Microstructure and Properties of Friction Stir Welded Aluminum Alloys

2019 ◽  
Author(s):  
Izabela Kalemba ◽  
Stanisław Dymek
Keyword(s):  
Mechanical Properties ◽  
Welding Process ◽  
High Strength ◽  
Limited Range ◽  
Friction Stir ◽  
Microstructure And Properties ◽  
Aerospace Applications ◽  
Cu Alloys ◽  
Wide Range ◽  
Tool Rotation

Aluminium alloy 7136 belongs to the Al–Zn–Mg–Cu group of aluminium alloys strengthened by precipitation. These alloys offer very good properties, i.e. high strength combined with good corrosion resistance, which makes them suitable for aerospace applications. The limited range of applications of these alloys is due to problems associated with their welding. The Al–Zn–Mg–Cu alloys are classified as non-weldable. The aim of this study was to determine the quality and properties of friction stir welded (FSW) joints of alloy 7136-T76. This article presents the results of a detailed study into the microstructure and mechanical properties of FSW welds. The paper demonstrates that the FSW method is suitable for joining Al–Zn–Mg–Cu alloys. The FSW joints are of good quality and high mechanical properties. Tests of joints created at various tool rotation speeds have shown that joints of suitable quality, in terms of microstructure and properties, can be obtained for a relatively wide range of process parameters. The tool rotation speeds applied during the welding process did not have a significant influence on the quality of the welds.

Influence of Tool Rotational Speed on the Mechanical Properties of Friction Stir Welded Al-Cu-Li Alloy

2016 ◽  
Vol 857 ◽  
pp. 228-231
Author(s):  
Ho Sung Lee ◽  
Ye Rim Lee ◽  
Kyung Ju Min
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Space Shuttle ◽  
Welding Process ◽  
High Strength ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Mechanical And Microstructural Properties ◽  
Tool Rotation

Aluminum-Lithium alloys have been found to exhibit superior mechanical properties as compared to the conventional aerospace aluminum alloys in terms of high strength, high modulus, low density, good corrosion resistance and fracture toughness at cryogenic temperatures. Even though they do not form low-melting eutectics during fusion welding, there are still problems like porosity, solidification cracking, and loss of lithium. This is why solid state friction stir welding is important in this alloy. It is known that using Al-Cu-Li alloy and friction stir welding to super lightweight external tank for space shuttle, significant weight reduction has been achieved. The objective of this paper is to investigate the effect of friction stir tool rotation speed on mechanical and microstructural properties of Al-Cu-Li alloy. The plates were joined with friction stir welding process using different tool rotation speeds (300-800 rpm) and welding speeds (120-420 mm/min), which are the two prime welding parameters in this process.

Studies on Friction Stir Welding of Al-Cu-Li (AA2195) Alloy

2015 ◽  
Vol 830-831 ◽  
pp. 274-277
Author(s):  
M. Agilan ◽  
R. Anbukkarasi ◽  
T. Venkateswran ◽  
Paul G. Panicker ◽  
Sathish V. Kailas ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Rotation Speed ◽  
Welding Process ◽  
High Strength ◽  
Travel Speed ◽  
High Modulus ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Aerospace Applications ◽  
Tool Rotation

For aerospace applications, Al-Cu-Li alloys are more attractive than conventional aluminum alloys due to their low density, high modulus and high strength. AA2195 is a third generation Al-Li alloy, developed with improved weldability. In this study, AA2195 alloy of 5mm thick sheets were welded by friction stir welding process (FSW). Tool rotational speed was varied from 400 rpm to 1000 rpm at constant travel speed of 60mm/min. Optimum tool rotation speed was identified and defect free weld coupons were processed with optimized parameter. Mechanical properties and micro structural characterization have been conducted on FSW welds.

scholarly journals Comprehensive Analysis of the Microstructure and Mechanical Properties of Friction-Stir-Welded Low-Carbon High-Strength Steels with Tensile Strengths Ranging from 590 MPa to 1.5 GPa

2021 ◽  
Vol 11 (12) ◽  
pp. 5728
Author(s):  
HyeonJeong You ◽  
Minjung Kang ◽  
Sung Yi ◽  
Soongkeun Hyun ◽  
Cheolhee Kim
Keyword(s):  
Mechanical Properties ◽  
Tensile Test ◽  
Joint Strength ◽  
Solid Phase ◽  
Welding Process ◽  
High Strength Steels ◽  
High Strength ◽  
Low Carbon ◽  
Friction Stir ◽  
Welding Processes

High-strength steels are being increasingly employed in the automotive industry, requiring efficient welding processes. This study analyzed the materials and mechanical properties of high-strength automotive steels with strengths ranging from 590 MPa to 1500 MPa, subjected to friction stir welding (FSW), which is a solid-phase welding process. The high-strength steels were hardened by a high fraction of martensite, and the welds were composed of a recrystallized zone (RZ), a partially recrystallized zone (PRZ), a tempered zone (TZ), and an unaffected base metal (BM). The RZ exhibited a higher hardness than the BM and was fully martensitic when the BM strength was 980 MPa or higher. When the BM strength was 780 MPa or higher, the PRZ and TZ softened owing to tempered martensitic formation and were the fracture locations in the tensile test, whereas BM fracture occurred in the tensile test of the 590 MPa steel weld. The joint strength, determined by the hardness and width of the softened zone, increased and then saturated with an increase in the BM strength. From the results, we can conclude that the thermal history and size of the PRZ and TZ should be controlled to enhance the joint strength of automotive steels.

Investigations on the Mechanical Properties and Formability of Friction Stir Welded Tailored Blanks

2007 ◽  
Vol 344 ◽  
pp. 143-150 ◽  
Author(s):  
Gianluca Buffa ◽  
Livan Fratini ◽  
Marion Merklein ◽  
Detlev Staud
Keyword(s):  
Mechanical Properties ◽  
Stress Condition ◽  
Research Effort ◽  
High Strength Steels ◽  
High Strength ◽  
Tensile Tests ◽  
Friction Stir ◽  
Tailored Blanks ◽  
Sheet Stamping ◽  
Wide Range

Tight competition characterizing automotive industries in the last decades has determined a strong research effort aimed to improve utilized processes and materials in sheet stamping. As far as the latter are regarded light weight alloys, high strength steels and tailored blanks have been increasingly utilized with the aim to reduce parts weight and fuel consumptions. In the paper the mechanical properties and formability of tailored welded blanks made of a precipitation hardenable aluminum alloy but with different sheet thicknesses, have been investigated: both laser welding and friction stir welding have been developed to obtain the tailored blanks. For both welding operations a wide range of the thickness ratios has been considered. The formability of the obtained blanks has been characterized through tensile tests and cup deep drawing tests, in order to show the formability in dependency of the stress condition; what is more mechanical and metallurgical investigations have been made on the welded joints.

scholarly journals Incorporating oxygen-free copper to improve the microstructure and mechanical properties of friction-stir-welded joints for aluminum alloys

2018 ◽  
Vol 25 (6) ◽  
pp. 1219-1228
Author(s):  
Her-Yueh Huang ◽  
Chung-Wei Yang ◽  
Wen-Yao Deng
Keyword(s):  
Mechanical Properties ◽  
Rotation Speed ◽  
Welding Process ◽  
Weld Nugget ◽  
Nugget Zone ◽  
Friction Stir ◽  
Copper Particles ◽  
Dissimilar Metal ◽  
Tool Rotation ◽  
Traveling Speed

AbstractThe main objective of the present work was to establish a friction-stir-welding process to weld dissimilar metal joints on AA6082 and AA6066 aluminum alloy plates. Joints were made while varying tool rotation speed at a constant traveling speed and at the same time adding oxygen-free copper reinforcement inside the weld nugget for the purpose of analyzing the microstructural evolution and mechanical properties of the joint. Results showed that the morphology of the microstructure in the weld nugget changed significantly with rotation speed. Optical microscopy, scanning electron microscopy, and energy dispersive spectroscopy analyses revealed that oxygen-free copper particles could be uniformly dispersed into the weld nugget because of higher rotation speeds. Because of the presence of reinforcement particles homogenously distributed inside the nugget zone, the mechanical properties, such as ultimate tensile strength and hardness of weld joint, were greatly improved.

Investigation of the effects of welding variables on the welding defects of the friction stir welded high density polyethylene sheets

2021 ◽  
pp. 009524432110588
Author(s):  
Mustafa Kemal Bilici
Keyword(s):  
Friction Stir Welding ◽  
High Density Polyethylene ◽  
Welding Process ◽  
High Strength ◽  
High Density ◽  
Welding Parameters ◽  
Friction Stir ◽  
Wide Range ◽  
Welding Defects ◽  
Welding Processes

Modern thermoplastic materials are used in an expanding range of engineering applications, such as in the automotive industry, due to their enhanced stress-to-weight ratios, toughness, a very short time of solidification, and a low thermal conductivity. Recently, friction stir welding has started to be used in joining processes in these areas. There are many factors that affect weld performance and weld quality in friction stir welding (FSW). These factors must be compatible with each other. Due to the large number of welding variables in friction stir welding processes, it is very difficult to achieve high strength FSW joints, high welding performance, and control the welding process. Welding variables that form the basis of friction stir welding; machine parameters, tool variables, and material properties are divided into three main groups. Each welding variable has different effects on the weld joint. In this study, friction stir welds were made on high density polyethylene (HDPE) sheets with factors selected from machine parameters and welding tool variables. Although the welding performance, quality, and strength gave good results in some conditions, successful joints could not be realized in some conditions. In particular, welding defects occurring in the combination of HDPE material with FSW were investigated. Welding quality, defects, and performances were examined with macrostructure. In addition, the tensile strength values of some the joints were determined. The main purpose of this study is to determine the welding defects that occur at the joints. The causes of welding defects, prevention methods, and which weld variables caused were investigated. Welding parameters and welding defects caused by welding tools were examined in detail. In addition, the factors causing welding defects were changed in a wide range and the changes in the defects were observed.

Mechanical Properties and Microstructure of SS400 Friction Stir Welds Pursuant to Welding Distance

2011 ◽  
Vol 399-401 ◽  
pp. 273-276
Author(s):  
Kwang Jin Lee ◽  
Hyun Kuk Park ◽  
Sang Hyuk Kim ◽  
Hyun Kuk Park ◽  
Ik Hyun Oh
Keyword(s):  
Mechanical Properties ◽  
Melting Point ◽  
Abrasion Resistance ◽  
Industrial Development ◽  
Welding Process ◽  
High Strength ◽  
High Melting ◽  
High Melting Point ◽  
Friction Stir ◽  
Metallic Compounds

FSW have advantage as defect such as porosity, metallic compounds decrease than other welding process. So, FSW was researched about low melting point materials. However, welding of high melting point and high strength materials attract attention because of high mechanical properties was needed due to industrial development. In this study, FSW is enforced using the kind of high melting point materials as SS400(SPHC). However, the tool must have super heat-resisting and abrasion resistance. So, WC-X%Co tool was manufactured by SPS method. The result, welding is successfully practice using WC-X%Co tool to 50m without fracture of tool.

The Role of Friction Stir Welding Process Parameter on Mechanical Properties of Magnesium Alloy AZ31B

2013 ◽  
Vol 849 ◽  
pp. 38-44
Author(s):  
S. Vijayan ◽  
S. Prasath
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Microstructure Evolution ◽  
Welding Process ◽  
High Strength ◽  
Fusion Welding ◽  
Friction Stir ◽  
Current State ◽  
Magnesium Alloy Az31b

The Friction Stir welding is a solid state welding invented in the year 1991.This welding technique is highly energy efficient, eco-friendly in joining the high strength aerospace aluminums alloys and its other alloys which are not able to weld by the conventional fusion welding process. Initially FSW is use to weld aluminums alloys and gradually it applies to all form of metals and alloys. In this review article the current state of understanding and development of FSW with respect to Magnesium alloys AZ 31 B is addressed. And particular emphasis is given to the effect of FSW process parameters on the mechanical properties, corrosion behavior and microstructure evolution. At this stage there is wide gap in understanding the mechanism of dissimilar Magnesium welds on microstructure evolution and microstructure property relationships with respect to FSW and Submersible FSW process.

Governance of Various Tool Rotational Speeds on Mechanical Properties of Friction Stir Welded AA 7075-T651

2016 ◽  
Vol 852 ◽  
pp. 344-348
Author(s):  
R. Mohammed Ryan ◽  
E. Sangeeth Kumar
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Aerospace Industry ◽  
Weight Ratio ◽  
Welding Process ◽  
High Strength ◽  
Micro Hardness ◽  
Friction Stir ◽  
Aa 7075

The development of the friction stir welding being a solid state welding has provided an improved way of manufacturing aluminum joints in a quicker and reliable manner. The heat treatable aluminum alloy AA7075 is used substantially in the aerospace industry because of its high strength to weight ratio and good ductility. The objective of our work is to research the parameters of welding on the mechanical properties of friction stir welded joints of AA7075-T651. The parameters namely rotational speeds (500 rpm, 700 rpm, 900 rpm, 1100 rpm, 1300 rpm and 1500 rpm) were thought-about and table transverse speed of 50 mm/min, axial force of 8 KN is constrained throughout the welding process. The result of these parameters on weld quality is analyzed by its mechanical properties namely micro hardness and tensile strength.

Friction Stir Welding of Oxygen Free Copper and 60%Cu-40%Zn Copper Alloy

2008 ◽  
Vol 580-582 ◽  
pp. 447-450
Author(s):  
Hwa Soon Park ◽  
Byung Woo Lee ◽  
Taichi Murakami ◽  
Kazuhiro Nakata ◽  
Masao Ushio
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Base Metal ◽  
Welding Speed ◽  
Copper Alloy ◽  
Rotation Speed ◽  
Friction Stir ◽  
Wide Range ◽  
Hardness Values ◽  
Tool Rotation

The mechanical properties of the friction stir welds of the oxygen free copper (OFC) and 60%Cu-40%Zn copper alloy(60/40 brass) were investigated. The defect-free welds were obtained in a relatively wide range of welding conditions; the tool rotation speed had rpm of 1000 to 2000 in the OFC and 1000 to 1500 in the 60/40 brass, with the welding speed of 500 to 2000 mm/min. The SZ hardness values of the OFC welds were almost the same or slightly lower than those of the base metal. However, the SZ hardness values of the 60/40 brass in all welding conditions were much higher than those of the base metal. The SZ hardness values of both metals increase with a decrease in heat input. The tensile properties of the all-SZ showed relative correspondence to the variation of the SZ hardness values.

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