scholarly journals Estimation of The IMC Layer Thickness of Friction-Stir-Welded Aluminum/Copper Lap Joints By Using Temperature Simulation

2021 ◽  
Author(s):  
Markus Krutzlinger ◽  
Michael Karl Kick ◽  
Manuel Kessler ◽  
Michael Friedrich Zaeh
Keyword(s):  
Layer Thickness ◽  
Dissimilar Materials ◽  
Interfacial Area ◽  
Lap Joints ◽  
Lap Joint ◽  
Friction Stir ◽  
Cooling Slope ◽  
Joint Properties ◽  
Wide Range ◽  
The Individual

Abstract Many studies demonstrated the suitability of Friction Stir Welding (FSW) for joining dissimilar materials. Especially the combination of aluminum and copper is of high interest for many applications. Intermetallic compounds (IMC) forming during FSW due to interdiffusion and the thickness of the IMC layers strongly influence the joint properties, e.g. the joint strength or the thermal and electrical conductivity. Therefore, it is important to predict the IMC layer thickness to tailor the joint properties to the individual application. For this purpose, a thermal-pseudo-mechanical model was built to simulate the temperature field during FSW of aluminum EN AW-1050 and copper CW008A in lap joint configuration. The simulated temperatures as well as the heat inputs corresponded well with experimental data for a wide range of parameter settings. In order to estimate the IMC layer thickness, the simulated temperatures close to the interface of the materials were used. Two approaches for calculating the layer thicknesses were compared. In the first approach, the thickness is calculated based on the peak temperature lasting for several seconds at the interfacial area. This approach was applied for constant feed rates, while the second approach also accounted for the cooling slope and could therefore be used for different feed rates.

Lap Joint Properties of FSBRed Dissimilar Metals AZ31 Mg Alloy and DP600 High-Strength Steel with Various Parameters

2011 ◽  
Vol 228-229 ◽  
pp. 427-432 ◽  
Author(s):  
Chang Qing Zhang ◽  
Bo Qiang Li ◽  
Xi Jing Wang
Keyword(s):  
Shear Strength ◽  
High Strength Steel ◽  
High Strength ◽  
Frictional Heat ◽  
Lap Joint ◽  
Workpiece Material ◽  
High Rotational Speed ◽  
Friction Stir ◽  
Az31 Mg Alloy ◽  
Joint Properties

The Friction stir blind riveting (FSBR) process consists of a blind rivet is driven at high rotational speed and brought into contact with the workpieces, thereby generating frictional heat between the rivet and the workpiece, which softens the workpiece material and enables the rivet to be driven into the workpieces under reduced force. The riveting of lap joint of AZ31B(3mm) magnesium alloys plate and a DP600 (1mm) high strength steel plate was produced by FSBR using 2200rpm rotation speed, various feet rates and different lap mode to investigate the effects of the joint morphology and strength. The joint strength depended strongly on the shank of rivet itself shear strength，however in which case the strength of joint impacted by rivet assembly quality (the lap of plates, the tightness rivet of workpiece). So positioning the steel sheet on the top is desirable, the maximum shear strength of the joint reached about 6.0KN.

Analysis of tool wear and deformation in friction stir welding of unequal thickness dissimilar Al alloys

2020 ◽  
pp. 146442072097176
Author(s):  
Tanveer Majeed ◽  
Yashwant Mehta ◽  
Arshad Noor Siddiquee
Keyword(s):  
Friction Stir Welding ◽  
Tool Wear ◽  
Tilt Angle ◽  
Dissimilar Materials ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Process Forces ◽  
Wide Range ◽  
Lower Tool

Friction stir welding between plates of unequal thickness, which are made from similar or dissimilar materials, finds wide range of applications in the aerospace and automotive sectors. Friction stir welding of plates made from dissimilar materials having unequal thicknesses is challenging. One of the major challenges is the control of rapid tool degradation which occurs during welding. This work reports a maiden study on tool degradation of high thickness ratio unequal thickness dissimilar material joints made between 6.3 mm thick AA2024-T3 and 2.5 mm thick AA7475-T7 plates. The degradation of friction stir welding tool made of T4 tool steel having tapered cylindrical pin and scrolled shoulder was analyzed. The geometry of tool (before and after welding) was compared; the degradation was categorized, characterized, and analyzed in the light of measured welding temperature, process forces, and process parameters. It was found that the pin undergoes significant degradation in the form of wear and deformation compared to the tool shoulder. The experimental results demonstrated that lower flow stresses caused by higher process temperature leads to lower tool wear and deformation, and vice versa. In addition to temperature and process forces, the surface tilt angle was found to significantly affect the pin deformation. The higher surface tilt angle caused an increase in tool wear and deformation.

scholarly journals Equal Load-Carrying Design of Lapped Joints of Al–Cu Dissimilar Materials

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4293
Author(s):  
Zhihao Chen ◽  
Jianxiao Ma ◽  
Hongyuan Fang ◽  
Zhida Ni ◽  
Ping Wang
Keyword(s):  
Bearing Capacity ◽  
Fracture Mode ◽  
Dissimilar Materials ◽  
Lap Joints ◽  
Holding Time ◽  
Lap Joint ◽  
Fracture Modes ◽  
Load Carrying ◽  
Tensile Curve ◽  
Static Tensile

In order to avoid the adverse effects of additional moment and stress concentration of traditional lap joints, a new lap joint was put forward, according to the concept of “equal load-carrying”. Through static analysis and brazing characteristics consideration, the equal load-carrying design method of Al–Cu lap joint based on brazing method was established. Through three types of brazing, the relationship among two fracture modes, brazing process and static tension curve of lap joint, was analyzed. The results demonstrated that the selection of solder was required to simultaneously meet the requirements of brazability and mechanical properties. A certain relationship existed between the fracture mode of the lap joint and the static tensile curve, while the segments of the static tensile curve corresponded to the fracture paths of the two fracture modes. When the brazing holding time was quite short, the interface bonding was poor, while the bearing capacity of the joint was low; when the holding time was suitable, the bearing capacity of the joint reached the corresponding highest, while the fracture mode conformed to the equal load-carrying design; when the brazing holding time was quite long, the bearing capacity of the joint remained at a high level, but the fracture mode was the same as the holding time was quite short.

scholarly journals Effect of Tool Geometry and Welding Parameters on Friction Stir Welded Lap Joint Formation with AA2099-T83 and AA2060-T8E30 Aluminium Alloys

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 872 ◽  
Author(s):  
Egoitz Aldanondo ◽  
Javier Vivas ◽  
Pedro Álvarez ◽  
Iñaki Hurtado
Keyword(s):  
Aluminium Alloys ◽  
Defect Formation ◽  
Lap Joints ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Lap Joint ◽  
Friction Stir ◽  
Reaction Forces ◽  
Cold Lap ◽  
Probe Geometry

In this paper the effect of tool geometry and welding parameters on friction stir welded lap joints with AA2099-T83 and AA2060-T8E30 aluminium alloys has been investigated through the study of the material flow and weld formation along with the reaction forces during friction stir welding (FSW) for various sets of welding parameters and two FSW tools with different geometrical features. The results showed that welding parameters and tool probe geometry strongly affect the characteristics of the typical defect features (hook and cold lap defects) of the friction stir welded lap joints. From the relationship established between the welding parameters, tool probe geometry and the hook and cold lap defect formation, some guidelines are concluded with the objective of guaranteeing appropriate FSW lap joint properties.

Microstructure and Residual Stress Formation during Friction-Stir Welding of Semi-Solid Cast ZK60-RE Magnesium Alloy

2014 ◽  
Vol 922 ◽  
pp. 688-693 ◽  
Author(s):  
E.P. Silva ◽  
Larissa Fernandes Batista ◽  
Bruna Callegari ◽  
Victor Ferrinho Pereira ◽  
Ricardo Henrique Buzolin ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Dynamic Recrystallization ◽  
Lap Joints ◽  
Lap Joint ◽  
Friction Stir ◽  
Fine Grained ◽  
Stress Maximum ◽  
Zk60 Alloy ◽  
Stress Formation ◽  
Semi Solid

In this work, we report on the friction stir weldability of a semi-solid cast ZK60 alloy modified with 1.5 wt% mischmetall in the lap-joint configuration using a 120WV4 steel tool with concave shoulder and conical pin. The coarser solidification microstructure in the semi-solid cast ZK60-1.5%RE alloy requires low strain rates and increased heat input to produce lap-joints without inner defects. This was achieved with 250 rpm tool rotation and 50 mm/min welding speed. Friction stir welding results in a very fine grained microstructure in the stir zone probably due to dynamic recrystallization. In the thermomechanically affected zones dynamic recrystallization seems to occur within the solute enriched intergranular zones. The distribution of longitudinal residual stresses exhibit stress maxima at both thermomechanically affected zones. A compression peak is observed at the retreating side, whereas a tensile stress maximum occurs at the advancing side.

scholarly journals Experimental Review on Friction Stir Welding of Aluminium Alloys with Nanoparticles

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 390
Author(s):  
Cyril Vimalraj ◽  
Paul Kah
Keyword(s):  
Friction Stir Welding ◽  
Dissimilar Materials ◽  
Strengthening Mechanism ◽  
High Heat ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir ◽  
Joint Properties ◽  
Weld Properties ◽  
Welding Processes

To reduce environmental impacts and ensure competitiveness, the fabrication and construction sectors focus on minimizing energy and material usage, which leads to design requirements for complex structures by joining of similar and dissimilar materials. Meeting these industrial demands requires compatible materials with improved properties such as good weight-to-strength ratios, where aluminum (Al) and its alloys are competing candidates for various complex applications. However, joining Al with fusion welding processes leads to joint deterioration. Friction stir welding (FSW) produces joints at temperatures below the melting temperature, thus avoiding flaws associated with high heat input, yet requires improvement in the resultant joint properties. Recent studies have shown that nanoparticle reinforcement in FSW joints can improve weld properties. The main focus of this study is to critically review similar and dissimilar friction stir welding of AA5083 and AA6082 with carbide and oxide nanoparticle reinforcement. The study also discusses the effect of welding parameters on reinforcement particles and the effect of nanoparticle reinforcement on weld microstructure and properties, as well as development trends using nanoparticles in FSW. Analysis shows that friction stir welding parameters have a significant influence on the dispersion of the reinforcement nanoparticles, which contributes to determining the joint properties. Moreover, the distributed nanoparticles aid in grain refinement and improve joint properties. The type, amount and size of reinforcement nanoparticles together with the welding parameters significantly influence the joint properties and microstructures in similar and dissimilar Al welds. However, research is still required to determine the strengthening mechanism used by nanoparticles and to assess other nanoparticle additions in FSW of Al alloys.

The Influence of Ultrasound Enhancement during Friction Stir Welding of Aluminum to Steel

2018 ◽  
Vol 767 ◽  
pp. 351-359 ◽  
Author(s):  
Marco Thomä ◽  
Guntram Wagner ◽  
Benjamin Straß ◽  
Bernd Wolter ◽  
Sigrid Benfer ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Dissimilar Materials ◽  
Dissimilar Joints ◽  
Power Ultrasound ◽  
Friction Stir ◽  
Wide Range ◽  
Steel Joints ◽  
Welding Processes ◽  
Ultrasound Enhancement

The innovative joining process of friction stir welding (FSW) offers a wide range of advantages for welding similar as well as dissimilar materials. Even for the field of poorly weldable material combinations like aluminum to steel with their strongly differing physical properties the method of FSW proved its capability for realizing dissimilar joints with tensile strengths up to more than 80 % of the aluminum base material. Trying to improve this value and other properties of the joints several approaches for hybrid friction stir welding processes were tested in the scientific community, whereas the ultrasound enhancement of FSW (USE-FSW) looked as one of the most promising reaching good results. To gain a deeper knowledge of the influence of the ultrasound on the friction stir welds different investigations were carried out in this paper. Therefore the method of USE-FSW was applied on two dissimilar aluminum/steel-joints with varying carbon content of the steel in this work. The material combinations AA6061/SAE1006 and AA6061/SAE1045 were welded successfully with and without additional power ultrasound. Afterwards a comparison between FSW-and USE-FSW-joints was carried out regarding the microstructure of the nugget and interface (IF) by light-microscopy as well as scanning electron microscopy. Furthermore the mechanical properties were characterized in a first step.

Observation of Metal Flow Phenomenon of Lap Joints during Friction Stir Welding

2004 ◽  
Vol 449-452 ◽  
pp. 421-424 ◽  
Author(s):  
Takeshi Shinoda ◽  
Junki Suzuki
Keyword(s):  
Thermal Analysis ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Metal Flow ◽  
Lap Joints ◽  
Probe Type ◽  
Lap Joint ◽  
Flow Phenomenon ◽  
Friction Stir ◽  
Fsw Experiments

Two kinds of aluminum alloys have been used as lap joint in FSW. Experiments are selected to observe metal flow by metallurgical procedures. One is for the effect of probe type and pre-friction time on metal flow at start point. Another is for the effect of probe type on metal flow for stable traveling stage. Thermal analysis also has been carried out.

Effect of Process Parameters on the Joint Integrity in Friction Stir Welding of Ti-6Al-4V Lap Joints

2013 ◽  
Vol 554-557 ◽  
pp. 1083-1090 ◽  
Author(s):  
Gianluca Buffa ◽  
Livan Fratini ◽  
Matthias Schneider ◽  
Marion Merklein
Keyword(s):  
Friction Stir Welding ◽  
Titanium Alloys ◽  
Process Parameters ◽  
Lap Joints ◽  
Fusion Welding ◽  
Main Process ◽  
Filling Material ◽  
Friction Stir ◽  
Wide Range ◽  
Welding Processes

Friction Stir Welding (FSW) is a solid state welding process patented in 1991 by TWI; initially adopted to weld aluminum alloys, is now being successfully used also for magnesium alloys, copper and steels. The wide diffusion the process is having is due to the possibility to weld materials traditionally considered difficult to be welded or “unweldable” by traditional fusion welding processes due to peculiar thermal and chemical material properties. Additionally, the process allows welding a wide range of sheet thickness (up to 50mm) avoiding typical fusion welding processes defects, like cavities and porosities, with no shielding gas, filling material or joint preparation. Recently, research is focusing on titanium alloys thanks to the high interest that such materials are getting from the industry due to the extremely high strength-weight ratio together with good corrosion resistance properties. Welding of titanium alloys by traditional fusion welding techniques presents several difficulties due to high material reactivity resulting in bonding with oxygen, hydrogen, and nitrogen with consequent embrittlement of the joint. In this way FSW can represent a cost effective and high quality solution. A few studies have been developed on the FSW of titanium alloys butt joints, while there is a complete lack of knowledge as far as different joint morphologies are regarded (lap joints, T joints, etc.). In the paper the results of an experimental campaign on lap joints made out of thin Ti-6Al-4V sheets are presented. The effect of the main process parameters on the micro and macro mechanical properties has been investigated and related to the microstructural transformations occurring during the process because of the thermo-mechanical action of the tool.

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