scholarly journals Fractal Dimension Characterization of Joint Surface Morphology on Dissimilar Friction Stir Lap Welding of Al/Mg

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3941 ◽  
Author(s):  
Yadong Zhao ◽  
Yalong Luo ◽  
Zhipeng Zhang ◽  
Haixiao Zhang ◽  
Xuefeng Guo ◽  
...  
Keyword(s):  
Fractal Dimension ◽  
Response Surface ◽  
Process Parameters ◽  
Welding Process ◽  
Response Surface Model ◽  
Joint Surface ◽  
Surface Model ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Lap Welding

The joint surface of the 1060 aluminum and AZ31 magnesium alloy was prepared through friction stir lap welding (FSLW) under different welding process parameters. The joint surface was characterized three-dimensionally using a three-dimensional (3D) optical profiler, and the coordinate data were obtained. The fractal dimension of the joint surface was calculated by the box-width transformation method using a MATLAB program. Furthermore, the influence of the welding process parameters on the fractal dimension of the joint surface was studied. The response surface model was established based on the principle of central composite design (CCD), and analysis of variance (ANOVA) was carried out to test the accuracy of the response surface. The results showed that the joint surface morphology had fractal characteristics, and the fractal dimension could be used as an index to characterize the quality of the joint surface. The change of the welding process parameters had a great impact on the fractal dimension of the joint surface, the interaction between the parameters was small, and the fitting accuracy of the response surface model was high. The fractal dimension of the joint surface decreased with the increase in the welding and rotational speeds and the effect of the rotational speed was more significant.

Dissimilar Friction Stir Lap Welding of AA2198 and AA7075 Sheets: Forces, Microstructure and Mechanical Properties

2021 ◽  
Author(s):  
Antonello Astarita ◽  
Fausto Tucci ◽  
Alessia Teresa Silvestri ◽  
Michele Perrella ◽  
Luca Boccarusso ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Welding Process ◽  
Processing Parameters ◽  
Processing Parameter ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Lap Shear ◽  
Microstructure And Mechanical Properties ◽  
Lap Welding ◽  
Factorial Design Of Experiments

Abstract This paper deals with the dissimilar friction stir lap welding of AA2198 and AA7075 sheets. The influence of processing parameters, namely welding speed and tool rotational speed on joint features, microstructure, and mechanical properties were investigated implementing a full factorial design of experiments. During the welding process, axial and transversal forces were continuously measured using a dedicated sensed fixture aiming at the correlation of this processing parameter with the quality of the achieved joints. The reported outcomes showed a very narrow processing window in which it was possible to avoid the formation of defects while the formation of an hook was observed for all the joints welded. The influence of the weld bead morphology on the lap shear strength was elucidated proving that the strength is ruled by the hook morphology. A correlation between the process parameters and the forces arising was also attempted. The final microstructure of the joints was studied and explained and also compared with the microhardness results.

Effects of Welding Parameters in Micro Friction Stir Lap Welding of Aluminum A1100

2013 ◽  
Vol 789 ◽  
pp. 356-359 ◽  
Author(s):  
Ario Sunar Baskoro ◽  
A.A.D. Nugroho ◽  
D. Rahayu ◽  
Suwarsono ◽  
Gandjar Kiswanto ◽  
...  
Keyword(s):  
Tilt Angle ◽  
Welding Process ◽  
Tool Material ◽  
Tensile Load ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Lap Welding ◽  
Welding Processes

Technology of Friction Stir Welding (FSW) as a technique for joining metal is relatively new. In some cases on Aluminum joining, FSW gives better results compared with the Arc Welding processes, including the quality of welds and less distortion. FSW can even use milling machine or drilling machine, by replacing the tools and the appropriate accessories. The purpose of this study is to analyze the effect of process parameters onmicro Friction Stir Lap Weldingto the tensile load of welds. In this case, Aluminum material A1100, with thickness of 0.4 mm was used. Tool material of HSS material was shaped with micro grinding process. Tool shoulder diameter was 3 mm, while the diameter pin was 2 mm and a length of pin was 0.7 mm. The parameter variations used in this study were the variable of spindle speed (2300, 2600, and 2900 rpm), variable oftooltilt angle(0, 1, 2 degree) and a variable ofFeed rate(50, 60, 70 mm/min). Where the variation of these parameters will affect to the mechanical properties of welds (as response) was the tensile load. Analysis and optimization parameters between the micro FSLW parameters with the tensile load of welds, is used aResponse Surface Methods(RSM). From the result of experiment and analysis, it is shown that the important welding parameter in Micro Friction Stir Lap welding process is tilt angle.

Application of Response Surface Methodology to Predict Ovality of AA6082 Flow Formed Tubes

2013 ◽  
Vol 3 (1) ◽  
pp. 52-65 ◽  
Author(s):  
M. Srinivasulu ◽  
M. Komaraiah ◽  
C.S. Krishna Prasada Rao
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Response Surface Model ◽  
Surface Model ◽  
Flow Forming ◽  
Box Behnken Design ◽  
Standard Response ◽  
Tubular Components ◽  
Roller Radius

Flow-forming is eco-friendly, chipless manufacturing process employed in the manufacture of thin walled seamless tubes. Ovality, the out of roundness is one of basic form of errors encountered in the tubular components. In the present research, a response surface model has been developed to predict ovality of AA6082 alloy pre-forms using Design of Experiments. The experiments are performed on a flow forming machine with a single roller. The process parameters selected for the present investigation are axial feed of the roller, the speed of the mandrel, and roller radius. Box-Behnken Design, a standard response surface methodology has been used to conduct the experimental runs. The developed response surface model successfully predicts the ovality of AA6082 flow formed tube within the range of selected process parameters. It has been found that, roller feed is the most important process parameter influencing the ovality of AA6082 flow formed tube.

scholarly journals Study on Friction Stir Lap Welding of Aluminium to Steel Sheets

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 498
Author(s):  
Lingfei Meng ◽  
Shujin Chen ◽  
Jiaqi Zhang ◽  
Di Wang ◽  
Hao Zhang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Melting Point ◽  
Welding Process ◽  
Zinc Content ◽  
Galvanized Steel ◽  
Formation Mechanisms ◽  
Friction Stir Lap Welding ◽  
Rotating Speed ◽  
Friction Stir ◽  
Lap Welding

Friction stir lap welding (FSLW) of 6061-T6 aluminium sheet and DX51D galvanized steel sheet was carried out by adding zinc foil to the lap interface and studying the influence of the zinc foil on the formation mechanisms and mechanical properties. The influence of the thickness of zinc foil, the plunge depth of the shoulder and the shape of the tools on the mechanical properties of the weld are discussed. Zinc foil reduced the generation of brittle intermetallic compounds, such as Fe4Al13. During the welding process, the axial force was small due to the high rotating speed. Liquid zinc was retained at the interface, where eutectic Al–Zn with low melting point and an Fe–Zn compound were generated to achieve the metallurgical combination of aluminium and steel. The fracture was located in the heat affected zone (HAZ) of the 6061-T6 base aluminium. The results showed that when the zinc foil was too thin, there was less zinc content at the interface; the resulting Al–Zn eutectic had low melting point, was not fully spread and had poor continuity, resulting in poor mechanical properties. When the zinc foil was too thick, a large amount of zinc-based solid solution was generated at the interface, and most of the fracture occurred in the zinc-rich layer.

Friction Stir Lap Welding of Light Alloy Sheets

2013 ◽  
Vol 814 ◽  
pp. 187-192 ◽  
Author(s):  
Radu Cojocaru ◽  
Lia Boțilă ◽  
Cristian Ciucă ◽  
Horia Florin Dascau ◽  
Victor Verbiţchi
Keyword(s):  
Welding Process ◽  
Welding Parameters ◽  
Friction Stir Lap Welding ◽  
Light Alloy ◽  
Shipbuilding Industry ◽  
Light Alloys ◽  
Butt Welding ◽  
Friction Stir ◽  
Lap Welding ◽  
Welding Materials

Aluminum alloys are widely used in aerospace, automotive, railway and shipbuilding industry, as materials having remarkable properties for applications in these fields. For this reason, in recent years the interest for friction stir lap welding of sheets from these alloys increased.The behaviour of welding materials from the plastic and mechanic viewpoint are different in case of friction stir lap welding compared to friction stir butt welding.The welding tools for friction stir lap welding can have different configurations and sizes compared to butt welding. The used welding parameters must be reconsidered in order to obtain a proper flow of material for obtaining a friction stir lap welded joint.In addition, it is very important how to prepare the sheets surfaces that come into contact and their placement (relative to each other).The paper presents considerations regarding friction stir lap welding, with examples/concrete results obtained in welding of similar and dissimilar light alloys (alloys of aluminum, magnesium and titanium). It also presents data on the characteristics of obtained welded joints, related with particularities of friction stir lap welding.The obtained results showed that light alloys sheets used in various industrial fields can be joined with respect of basis conditions specific for the friction stir lap welding process.

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