scholarly journals Experimental Study the Effect of Tool Design on the Mechanical Properties of Bobbin Friction Stir Welded 6061-T6 Aluminum Alloy

2018 ◽  
Vol 14 (3) ◽  
pp. 1-11 ◽  
Author(s):  
Samir Ali Amin ◽  
Mohannad Yousif Hanna ◽  
Alhamza Farooq Mohamed
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Rolling Direction ◽  
Welding Process ◽  
Tool Design ◽  
Flat Surfaces ◽  
Friction Stir ◽  
Welding Joints

Bobbin friction stir welding (BFSW) is a variant of the conventional friction stir welding (CFSW); it can weld the upper and lower surface of the work-piece in the same pass. This technique involves the bonding of materials without melting. In this work, the influence of tool design on the mechanical properties of welding joints of 6061-T6 aluminum alloy with 6.25 mm thickness produced by FSW bobbin tools was investigated and the best bobbin tool design was determined. Five different probe shapes (threaded straight cylindrical, straight cylindrical with 3 flat surfaces, straight cylindrical with 4 flat surfaces, threaded straight cylindrical with 3 flat surface and threaded straight cylindrical with 4 flat surfaces) with various dimensions of the tool (shoulders and pin) were used to create the welding joints. The direction of the welding process was perpendicular to the rolling direction for aluminum plates. Tensile and bending tests were performed to select the right design of the bobbin tools, which gave superior mechanical properties of the welded zone.  The tool of straight cylindrical with four flats, 8 mm probe and 24 mm shoulders diameter gave better tensile strength (193 MPa), elongation (6.1%), bending force (5.7 KN), and welding efficiency (65.4%) according to tensile strength.     

Analysis and Correlation of Output Parameters against Input Parameters for Friction Stir Welding of Three Dissimilar Aluminum Alloy

2018 ◽  
Vol 1146 ◽  
pp. 38-43
Author(s):  
Ana Boşneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Cristian Ciucă
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Joints ◽  
Aluminum Plates ◽  
Joining Process

Friction Stir Welding, abbreviated FSW is an innovative joining process. The FSW is a solid-state welding process with a lot of advantages comparing to the traditional arc welding, such as the following: it uses a non-consumable tool, it results of good mechanical properties, it can use dissimilar materials and it have a low environmental impact. First of all, the FSW process was developed to join similar aluminum plates, and now, the technology was developed and the FSW process is used to weld large types of materials, similar or dissimilar. In this paper it is presented an experimental study and the results of it, which includes the welding of three dissimilar aluminum alloy, with different chemical and mechanical properties. This three materials are: AA2024, AA6061 and AA7075. The welding joints and the welding process were analyzed considering: process temperature, micro-hardness, macrostructure and microstructure.

Effect of Pre and Post Weld Heat Treatment on the Mechanical Properties of Friction Stir Welded AA6061-T6 Joint

2020 ◽  
Vol 17 (2) ◽  
pp. 7882-7889 ◽  
Author(s):  
J.C. Verduzco Huarez ◽  
R. Garcia Hernandez ◽  
G. M. Dominguez Almaraz ◽  
J.J. Villalón López
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Research Work ◽  
Base Material ◽  
Welding Process ◽  
Post Weld Heat Treatment ◽  
Friction Stir

This research work focuses on the study of the improvement of mechanical properties, specifically the tensile strength of 6061-T6 aluminum alloy on prismatic specimens with 9.5 mm thickness that has been subjected to friction stir welding process and two heat treatments; solubilized and aging before or after the welding process. Three cases studied and evaluated were, welding of the base material without heat treatment (BMW), solubilized heat treatment and partial aging of the base material before welding (HTBW), and heat treatment of solubilized and aging of the base material after welding (HTAW). The obtained results show an increase of about 10% (20 MPa) of tensile strength for the HTBW process, compared to BMW case. In addition, for the case of HTAW, the obtained tensile resistance presents a joint efficiency of 96%, which is close to the tensile strength of the base material (»310 MPa).

Effect of Preheat Temperature on Friction Stir Welded Aluminum Alloy 5052 Joints

2014 ◽  
Vol 597 ◽  
pp. 253-256 ◽  
Author(s):  
Nurul Muhayat ◽  
Triyono ◽  
Bambang Kusharjanta ◽  
Radian T. Handika
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Preheat Temperature ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Heated Air

The effects of preheat temperature on mechanical properties and the microstructure of friction stir welded (FSW) aluminum alloy 5052 joints were studied in the present work. Heated air from Hot Gun was applied in front of the FSW tool to give the preheat on friction stir welding process. Preheat temperature was set 150°C, 250°C and 300°C. Mechanical properties were correlated and analyzed according to tensile strength, macro and microstructure. Defect free weldswere obtained at all preheat variations. The increasing preheat temperature produced the coarser grain size, it influencedthe little decrease both the tensile strength and hardness of joints.

Study on the Microstructure and Mechanical Properties of Welding Joints of 7A05 Aluminum Alloy by FSW

2014 ◽  
Vol 496-500 ◽  
pp. 110-113
Author(s):  
Dong Gao Chen ◽  
Jin He Liu ◽  
Zhi Hua Ma ◽  
Wu Lin Yang
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Welded Joint ◽  
Optical Microscope ◽  
Nugget Zone ◽  
Friction Stir ◽  
Microstructure And Mechanical Properties ◽  
Welding Joints

The7A05 aluminum alloy of the 10mm thickness was welded by the friction stir welding. The microstructure and mechanical Properties of the welded joint was researched by the optical microscope, etc. The results showed: the microstructure of the weld nugget zone and the thermal mechanically affected zone were refined as the welding speed increasing when the rotate speed is constant. As the welding speed increasing the strength of extension of the welded joint is increasing at first and then stable basically. but the yield strength had no obvious change.

Heat Transfer Simulations and Analysis of Joint Cross-Sectional Microstructure on Friction Stir Welding between Steel and Aluminium

2020 ◽  
Vol 863 ◽  
pp. 85-95
Author(s):  
Truong Minh Nhat ◽  
Truong Quoc Thanh ◽  
Tu Vinh Thong ◽  
Tran Trong Quyet ◽  
Luu Phuong Minh
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Thermal Contact ◽  
Welding Process ◽  
Welding Parameters ◽  
Thermal Imager ◽  
Sem Images ◽  
Cross Sectional ◽  
Friction Stir

This study presents conducted heat simulations and experimental jointing flat-plate of aluminum alloy 6061 and SUS 304. Temperature is simulated by the COMSOL software in three states: (1) Preheat the Friction Stir Welding (FSW) by TIG welding, (2) Thermal contact resistance between Aluminium and steel, and (3) The welding process using stiring friction is simulated. The simulations intended to predicting the temperature which is used for preheat and welding process to ensuring the required solid-state welding. The temperature is also determined and checked by a thermal imager comparing with simulation results. Besides, the results of tensile strength is carried out. The Box - Behnken method is used to identify the relationship between the welding parameters (rotation, speed and offset), temperature and tensile strength. The maximum tensile strength is 77% compared to the strength of aluminum alloy. The optimal set of parameters for the process is n = 676 rpm, v = 46 mm / min and x = 0.6 mm. The optimizing welding parameters to achieving good quality of welding process are described. SEM images to determine some properties of welding materials. This is also the basis for initial research to identify some defects in welding of two different materials (IMC thickness and interconnected pores) and the cause of these defects.

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.

Researching on hybrid friction stir welding between two differential materials as steel and aluminium

2020 ◽  
Vol 3 (SI1) ◽  
pp. First
Author(s):  
Truong Minh Nhat ◽  
Truong Quoc Thanh ◽  
Tran Trong Quyet ◽  
Luu Phuong Minh
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Welding Process ◽  
Welding Parameters ◽  
Thermal Imager ◽  
Friction Stir ◽  
Hybrid Techniques ◽  
State Process

Friction stir welding exploits its solid-state process behavior to join aluminum to steel, which differs in thermal and mechanical properties, and where a combination of these metallic alloys by fusion welding prompts a deleterious reaction as a result of the melting and resolidification phases. Recently, hybrid techniques have been employed in FSW for several materials and alloys, particularly for steel–steel joining. These methods are generally aimed to pre-heat the steel plate materials. This study presents conducted heat simulations and experimental jointing flat-plate of aluminum alloy 6061 and SUS 304. Temperature is simulated by the COMSOL software in three states: (1) Preheat the Friction Stir Welding (FSW) by TIG welding, (2) Thermal contact resistance between aluminum and steel, and (3) The welding process using stirring friction is simulated. The simulations intended to predict the temperature, which is used for the preheating and welding process to ensuring the required solid-state welding. The temperature is also determined and checked by a thermal imager comparing with simulation results. Besides, the results of tensile strength are carried out. The Box - Behnken method is used to identify the relationship between the welding parameters (rotation, speed, and offset), temperature, and tensile strength. The maximum tensile strength is 77% compared to the strength of the aluminum alloy. The optimal set of parameters for the process is n = 676 rpm, v = 46 mm / min and x = 0.6 mm. The optimizing welding parameters to achieving a good quality of the welding process are described. SEM images to determine some properties of welding materials. This is also the basis for initial research to identify some defects in the welding of two different materials (IMC thickness and interconnected pores) and the cause of these defects.

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