scholarly journals Experimental Investigation of Dry and Cryogenic Friction Stir Welding of AA7075 Aluminium Alloy

2021 ◽  
Vol 2021 ◽  
pp. 1-21
Author(s):  
A. Praveen Raj Navukkarasan ◽  
K. Shanmuga Sundaram ◽  
C. Chandrasekhara Sastry ◽  
M. A. Muthu Manickam
Keyword(s):  
Grain Size ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Aluminium Alloys ◽  
Dry Friction ◽  
Weld Zone ◽  
Grain Structure ◽  
Temperature Differential ◽  
Friction Stir ◽  
Aa 7075

An attempt has been made to investigate dry and cryogenic friction stir welding of AA 7075 aluminium alloy, which is predominantly availed in aerospace and defence component industries. These industries avail friction stir welding for joining two nonferrous materials, and minimal deviations and maximum strength are the preliminary and long time goal. A cryogenic friction stir welding setup was developed to conduct the joining of two aluminium alloy pipes. An increase of 0.76–42.93% and 3.79–31.24% in microhardness and tensile strength, respectively, is ascertained in cryogenic friction stir welding in correlation to dry friction stir welding of aluminium alloys. TOPSIS evaluation for the experimental run indicated tool profile stepped type, pipe rotation speed of 1000 rpm, welding speed of 50 mm/min, and axial force of 8 kN as close to unity ideal solution for dry and cryogenic friction stir welding of AA 7075 aluminium alloys. The friction stir-welded component under the cryogenic environment showcased drop in temperature, curtailed surface roughness, and fine grain structure owing to reduction in temperature differential occurring at the weld zone. A curtailment of 50.84% is ascertained in the roughness value for cryogenic friction stir welding in correlation to dry friction stir welding of AA 7075 alloy. A decrement of 21.68% is observed in the grain size in the cryogenic condition with correlation to the dry FSW process, indicating a drop in the coarse structure. With the curtailment of grain size and drop in temperature differential, compressive residual factor and corrosion resistance attenuated by 40.14% and 67.17% in the cryogenic FSW process in correlation to the dry FSW process, respectively.

Effect of friction stir welding tool profiles on mechanical properties of dissimilar welded aluminum alloy plates

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Bhanodaya Kiran Babu Nadikudi
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Tensile Properties ◽  
Aluminium Alloys ◽  
Testing Machine ◽  
Weld Zone ◽  
Content Type ◽  
Friction Stir ◽  
Tool Pin

PurposeThe main purpose of the present work is to study the effect of tool pin profiles on mechanical properties of welded plates made with two different aluminium alloy plates.Design/methodology/approachThe welded plates were fabricated with the three different kinds of pin profiled tools such as taper cylindrical, taper threaded cylindrical and stepped cylindrical pin profiles. Tensile properties of welded plates were evaluated using tensile testing machine at room temperature. Microstructures studies were carried out using scanning electron microscope.FindingsTensile properties were improved with the use of taper threaded cylindrical pin tool in friction stir welding process when compared with taper cylindrical and stepped cylindrical pin tools. This is due to refinement of grains and mixing of plasticized material occurred with generation of sufficient heat with the taper threaded pin tool. Through these studies, it was confirmed that friction stir welding can be used to weld Al6061 and Al2014 aluminium alloy plates.Research limitations/implicationsIn the present study, the friction stir welding is performed with constant process parameters such as tool rotational speed of 900 rpm, transverse speed of 24 mm/min and tilt angle of 1°.Practical implicationsAluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. These aluminium alloy blanks can be developed with friction stir welding method with better properties.Originality/valueVery limited work had been carried out on friction stir welding of aluminium alloys of Al 6061 and Al2014 with different tool pin profiles. Furthermore, this work analyzed with tensile properties of welded plates correlated with weld zone microstructures.

scholarly journals Induction Assisted Hybrid Friction Stir Welding of Dissimilar Materials AA5052 Aluminium Alloy and X12Cr13 Stainless Steel

2021 ◽  
Vol 21 (3) ◽  
pp. 17-30
Author(s):  
Dhanesh G. Mohan ◽  
Jacek Tomków ◽  
S. Gopi
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Weld Zone ◽  
Dissimilar Materials ◽  
Grain Structure ◽  
Friction Stir ◽  
Transverse Tensile ◽  
Transverse Tensile Strength

Abstract This research aimed to study the induction in-situ heated hybrid friction stir welding (IAFSW) method to join AA5052 aluminium alloy with X12Cr13 stainless steel (SS) to enhance joint strength. The potency of this method on the mechanical properties and microstructural characterizations were also investigated. The results show that the transverse tensile strength gained was 94% of the AA5052 base metal that is 229.5 MPa. This superior strength was achieved due to the annealing that happened to the AA 5052 region and elevated plastic flow in the weld zone by the in-situ induction heating, which resulted in the elongation of the weld region. The microstructure characterization indicates that a refined grain structure was gained in the nugget zone without defects.

The Use of Bobbin Tools for Friction Stir Welding of Aluminium Alloys

2010 ◽  
Vol 638-642 ◽  
pp. 1179-1184 ◽  
Author(s):  
Philip L. Threadgill ◽  
M.M.Z. Ahmed ◽  
Jonathan P. Martin ◽  
Jonathan G. Perrett ◽  
Bradley P. Wynne
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Axial Force ◽  
Aluminium Alloys ◽  
Processing Parameters ◽  
Machine Design ◽  
Friction Stir ◽  
Triangular Zone

The use of a double sided friction stir welding tool (known as a bobbin tool) has the advantage of giving a processed zone in the workpiece which is more or less rectangular in cross section, as opposed the triangular zone which is more typically found when conventional friction stir welding tool designs are used. In addition, the net axial force on the workpiece is almost zero, which has significant beneficial implications in machine design and cost. However, the response of these tools in generating fine microstructures in the nugget area has not been established. The paper presents detailed metallographic analyses of microstructures produced in 25mm AA6082-T6 aluminium wrought alloy, and examines grain size, texture and mechanical properties as a function of processing parameters and tool design, and offers comparison with data from welds made with conventional tools.

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.

scholarly journals Effect of Tool Rotational Speeds on Friction Stir Welded AA6082-T6 Aluminium Alloy Joints

2020 ◽  
Vol 9 (1) ◽  
pp. 62-67
Keyword(s):  
Tensile Strength ◽  
Aluminium Alloy ◽  
Rotational Speed ◽  
Mechanical Characteristics ◽  
Weld Zone ◽  
Grain Structure ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Average Grain Size ◽  
Equiaxed Grain

In the current work, an attempt has been made to investigate the effect of tool rotational speed on microstructural and mechanical properties of friction stir welded AA6082-T6 aluminium alloy. Four different tool rotational speeds such as 500, 700, 900 and 1100 rpm were used to produce the joints while keeping the other process parameters constant. The tool used to fabricate the welded samples was tungsten carbide with straight cylindrical pin profile. The microstructural properties were examined using an optical and scanning electron microscope and found that the 700 rpm produced joint showed equiaxed grain structure with 14.3 µm average grain size. The mechanical characteristics such as tensile strength, impact strength and microhardness were evaluated and found the highest tensile strength of 265 MPa, impact energy of 10 J and micro hardness of 76 HV in the weld zone for the sample prepared with 700 rpm tool rotational speed. The fractographic studies were also carried out to study the mode of failure.

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.

scholarly journals Mechanical Properties and Microstructural Characterization of Dissimilar Friction Stir Welded AA5083 and AA6061 Aluminium Alloys

Mechanika ◽  
2020 ◽  
Vol 26 (6) ◽  
pp. 545-552
Author(s):  
Sasi Lakshmikhanth RAJASEELAN ◽  
Subbaiah KUMARASAMY
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Welded Joints ◽  
Aluminium Alloys ◽  
Microstructural Analysis ◽  
Testing Machine ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir

Solidification is one of the major issues that was faced during the fusion welding of dissimilar non-heat treatable and heat treatable aluminium alloys. To overcome this issue Friction Stir Welding played a very vital role, since it is a solid state welding process. In the current study, dissimilar friction stir welding was carried out between non heat-treatable aluminium alloy AA5083-H111 and heat-treatable aluminium alloy AA6061-T6. The microstructural analysis and the mechanical properties of the dissimilar friction stir welded aluminium alloy AA5083-H111 and AA6061-T6 have been investigated. Both optical microscopy and scanning electron microscopy was used to evaluate the microstructural features. The elemental analysis was carried out using SEM-EDX. The tensile properties are studied using Universal Testing Machine. Hardness at various zones of the welded joints was measured using Vicker’s Hardness Testing Machine. The mechanical properties of the friction stir welded joints were correlated with the microstructure of the dissimilar welded joints.

Superplastic Deformation and Microstructure Evolution of Friction Stir Weld of 1420 Al-Li Alloy

2005 ◽  
Vol 475-479 ◽  
pp. 3033-3036 ◽  
Author(s):  
He Ping Guo ◽  
Xiu Quan Han ◽  
Wei Wu ◽  
Zhi Qiang Li
Keyword(s):  
Grain Size ◽  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Superplastic Deformation ◽  
Friction Stir Weld ◽  
Black Line ◽  
Friction Stir ◽  
Fine Grain ◽  
Friction Weld ◽  
Welding Technique

Friction stir welding is a novel welding technique which has been successfully applied in structure manufacturing of aluminium alloys (including 2XXX and 7XXX). Friction stirring in aluminium alloy welds produces a combination of very fine grain size. This paper deals with the SPF response in 1420 Al-Li alloy welds. The results showed that the friction stir weld could achieve good superplasticity performance. The lateral elongation in the weld could reach 120% and the grain size still remain the same size with little change. And the drawback in the friction weld is the obstacle to fufill the good SPF ability. During the friction stir welding, some oxides or contaminates were stired into the weld in the form of black line. When the weld was experienced superplastic deformation, the crack initiated from the line and finally reach the surface and bottom of the plate. The oxide was formed mainly in the nugget of the friction weld. So the parameters and preparation before welding must be optimized so that the weld can achieve maximum superplasticity performance.

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