Effect of brass interlayer on microstructure, mechanical and corrosion behaviour of friction stir welded AA6061-T6 alloy

2021 ◽  
pp. 095440622110614
Author(s):  
Korra Nagu ◽  
Adepu Kumar
Keyword(s):  
Uniform Distribution ◽  
Material Flow ◽  
Corrosion Behaviour ◽  
Travel Speed ◽  
Immersion Test ◽  
Friction Stir ◽  
Average Grain Size ◽  
Polarization Test ◽  
Metallurgical Bond ◽  
Proper Material

In this study, friction stir welding (FSW) was performed on AA6061-T6 with and without brass interlayer. The FSW with interlayer was performed for various tool rotational speeds (600–1000 r/min) and at constant travel speed (25 mm/min). The defect-free joint with uniform distribution of brass particles in the stir zone (SZ) and formation of the uniform composite structure was observed at an intermediate optimized tool rotational speed of 800 r/min due to the proper material flow. A strong metallurgical bond between brass particles with aluminium alloy resulted in the formation of Al2Cu and Al4Cu9 strengthening intermetallic compounds (IMCs). The average grain size obtained for the weld with interlayer is smaller than weld without interlayer. The presence of the interlayer enhanced the hardness and the tensile strength compared to the weld without interlayer. This improvement in mechanical properties with interlayer is attributed to the formation and uniform distribution of strengthening IMCs. The corrosion analysis was carried out in 3.5% NaCl solution using immersion test and electrochemical polarization test. The weld with interlayer showed enhanced corrosion resistance than the weld without interlayer which is attributed to the formation of major Al2Cu IMC which has less activation energy for the corrosion process.

scholarly journals A Comparative Investigation on Conventional and Stationary Shoulder Friction Stir Welding of Al-7075 Butt-Lap Structure

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1264 ◽  
Author(s):  
Yu Chen ◽  
Huaying Li ◽  
Xiaoyu Wang ◽  
Hua Ding ◽  
Fenghe Zhang
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Comparative Investigation ◽  
Flow Mode ◽  
Nugget Zone ◽  
Friction Stir ◽  
Stationary Shoulder ◽  
Average Grain Size ◽  
Al 7075

Both conventional friction stir welding (C-FSW) and stationary shoulder friction stir welding (S-FSW) were employed to join the Al-7075 butt-lap structure, then the microstructural evolution and mechanical characterization of all FSW joints were systematically studied. The C-FSW joint exhibited a rough surface with flashes and arc corrugations, while the surface of the S-FSW joint became smooth. Moreover, for the S-FSW joint, the shoulder-affected zone got eliminated and the material flow mode during FSW was changed owning to the application of stationary shoulder. Furthermore, in comparison to C-FSW, the lower welding heat input of S-FSW decreased the average grain size in the nugget zone and inhibited the coarsening of strengthening precipitates in the heat-affected zone, elevating the overall hardness for the S-FSW joint. In addition, the tensile strength of the S-FSW joint became higher compared to the C-FSW joint, and all the FSW joints failed inside the nugget zone attributing to the existence of hook defect. The sharp-angled hook defect deteriorated the plasticity of the C-FSW joint further, which was only 70% that of the S-FSW joint.

Role of Mg2Si particles on mechanical, wear, and corrosion behaviors of friction stir welding of AA6061-T6 and Al-Mg2Si composite

2020 ◽  
Vol 54 (26) ◽  
pp. 4035-4057 ◽  
Author(s):  
A Moharami ◽  
A Razaghian ◽  
B Babaei ◽  
OO Ojo ◽  
M Šlapáková
Keyword(s):  
Material Flow ◽  
Travel Speed ◽  
Friction Stir ◽  
Base Materials ◽  
Al Composite ◽  
Wear And Corrosion ◽  
Corrosion Behaviors ◽  
Si Joint ◽  
Tool Pin

This paper investigates the effect of different tool pin morphologies on the inter-mixing capability, microstructure, mechanical properties, corrosion, fracture, and wear behaviors of the dissimilar friction stir welded AA6061-T6 alloy--Al 20wt% Mg2Si composite. Grooved shoulder tools with varying pin profiles such as tapered cylindrical, threaded tapered cylindrical, and triangular tapered pins were used for joining the base materials. The parameter combination of 80 mm/min travel speed and 1000 r/min rotation speed (at which no visible flow-induced defect was obtained) was used for this study. Among the pin profiles, the triangular tapered pin produced significantly improved intermingling/inter-material flow, fragmentation, and dispersion of the primary Mg2Si particles in the AA6061-T6/Al-Mg2Si joint. The triangular tapered tool reduced the average grain sizes of the AA6061 alloy and the Mg2Si particles from 18.4 to 4.6 µm and from 115 to 7.5 µm, respectively. Intermetallic phases of Mg2Si, AlFe, Al3.21Si0.47, and Al0.7Fe3Si0.3 are formed in the weld nugget of all the AA6061/Al-Mg2Si joints. The tensile strengths of the joints fabricated with tapered cylindrical, threaded tapered cylindrical, and triangular tapered tools are 108, 139, and 141 MPa, respectively. Abrasive wear is promoted in the joints fabricated with triangular tapered tool due to the homogeneous dispersion and fragmentation of the inherent hard Mg2Si particles. The corrosion attack is dependent on the fragmentation level of the Mg2Si phase. Triangular tapered pin tool is recommended for dissimilar Al/composite welding due to favorable tool-induced material flow, dispersion, and fragmentation of reinforcement.

scholarly journals Investigation into the Dissimilar Friction Stir Welding of AA5052 and AA6061 Aluminum Alloys Using Pin-Eccentric Stir Tool

Metals ◽  
2019 ◽  
Vol 9 (7) ◽  
pp. 718 ◽  
Author(s):  
Yu Chen ◽  
He Wang ◽  
Huaying Li ◽  
Xiaoyu Wang ◽  
Hua Ding ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Material Flow ◽  
Tensile Tests ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Dissimilar Friction Stir Welding ◽  
Average Grain Size ◽  
Dislocation Strengthening ◽  
Onion Ring

Friction stir welding with different pin-eccentric stir tools (the pin eccentricities were 0, 0.4, and 0.8 mm, respectively) was successfully utilized for joining dissimilar aluminum alloys AA5052 and AA6061, and the influences of pin eccentricity on the microstructural evolution and mechanical properties of joints were investigated. The results showed that sound joints could be obtained by placing the hard AA6061 in the advancing side, while the welding heat input led to both the coarsening of strengthening precipitates and dynamic recrystallization and softening of the nugget zone (NZ). The application of pin eccentricity promoted the material flow in the NZ and enlarged the area of the “onion ring”. Furthermore, the average grain size and fraction of recrystallized grain in the NZ decreased as the pin eccentricity increased. All joints failed in the NZ during tensile tests, and the joint produced by the 0.8 mm-pin-eccentric stir tool performed the highest tensile strength due to the enhanced grain-boundary and dislocation strengthening.

scholarly journals Effects of processing parameters on mechanical, material flow and wear behaviour of friction stir welded 6101-T6 and 7075-T651 aluminium alloys

2020 ◽  
Vol 7 ◽  
pp. 1 ◽  
Author(s):  
Olatunji P. Abolusoro ◽  
Esther T. Akinlabi
Keyword(s):  
Rotational Speed ◽  
Aluminium Alloys ◽  
Material Flow ◽  
Travel Speed ◽  
Processing Parameters ◽  
Wear Behaviour ◽  
Tensile Behaviour ◽  
Nugget Zone ◽  
Friction Stir ◽  
Dissimilar Friction Stir Welding

Dissimilar friction stir welding (FSW) between 6101-T6 and 7075-T651 aluminium alloys was conducted. Three different parameters each were investigated for rotational speed and travel speed, and the effects of these parameters on the tensile behaviour, hardness and wear were evaluated. The results indicate that the ultimate tensile strength increases with an increase in the feed rate. However, the increase in rotational speed decreases the ultimate tensile values. The fractured analysis of the tensile samples shows similarities in the fractured pattern as all the samples failed at heat affected zone close to the 6101-T6 alloy. The hardness varies across the heat affected zones and nugget zone both at constant rotational speed and welding speeds. The highest resistance to wear occurred at 65 mm min−1 and 1850 rpm welding speed and rotational speed respectively while better material mixing was achieved at the nugget zone of the welds at 1250 rpm and 110 mm/min.

Investigation of the material flow and texture evolution in friction-stir welded aluminum alloy

2009 ◽  
Vol 15 (6) ◽  
pp. 1027-1031 ◽  
Author(s):  
Suk Hoon Kang ◽  
Heung Nam Han ◽  
Kyu Hwan Oh ◽  
Jae-Hyung Cho ◽  
Chang Gil Lee ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Material Flow ◽  
Texture Evolution ◽  
Friction Stir

Thermo-Mechanical Modelling of Friction Stir Welding Process

2013 ◽  
Vol 774-776 ◽  
pp. 1155-1159 ◽  
Author(s):  
Xiao Cong He
Keyword(s):  
Finite Element Analysis ◽  
Friction Stir Welding ◽  
Mechanical Behaviour ◽  
Material Flow ◽  
Welding Process ◽  
Element Analysis ◽  
Friction Stir ◽  
Mechanical Modelling ◽  
Major Factors ◽  
Realistic Prediction

Friction stir welding (FSW) is a solid-state welding process where no gross melting of the material being welded takes place. Numerical modelling of the FSW process can provide realistic prediction of the thermo-mechanical behaviour of the process. Latest literature relating to finite element analysis (FEA) of thermo-mechanical behaviour of FSW process is reviewed in this paper. The recent development in thermo-mechanical modelling of FSW process is described with particular reference to two major factors that influence the performance of FSW joints: material flow and temperature distribution. The main thermo-mechanical modelling used in FSW process are discussed and illustrated with brief case studies from the literature.

Grain Structure Formation Ahead of Tool during Friction Stir Welding of AZ31 Magnesium Alloy

2010 ◽  
Vol 160 ◽  
pp. 313-318 ◽  
Author(s):  
Uceu Suhuddin ◽  
Sergey Mironov ◽  
H. Takahashi ◽  
Yutaka S. Sato ◽  
Hiroyuki Kokawa ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Magnesium Alloy ◽  
Structure Formation ◽  
Material Flow ◽  
Boundary Migration ◽  
Deformation Mode ◽  
Grain Structure ◽  
Az31 Magnesium Alloy ◽  
Structure Evolution ◽  
Friction Stir

The “stop-action” technique was employed to study grain structure evolution during friction-stir welding of AZ31 magnesium alloy. The grain structure formation was found to be mainly governed by the combination of the continuous and discontinuous recrystallization but also involved geometric effect of strain and local grain boundary migration. Orientation measurements showed that the deformation mode was very close to the simple shear associated with the rotating pin and material flow arose mainly from basal slip.

Influence of Tool Geometry and Contact Condition on Friction Stir Welding of Al-Cu Laminated Composites

2013 ◽  
Vol 856 ◽  
pp. 16-21
Author(s):  
R. Beygi ◽  
Mohsen Kazeminezhad ◽  
A.H. Kokabi ◽  
S. Mohammad Javad Alvani ◽  
D. Verdera ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Laminated Composites ◽  
Flow Behavior ◽  
Tool Geometry ◽  
Contact Conditions ◽  
Friction Stir ◽  
Tool Geometries ◽  
Welding Procedure ◽  
Sem Analyses

In this study friction stir welding of Al-Cu laminated composites were carried out by two different tool geometries. Welding procedure was carried out from both sides of Al and Cu. Analyzing cross section of welds showed that different contact conditions between shoulder and material, offers different material flow behavior which is dependent on the tool geometry. SEM analyses showed that mixing of materials in nugget region is more pronounced in the advancing side. Also XRD results indicated that welding from Cu side, leads to intermetallic formation in mixed regions.

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