Effect of friction stir welding parameters on the material flow, mechanical properties and corrosion behavior of dissimilar AA5083-AA6061 joints

2021 ◽  
pp. 095440622110361
Author(s):  
Kethavath Kranthi Kumar ◽  
Adepu Kumar ◽  
MVNV Satyanarayana
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Corrosion Behavior ◽  
Process Parameters ◽  
Material Flow ◽  
Stir Zone ◽  
Friction Stir ◽  
Notch Tensile Strength ◽  
Mechanical Properties And Corrosion

Material flow has a significant impact on the joint properties and is one of the most challenging aspects to be understood in dissimilar friction stir welding. The present study emphasizes the role of process parameters on material flow, mechanical properties and corrosion behavior of dissimilar friction stir welds of AA5083-AA6061. Microstructural analysis revealed that the onion ring sub-layer width observed at the stir zone was substantially changed by varying process parameters. It was understood that the higher rotational speeds promote better intermixing and enhanced mechanical properties. The notch tensile strength values were in correlation with the intermixing of materials at the stir zone and the highest notch tensile strength value was obtained at 1400 rpm and 60 mm/min. A remarkable degree of material intermixing and fragmentation of intermetallics at higher rotational speeds resulted in better corrosion resistance.

scholarly journals The Effect of Vibration during Friction Stir Welding on Corrosion Behavior, Mechanical Properties, and Machining Characteristics of Stir Zone

Metals ◽  
2017 ◽  
Vol 7 (10) ◽  
pp. 421 ◽  
Author(s):  
Sajad Fouladi ◽  
Amir Ghasemi ◽  
Mahmoud Abbasi ◽  
Morteza Abedini ◽  
Amir Khorasani ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Corrosion Behavior ◽  
Stir Zone ◽  
Friction Stir ◽  
Machining Characteristics

Stir zone material flow patterns during friction stir welding of heavy gauge AA5056 workpieces and stability of its mechanical properties

2021 ◽  
Vol 23 (4) ◽  
pp. 140-154
Author(s):  
Tatiana Kalashnikova ◽  
◽  
Vladimir Beloborodov ◽  
Kseniya Osipovich ◽  
Andrey Vorontsov ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Elevated Temperatures ◽  
Thin Sheet ◽  
Stir Zone ◽  
Clear Correlation ◽  
Material Structure ◽  
Friction Stir ◽  
Significant Difference

Introduction. Friction stir welding and processing are almost identical processes of severe plastic deformation at elevated temperatures. These technologies differ mainly in the purpose of its use: the formation of a hardened surface layer or producing a welded joint. However, it is known that both during welding and during processing of heavy gauge workpieces temperature gradients occur. As a result, the conditions of adhesive interaction, material plastic flow, and the formation of the stir zone change as compared to thin-sheet workpieces with fundamentally different heat dissipation rates. In this connection, the purpose of the work is to determine the regularities of the structure formation and stability of the mechanical properties in different directions in the material of 35-mm-thick aluminum-magnesium alloy samples produced by friction stir welding/processing. Research Methodology. The technique and modes of friction stir welding and processing of AA5056 alloy workpieces with a thickness of 35 mm are described. Data on the equipment used for mechanical tests and structural research are given. Results and discussion. The data obtained show the excess mechanical properties of the processing zone material over the base metal ones in all studied directions. Material structure heterogeneities after friction stir welding/processing of heavy gauge workpieces have no determining effect on the stir zone properties. At the same time, there is no clear correlation between the tensile strength values and the load application direction, nor is there any significant difference in mechanical properties depending on the location of the samples inside the stir zone. The average ultimate tensile strength values in the vertical, transverse, and longitudinal directions are 302, 295 and 303 MPa, respectively, with the yield strength values of 155, 153 and 152 MPa, and the relative elongation of 27.2, 27.5, 28.7 %.

Prediction and optimization of the mechanical properties of dissimilar friction stir welding of aluminum alloys using design of experiments

2016 ◽  
Vol 232 (8) ◽  
pp. 1384-1394 ◽  
Author(s):  
R Palanivel ◽  
RF Laubscher ◽  
S Vigneshwaran ◽  
I Dinaharan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Ultimate Tensile Strength ◽  
Design Of Experiments ◽  
Process Parameters ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process

Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face–centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351–AA5083. Three weld parameters that influence weld quality were considered, namely, tool shoulder profile (flat grooved, partial impeller and full impeller), rotational speed and welding speed. Experimental results detailing the variation of the ultimate tensile strength as a function of the friction stir welding process parameters are presented and analyzed. An empirical model that relates the friction stir welding process parameters and the ultimate tensile strength was obtained by utilizing a design of experiments technique. The models developed were validated by an analysis of variance. In general, the full impeller shoulder profile displayed the best mechanical properties when compared to the other profiles. Electron backscatter diffraction maps were used to correlate the metallurgical properties of the dissimilar joints with the joint mechanical properties as obtained experimentally and subsequently modeled. The optimal friction stir welding process parameters, to maximize ultimate tensile strength, are identified and reported.

Effect of Friction Stir Welding pin Shape on Mechanical Properties of AA6061 Alloy Weldment

2013 ◽  
Vol 465-466 ◽  
pp. 1309-1313
Author(s):  
Mohd Hasbullah Idris ◽  
Mohd Shamsul Husin
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Material Flow ◽  
Weld Line ◽  
Butt Joint ◽  
Hardness Distribution ◽  
Plunge Depth ◽  
Friction Stir ◽  
Joint Properties

The present study is aimed to determine the effect of friction stir welding pin; square and diamond shape on mechanical properties of butt joint AA6061 weldment. Welding was carried out at different plunge depths of 0.0, 0.2, 0.3 and 0.4 mm together with rotation and transverse speeds of 500 rpm and 40 mm/min, respectively. Material flow, tensile strength and hardness of the weldment were evaluated. The results indicated that joint properties were significantly affected by tool design. It was found that material flow was higher for diamond pin tool compared to that of square pin resulting in considerable increased in tensile strength of the joint. In addition, the highest tensile strength was obtained on the samples welded with square shape pin at 0.4 mm plunge depth whilst the lowest was by diamond shape at the plunge depth of 0.0 mm. Regardless of pin shape and plunge depth; asymmetrical hardness distribution was observed for all weldments. The highest hardness was found to be close to the weld line produced by the diamond shaped pin at 0.0 mm plunge depth.

Estimation and Comparison of Welding Responses Using MRA, GMDH and ANN Technique of Al6061 and Al7075 Material in FSW

2019 ◽  
Author(s):  
Ugrasen Gonchikar ◽  
Holalu Venkatadasu Ravindra ◽  
Prathik Jain Sudhir ◽  
Umeshgowda Bettahally Mahadevegowda ◽  
Shankarnarayan Maskibail Suresh
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Solid State ◽  
Ultimate Tensile Strength ◽  
Process Parameters ◽  
Alloying Elements ◽  
Friction Stir ◽  
Al 6061 ◽  
Al 7075

Abstract Friction Stir Welding (FSW) is a solid state welding which uses non-consumable steel rod to weld two materials. Friction stir welding is an emerging process which is based on frictional heat generated through contact between a non-consumable rotating tool and work piece. Friction stir welding technique possesses several advantages over other conventional types of welding due to the fact that process is carried out in solid state. Removal of melting helps in minimizing porosity and eliminates oxide inclusion. In this study, we focus on the optimization of the process parameters in friction stir welding of two different aluminium alloys (6061, 7075) using Taguchi method of experimental design. Al 6061 and Al 7075 are the two different alloys of aluminium. Among these Al 7075 has mechanical properties nearly double than that of Al 6061, but Al 6061 is used more extensively than Al 7075 because of its low cost. Al 6061 and Al 7075 being alloys of aluminium varies in the composition of alloying elements used in their manufacturing. Al 6061 has magnesium and silicon as its major alloying elements whereas Al 7075 has zinc as its primary alloying element. Al 6061 comes with medium to high strength, exhibit good toughness and surface finish, excellent resistance to corrosion at environmental conditions and another important property is its good weldability. Al 7075 being stronger than Al 6061 lacks in its resistance to corrosion and has poor weldability. Al 6061 is readily weldable but Al 7075 is not, because it is prone to micro-cracking during welding. This study also describes the relation between process parameters and their response of friction stir weld on ultimate tensile strength and hardness of composite materials using mathematical models. The process parameters considered are rotational speed, welding speed and number of passes. Different methodologies are used to develop the models to predict the responses and mechanical properties such as ultimate tensile strength and hardness. The objective of Multiple Regression Analysis (MRA) is to construct a model that explains as much as possible, the variability in a dependent variable, using several independent variables. Group Method of data Handling Technique (GMDH) is a family of inductive algorithms for computer-based mathematical modelling of multi-parametric datasets that features fully automatic structural and parametric optimization of models. GMDH is used in such fields as data mining, knowledge discovery, prediction, complex systems modelling, optimization and pattern recognition. As the machining process is non-linear and time dependent, it is difficult for the traditional identification methods to provide an accurate model. Compared to traditional computing methods, the Artificial Neural Network’s (ANN) are robust and global. Estimation and comparison of machining responses were carried out by MRA, GMDH and ANN.

scholarly journals Effect of process parameters on mechanical properties of AA5052 joints using underwater friction stir welding

2020 ◽  
Vol 14 (1) ◽  
pp. 6259-6271
Author(s):  
Srinivasa Rao Pedapati ◽  
Dhanish Paramaguru ◽  
Mokhtar Awang ◽  
Hamed Mohebbi ◽  
Sharma V Korada
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Welding Process ◽  
Welding Parameters ◽  
Fracture Characterization ◽  
Friction Stir ◽  
Weld Joints ◽  
Underwater Friction Stir Welding

Underwater Friction Stir Welding (UFSW) is a solid-state joining technique which uses a non-consumable tool to weld metals. The objective of this investigation is to evaluate the mechanical properties of the AA5052 Aluminium alloy joints prepared by UFSW. The effect of different type of welding tools and welding parameters on the weld joint properties are studied. Square, tapered cylindrical and taper threaded cylindrical type of welding tools have been used to produce the joints with the tool rotational speed varying from 500 rpm to 2000 rpm while the welding speed varying from 50 mm/min to 150 mm/min. Tensile strength, micro-hardness distribution, fracture features, micro-and macrostructure of the fabricated weld joints have been evaluated. The effect of welding process parameters that influences the mechanical properties and fracture characterization of the joints are explained in detail. A maximum Ultimate Tensile Strength (UTS) value of 222.07 MPa is attained with a gauge elongation of 14.78%. Microstructural evaluation revealed that most of the fracture are found on the thermal mechanically affected zone (TMAZ)adjacent to the weld nugget zone (WNZ) due to bigger grain sizes. It is found that most of the joints exhibit ductile characteristics in failure. Fractography analysis has been used to find the behavior of weld joints in failure.

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