Effect of tool traverse speed on microstructure and mechanical performance of friction stir welded 7020 aluminum alloy

2015 ◽  
Vol 230 (2) ◽  
pp. 663-673 ◽  
Author(s):  
Reza Vatankhah Barenji
Keyword(s):  
Aluminum Alloy ◽  
Mechanical Performance ◽  
Traverse Speed ◽  
Friction Stir

scholarly journals Effect of Welding Speed on Defect Features and Mechanical Performance of Friction Stir Lap Welded 7B04 Aluminum Alloy

Metals ◽  
2016 ◽  
Vol 6 (4) ◽  
pp. 87 ◽  
Author(s):  
Huijie Zhang ◽  
Min Wang ◽  
Xiao Zhang ◽  
Zhi Zhu ◽  
Tao Yu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Welding Speed ◽  
Mechanical Performance ◽  
Friction Stir

Experimental Study on Friction Stir Welding of Marine Grade Aluminum Alloy

2009 ◽  
Vol 25 (01) ◽  
pp. 21-26
Author(s):  
Pankaj Biswas ◽  
N. R. Mandal
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Welded Joint ◽  
Traverse Speed ◽  
Rotating Speed ◽  
Friction Stir ◽  
Weld Parameters ◽  
5083 Aluminum Alloy ◽  
Selection Of

Friction stir welding, a comparatively new joining technique, is mainly used for welding aluminum alloys. In the present work, an attempt has been made to study the effect of weld parameters of friction stir welding of marine grade 5083 aluminum alloy. Several test runs were conducted to assess the effects of tool rotating speed and tool traverse speed on the microstructure and mechanical properties of the welded joint. It was observed that the tool traverse speed has a significant effect on the end properties of the welded joint. Grain refinement was observed in the thermomechanically affected zone (TMAZ), which led to improved mechanical properties of the welded joint. However, an increase in welding speed keeping rotational speed constant led to deterioration of mechanical properties. The study strongly indicates a possibility of achieving a superior welded joint in marine grade 5083 aluminum alloy with adequate selection of process parameters.

Joint Formation and Mechanical Performance of Friction Self-Piercing Riveted Aluminum Alloy AA7075-T6 Joints

2019 ◽  
Vol 141 (4) ◽  
Author(s):  
Yun Wu Ma ◽  
Yong Bing Li ◽  
Zhong Qin Lin
Keyword(s):  
Aluminum Alloy ◽  
Failure Mode ◽  
Feed Rate ◽  
Shear Failure ◽  
Mechanical Performance ◽  
Shear Fracture ◽  
Peak Load ◽  
Spindle Speed ◽  
Friction Stir ◽  
Lap Shear

AA7xxx series aluminum alloys have great potentials in mass saving of vehicle bodies due to pretty high specific strength. However, the use of these high strength materials poses significant challenges to the traditional self-piercing riveting (SPR) process. To address this issue, a novel process, friction self-piercing riveting (F-SPR), was applied to join aluminum alloy AA7075-T6 sheets. The effects of the spindle speed and rivet feed rate on F-SPR joint cross section geometry evolution, riveting force, and energy input were investigated systematically. It was found that the rivet shank deformation, especially the buckling of the shank tip before penetrating through the top sheet, has significant influence on geometry and lap shear failure mode of the final joint. A medium rivet feed rate combined with a high spindle speed was prone to produce a defect-free joint with sound mechanical interlocking. F-SPR joints with the failure mode of rivet shear fracture were observed to have superior lap shear peak load and energy absorption over the joints with mechanical interlock failure. The optimized F-SPR joint in this study exhibited 67.6% and 13.9% greater lap shear peak load compared with SPR and refill friction stir spot welding joints, respectively, of the same sheets. This research provides a valuable reference for further understanding the F-SPR process.

Process Window for Friction Stir Lap Welding of Aluminum Alloy 6061

2014 ◽  
Vol 783-786 ◽  
pp. 2839-2844
Author(s):  
Simon Larose ◽  
Maxime Guérin ◽  
Priti Wanjara
Keyword(s):  
Aluminum Alloy ◽  
Mechanical Performance ◽  
High Strength ◽  
Butt Joint ◽  
Process Window ◽  
Tool Geometry ◽  
Transportation Industry ◽  
Friction Stir ◽  
Planar Surfaces ◽  
Lap Welding

Precipitation-hardenable 6xxx series aluminum alloys are incorporated in many structural components with due consideration of their good combination of properties including a relatively high strength, outstanding extrudability and excellent corrosion resistance. Accordingly, AA6061 has been identified as a very good candidate material for structural lightweighting of transportation vehicles. However, the weldability of aluminum alloy (AA) 6061 by means of conventional technologies such as GMAW and GTAW methods is limited by sensitivity to solidification cracking. In this respect, friction stir welding (FSW) presents a tremendous potential for assembly of aluminum structures for the transportation industry due to the low heat involved that can mitigate crack formation and, thus, translate into improved mechanical performance of the assembly. In this work, FSW of 3.18 mm thick AA6061-T6 sheets in the lap joint configuration was investigated. This configuration is considered to be more challenging for assembly by FSW than the butt joint type due to the orientation of the interface with respect to the welding tools and the necessity to break the oxide layer on two aluminium alloy planar surfaces. Weld trials were performed to examine the influence of the FSW tool geometry and process parameters on the welding defects, microstructure, hardness and bend performance. Unacceptable material expulsion and/or significant thinning in one of the two overlapped sheets were produced under most conditions. A set of FSW tool geometries leading to a viable process operational window under which the risk of defects could be mitigated and/or eliminated was identified in this study.

scholarly journals Effect of Process Parameters on Defect Features and Mechanical Performance of Friction Stir Lap Welded AA6063 and ETP Copper Joints

2019 ◽  
Vol 8 (2S11) ◽  
pp. 879-883
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Defect Formation ◽  
Mechanical Performance ◽  
Traverse Speed ◽  
Weld Strength ◽  
Dissimilar Metals ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
The Difference

The effect of process parameters such as tool rotational speed and tool traverse speed on mechanical properties of AA-6063 and ETP Cu lap joint is investigated. At present, Friction Stir Welding is being employed to join dissimilar metals. However, the difference in the physical properties of the base metals makes it difficult to join these metals. The present study investigates the effect of using a compatible intermediate layer on weld strength. Different joint defects and their effect on joint strength has been discussed. The experiments were conducted with tool rotational speed of 800, 1000 and 1200 rpm each and with tool traverse speeds of 10, 15 and 20 mm/min. The dissimilar metals are successfully lap welded with fair tensile strength. The effect of process parameters on weld strength and defect formation is discussed

scholarly journals Effect of Friction Stir Welding Parameters on the Microstructure and Mechanical Properties of AA2024-T4 Aluminum Alloy

2018 ◽  
Vol 8 (1) ◽  
pp. 2493-2498 ◽  
Author(s):  
A. W. El-Morsy ◽  
M. Ghanem ◽  
H. Bahaitham
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Cross Section ◽  
High Performance ◽  
Traverse Speed ◽  
Butt Joint ◽  
Welding Parameters ◽  
Friction Stir

In this work, the effects of rotational and traverse speeds on the 1.5 mm butt joint performance of friction stir welded 2024-T4 aluminum alloy sheets have been investigated. Five rotational speeds ranging from 560 to 1800 rpm and five traverse speeds ranging from 11 to 45 mm/min have been employed. The characterization of microstructure and the mechanical properties (tensile, microhardness, and bending) of the welded sheets have been studied. The results reveal that by varying the welding parameters, almost sound joints and high performance welded joints can be successfully produced at the rotational speeds of 900 rpm and 700 rpm and the traverse speed of 35 mm/min. The maximum welding performance of joints is found to be 86.3% with 900 rpm rotational speed and 35 mm/min traverse speed. The microhardness values along the cross-section of the joints show a dramatic drop in the stir zone where the lowest value reached is about 63% of the base metal due to the softening of the welded zone caused by the heat input during joining.

Study of thermal cycle, mechanical, and metallurgical properties of friction stir welded aviation grade aluminum alloy

2018 ◽  
Vol 233 (11) ◽  
pp. 4202-4213 ◽  
Author(s):  
Shubham Verma ◽  
Meenu Gupta ◽  
Joy Prakash Misra
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Tilt Angle ◽  
Thermal Cycle ◽  
Dwell Time ◽  
Traverse Speed ◽  
Energy Beam ◽  
Friction Stir

This research work presents the study of thermal cycle during friction stir welding of aviation grade aluminum alloy. In addition, mechanical and metallurgical properties of friction stir welded joints are conceptually discussed. Experimentation has been conducted in two stages. Stage I experiments has been conducted as per one-factor-at-a-time approach with varying tilt angle and dwell time. It was concluded that maximum ultimate tensile strength is obtained at 2° tilt angle and 30 s dwell time by one-factor-at-a-time approach. On the basis of stage I results, full-factorial design is used for conducting main experiments by fixing the tilt angle and dwell time. Stage II has been attempted to optimize the most influencing friction stir welding parameters: rotational speed and traverse speed. It is observed that rotational speed is predominant factors for ultimate tensile strength and traverse speed for microhardness. In addition, eight thermocouples (L-shaped k type), four on the advancing side and four on the retreating side, are placed at equal distance from the centerline for measuring the temperature during the process. The optical microscope and energy beam scattered diffraction analysis have been carried out for scrutinizing the macrostructure and microstructure of friction stir welded joints. It is evident from energy beam scattered diffraction analysis that the grain size of nugget zone decreases as compared to base metal.

scholarly journals Examination of the Mechanical, Corrosion, and Tribological Behavior of Friction Stir Welded Aluminum Alloy AA8011

2021 ◽  
Vol 10 (1) ◽  
Author(s):  
Vaira Vignesh Ramalingam ◽  
R. Arun Kumar ◽  
N. Srirangarajalu ◽  
R. Padmanaban
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Rotation Speed ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Fishing Vessels ◽  
Joint Efficiency ◽  
Shoulder Diameter ◽  
Tool Rotation

Aluminum alloy AA8011 is emerging as a promising material for modern engineering applications in which improved tensile strength, hardness, corrosion-resistance, and wear-resistance of materials are required. Typically, AA8011 alloys are utilized in air-conditioning ducts and heat exchanger fins in ships, leisure boats, luxury vessels, workboats, fishing vessels, and patrol boats. However, the conventional welding of AA8011 is a challenging procedure. In this context, this paper focuses on the development of an effective solid-state welding methodology for AA8011 alloy welding. The AA8011 alloy was friction stir welded by varying the tool rotation speed, traverse speed, and shoulder diameter. The microhardness, tensile strength, joint efficiency, elongation, corrosion rate, and wear rate of the friction stir welded specimens were compared with the base material. Fractography analysis was conducted after the tensile test and surface morphology analysis after corrosion and wear tests, using scanning electron microscopy. The compositional elements in the corroded and worn section of the specimens were analyzed using energy-dispersive X-ray spectroscopy. Based on the joint efficiency as a primary constraint, the optimum process parameters for friction stir welding of aluminum alloy AA8011 have been established as follows: tool rotation speed of 1200 rpm, tool traverse speed of 45 mm/min, and tool shoulder diameter of 21 mm.

Microstructural and Mechanical Characterization of Friction Stir Processed 5086 Aluminum Alloy

2012 ◽  
Vol 710 ◽  
pp. 253-257 ◽  
Author(s):  
Shivanna Pradeep ◽  
Sumit Kumar Sharma ◽  
Vivek Pancholi
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Mechanical Characterization ◽  
Rotation Speed ◽  
Bulk Material ◽  
Base Material ◽  
Superplastic Forming ◽  
Traverse Speed ◽  
Friction Stir

In the present investigation friction stir processing (FSP) is carried out by single and multipass FSP on a 5086 aluminum alloy to modify microstructure and mechanical properties. The processing is carried out at constant rotation speed of 1025 rpm and at a traverse speed of 30 mm/min. Inhomogeneous microstructural distribution was observed across the processed zone. EBSD analysis has been done to evaluate the microstructure. Overlapping passes is showing same grain size as in single pass FSPed material. Material processed using multi pass FSP at 30 mm/min is showing higher mechanical strength as compared to base material. The bulk material produced due to multipass seems to be good for superplastic forming applications.

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