scholarly journals An experimental insight of friction stir welding of dissimilar AA 6061/Mg AZ 31 B joints

2021 ◽  
pp. 095440542110434
Author(s):  
N Rajesh Jesudoss Hynes ◽  
M Vivek Prabhu ◽  
P Shenbaga Velu ◽  
R Kumar ◽  
R Tharmaraj ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Arc Welding ◽  
Weight Ratio ◽  
Dissimilar Materials ◽  
Mechanical Tests ◽  
Friction Stir ◽  
Offset Distance ◽  
Lightweight Metals ◽  
Mechanical Performances ◽  
Joining Process

In the present scenario, aerospace and automobile industries depend on lightweight materials such as magnesium and aluminum alloys because of their great balance between mechanical properties and weight ratio. Despite these benefits during the joining process of these dissimilar materials by welding, many challenges arises. The prominent one is related to the low melting points of these lightweight metals which make it almost impossible the joining using conventional arc welding techniques. To tackle this challenge, Friction Stir Welding (FSW) can be considered as a promising candidate tool. In this study, to demonstrate the FSW performances of joining two dissimilar materials we have investigated the joining of AA 6061 and Mg AZ 31 B using a built-in house a modified milling machine. The dissimilar combinations of AA 6061 and Mg AZ 31 B joints were successfully joined by embedding different welding conditions and varying the offset distance. The mechanical performances were evaluated by conducting specific mechanical tests such as micro-hardness, tensile, and impact tests, respectively. To explain the mechanical results, we have applied optical microscopy observation on the microstructure associated with the bonding location. The results prove that the strength of the Friction Stir Welded joints is much higher as compared to other techniques especially in terms of dissimilar metals.

Analysis and Correlation of Output Parameters against Input Parameters for Friction Stir Welding of Three Dissimilar Aluminum Alloy

2018 ◽  
Vol 1146 ◽  
pp. 38-43
Author(s):  
Ana Boşneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Cristian Ciucă
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Joints ◽  
Aluminum Plates ◽  
Joining Process

Friction Stir Welding, abbreviated FSW is an innovative joining process. The FSW is a solid-state welding process with a lot of advantages comparing to the traditional arc welding, such as the following: it uses a non-consumable tool, it results of good mechanical properties, it can use dissimilar materials and it have a low environmental impact. First of all, the FSW process was developed to join similar aluminum plates, and now, the technology was developed and the FSW process is used to weld large types of materials, similar or dissimilar. In this paper it is presented an experimental study and the results of it, which includes the welding of three dissimilar aluminum alloy, with different chemical and mechanical properties. This three materials are: AA2024, AA6061 and AA7075. The welding joints and the welding process were analyzed considering: process temperature, micro-hardness, macrostructure and microstructure.

scholarly journals Analysis of the influence of position of welding materials on the FSW seams properties for three dissimilar aluminium alloy

2018 ◽  
Vol 178 ◽  
pp. 03003 ◽  
Author(s):  
Ana Bosneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Monica Iordache
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Workpiece Material ◽  
Friction Stir ◽  
Welding Joints ◽  
Welding Materials

Friction Stir Welding, abbreviated FSW is a new and innovative welding process. This welding process is increasingly required, more than traditional arc welding, in industrial environment such us: aeronautics, shipbuilding, aerospace, automotive, railways, general fabrication, nuclear, military, robotics and computers. FSW, more than traditional arc welding, have a lot of advantages, such us the following: it uses a non-consumable tool, realise the welding process without melting the workpiece material, can be realised in all positions (no weld pool), results of good mechanical properties, can use dissimilar materials and have a low environmental impact. This paper presents the results of experimental investigation of friction stir welding joints to three dissimilar aluminium alloy AA2024, AA6061 and AA7075. For experimenting the value of the input process parameters, the rotation speed and advancing speed were kept the same and the position of plates was variable. The exit date recorded in the time of process and after this, will be compared between them and the influence of position of plate will be identified on the welding seams properties and the best position of plates for this process parameters and materials.

Evaluation of Thermal Distribution in Friction Stir Welding on Dissimilar Materials (Cu-Al) Using Infrared Thermography and Numerical Simulation

2016 ◽  
Vol 1138 ◽  
pp. 113-118
Author(s):  
Monica Iordache ◽  
Eduard Nitu ◽  
Claudiu Badulescu ◽  
Doina Iacomi ◽  
Lia Nicoleta Boţilă ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Infrared Thermography ◽  
Three Dimensional ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Element Model ◽  
Fe Model ◽  
Friction Stir ◽  
Solid State Joining ◽  
Joining Process

Friction Stir Welding (FSW) is a solid state joining process realized by the interaction between a non-consumable welding tool that rotates on the contact surfaces of the combined parts. Welding dissimilar materials aluminum and copper by FSW are of great interest because Al and Cu are two most common engineering materials widely used in many industries. This paper presents an investigation concerning the influence of the rotation of the tool on temperatures during the welding process. Also, the welding of copper and aluminum materials by FSW process was simulated using a finite element model. Three-dimensional FE model has been developed in ABAQUS/Explicit using the Coupled Eulerian Lagrangian method, the Johnson–Cook material law and the Coulomb’s Law of friction and was validated by infrared thermography method and thermocouple measurement.

scholarly journals Friction Stir Welding of Aerospace Alloys

2019 ◽  
Vol 48 (1) ◽  
pp. 37-46
Author(s):  
Akshansh Mishra ◽  
Devarrishi Dixit
Keyword(s):  
Friction Stir Welding ◽  
Welding Process ◽  
Space Vehicles ◽  
Friction Stir ◽  
Aerospace Applications ◽  
Aerospace Alloys ◽  
Fuel Tanks ◽  
Higher Temperature ◽  
Solid State Joining ◽  
Joining Process

Friction Stir Welding (FSW) is a solid state joining process which possesses a great potential to revolutionise the aerospace industries. Distinctive materials are selected as aerospace alloys to withstand higher temperature and loads. Sometimes these alloys are difficult to join by a conventional welding process but they are easily welded by FSW process. The FSW process in aerospace applications can be used for: aviation for fuel tanks, repair of faulty welds, cryogenic fuel tanks for space vehicles. Eclipse Aviation, for example, has reported dramatic production cost reductions with FSW when compared to other joining technologies. This paper will discuss about the mechanical and microstructure properties of various aerospace alloys which are joined by FSW process.

Influence of Friction Stir Welding Process on the Weld Formation and Tensile Strength of Titanium and Aluminum Dissimilar Alloys Welded Joint

2011 ◽  
Vol 189-193 ◽  
pp. 3266-3269 ◽  
Author(s):  
Yu Hua Chen ◽  
Peng Wei ◽  
Quan Ni ◽  
Li Ming Ke
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Welded Joint ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Influence Of Process Parameters ◽  
Friction Stir ◽  
Dissimilar Alloys ◽  
Titanium Aluminum

Titanium alloy TC1 and Aluminum alloy LF6 were jointed by friction stir welding (FSW), and the influence of process parameters on formation of weld surface, cross-section morphology and tensile strength were studied. The results show that, Titanium and Aluminum dissimilar alloy is difficult to be joined by FSW, and some defects such as cracks and grooves are easy to occur. When the rotational speed of stir head(n) is 750r/min and 950r/min, the welding speed(v) is 118mm/min or 150mm/min, a good formation of weld surface can be obtained, but the bonding of titanium/aluminum interface in the cross-section of weld joint is bad when n is 750r/min which results in a low strength joint. When n is 950r/min and v is 118mm/min，the strength of the FSW joint of Titanium/Aluminum dissimilar materials is 131MPa which is the highest．

scholarly journals Friction Stir Welding with Low-Medium-High Tool Travel Speed of 0.95 Mg-Al-Alloy and Pure Copper: Electrochemical and Surface Studies

2018 ◽  
Author(s):  
Neetesh Soni ◽  
Ambrish Singh
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Pure Copper ◽  
Travel Speed ◽  
Localized Corrosion ◽  
Al Alloy ◽  
Kelvin Probe ◽  
Friction Stir ◽  
Surface Optical ◽  
Joining Process

The aim of this work is to assess the influence of Friction Stir Welding (FSW), process parameters, optimized tool traveling speed, and corrosion resistance of the 0.95 Mg-Al-alloy and pure copper weldment. Samples of aluminum-copper with and without deformation were characterized to investigate the metallurgical effects created during the welding deformation process. Effect of process parameters on microstructure and corrosion rate have been investigated for all the samples. All the electrochemical and polarization tests were done in 3.5 wt.% NaCl solution. Scanning Kelvin Probe (SKP) was done to detect the localized corrosion on the surface. Optical micrography observation indicated that the primary α-Al phase, which was formed during solidification can effectively limit the growth of Cu9Al4 phase. Finer acicular α-Al precipitates were observed in CuAl matrix during joining process that tends to coarser with the increase in tools travel speed. The electrochemical and polarization results showed that among all the tool travelling speed the specimen joined at tool travelling speed of 40 mm/min shows the best non-corrosive property.

scholarly journals Influence of Mx-Trivex, A-Skew, Three Flat Threaded and Concave Shouldered Mx-Triflute Tool Pin Profiles on Tensile Properties and Fractural Behaviour of Aa 6082-T6 Weldments During Friction Stir Welding

2020 ◽  
Vol 9 (4) ◽  
pp. 1376-1384
Keyword(s):  
Friction Stir Welding ◽  
Tensile Test ◽  
Weld Zone ◽  
Base Material ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Pin ◽  
Solid State Joining ◽  
Joining Process ◽  
Brass Wire

Friction Stir Welding (FSW) is a topical and propitious solid-state joining process producing economical and strengthened joints of age-hardened and heat-treatable Aluminium Alloy AA 6082-T6. Mechanical and fractural behaviour of weldments were investigated in order to find crack initiation and necking on the weld zone thereby perceiving the complete behaviour of fracture occurred near the weld zone. Weldments are fabricated by employing four tool pin profiles namely MX-TRIVEX, A-SKEW, Three flat threaded and Concave shouldered MX-TRIFLUTE tools at various rotational speeds 1000 rpm, 1200 rpm and 1400 rpm at single traverse speed 25 mm/min. EXCETEX-EX-40 CNC wire cut EDM with 0.25 mm brass wire diameter has been employed to perform the extraction of tensile test specimens from the weldments according to ASTM E8M-04 standard. Tensile test was performed on elctromechanically servo controlled TUE-C-200 (UTM machine) according to ASTM B557-16 standards Maximum Ultimate Tensile Strength (UTS) of 172.33 MPa (55.5% of base material) and 0.2% Yield Stress (YS) of 134.10 MPa (51.5% of base material) were obtained by using A-SKEW at 1400 rpm, 25 mm/min and maximum % Elongation (%El) of 11.33 (113.3% of base material) was obtained at MX-TRIVEX at 1000 rpm, 25 mm/min. Minimum UTS of 131.16 MPa (42.30% of base material) and 0.2% YS of 105.207 MPa (40.46% of base material )were obtained by using Concave shouldered MX-TRIFLUTE at 1400 rpm, 25 mm/min. Minimum % El of 5.42 ( 54.2% of base material) was obtained by using A-SKEW at 1000 rpm, 25 mm/min.

Multiaxial Mechanical Strength of AA-2024-T3 Aluminium Alloy Sheets Joined by Friction Stir Welding Processes

2009 ◽  
Vol 83-86 ◽  
pp. 1243-1250 ◽  
Author(s):  
R.L.L.P. Cerveira ◽  
G. F. Batalha
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Short Review ◽  
Multiaxial Loading ◽  
Angle Variation ◽  
Friction Stir ◽  
Aa 2024 ◽  
Aeronautical Industry ◽  
Welding Processes ◽  
Joining Process

The aim is to analyze a junction produced by a Friction Stir Welding (FSW) joining process under multiaxial loading, employing a modified Arcan test that allows an angle variation of the loading in order to evaluate the failure of the FSW weldment as compared to the base material. A short review of the earlier studies and relevant theories about the FSW processes and fracture modes I and II under multiaxial loading are presented and were experimentally evaluated for an AA2024-T3 aluminum alloy sheets (t = 1.6 mm) processed by FSW. The results obtained can serve as a basis to compare the junctions made using FSW and conventional joint methods such as rivets (very common practice in the aeronautical industry).

Sign in / Sign up

Export Citation Format

Share Document