(s):  
A.A. Saleh
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Weld Zone ◽  
Friction Stir ◽  
Fine Grain ◽  
Base Materials ◽  
Microstructure And Mechanical Properties ◽  
Metal Research ◽  
Weld Area

Purpose: This work aims to investigate the microstructure and mechanical properties achieved by FSW of butt joints, namely of dissimilar sheets namely of 2014-T3 to 5059-H11 Al alloys by bonding the two materials perpendicular to their rolling directions. Design/methodology/approach: AA 2014T3 and AA 5059H11 were two dissimilar aluminium alloys friction stir welded. The joint has been examined in terms of hardness, microstructure, and mechanical properties. The microstructure of the weld area was characterized by using optical microscopy. Seven diverse regions of the microstructure in the joint can be illustrious. Findings: It has been noticed that a structure of fine grain is formed in the nugget region as a consequence of recrystallization. The thermos mechanically affected and heat affected zones of aluminium alloy 2014 are characterized by the lowest hardness values in spite of there are a general hardness decrease through the weld zone compared to both base metals. The ultimate tensile strength values of the dissimilar joint were found to be varying between 54% to 66% those of the base metal. Research limitations/implications: The t joining in FSW takes place with the base materials remnant in the solid state, which gives a considerable possibility to produce joints between the alleged difficult-to-weld heat treatable aluminium alloys. Originality/value: The outcomes display that friction stir welding can be effectively applied for the joining of dissimilar aluminium alloys.

A Survey of the Parameters of the Friction Stir Welding Process of Aluminum Alloys 6xxx Series

2021 ◽  
Vol 9 (1) ◽  
pp. 51-60
Author(s):  
Meshal Essa ◽  
Fahad Salem Alhajri
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Process ◽  
Literature Survey ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Welding Processes ◽  
6Xxx Series

Friction stir welding is a modern innovation in the welding processes technology, there are ‎several ways in which this technology has to be investigated in order to refine and make it ‎economically responsible. Aluminum alloys have strong mechanical properties when they are ‎welded by using the Friction Stir welding. Therefore, certain parameters of the welding ‎process need to be examined to achieve the required mechanical properties. In this project, a ‎literature survey has been performed about the friction stir welding process and its parameters ‎for 6xxx series aluminum alloys‎.  

scholarly journals Performance evaluation of a novel force measuring device for Friction Stir Welding (FSW) of aluminum alloys

DYNA ◽  
2019 ◽  
Vol 86 (210) ◽  
pp. 150-155
Author(s):  
Elizabeth Hoyos Pulgarín ◽  
María Zuluaga-Posada ◽  
Yesid Montoya
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Force Measurement ◽  
Butt Joint ◽  
Fusion Welding ◽  
Significant Information ◽  
Measuring Device ◽  
Friction Stir ◽  
Aa 7075 ◽  
Welding Processes

Friction Stir Welding (FSW) has the advantage of generating sound welds on materials that generally present low weldability by traditional fusion welding processes, such as 2xxx and 7xxx aluminum alloys. Force measurement in FSW provides significant information about the process, the machine requirements, the effect of selected parameters, and weld soundness. In this paper, an axial force measuring device was designed, built, and tested to be used in a CNC adapted system. All tests were performed using AA 7075-T6 and a butt joint configuration. The forces obtained by the device match, in profile, key values, and trends, the ones found in literature which allows to conclude that this is a functional and sufficient device for the application.

Microstructural Changes Determining Joint Strength in Friction Stir Welding of Aluminium Alloys

2005 ◽  
Vol 6-8 ◽  
pp. 591-598 ◽  
Author(s):  
A. Barcellona ◽  
Gianluca Buffa ◽  
D. Contorno ◽  
Livan Fratini ◽  
D. Palmeri
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Aluminium Alloys ◽  
Joint Strength ◽  
Butt Joints ◽  
Microstructural Changes ◽  
Parent Materials ◽  
Friction Stir ◽  
Experimental Activity ◽  
Welding Processes

In the paper the results of a wide experimental activity on friction stir welding (FSW) of aluminum alloys are reported. In particular the butt joints of two different materials, namely AA1050-O and AA6082-T6 were considered. Grains dimensions and precipitates density were investigated both in the parent materials and after the welding processes. Furthermore post-welding heat treatments effects on the joint strength were studied.

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