scholarly journals Effect of Backing Plate Materials in Micro-Friction Stir Butt Welding of Dissimilar AA6061-T6 and AA5052-H32 Aluminum Alloys

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 933
Author(s):  
SeongHwan Park ◽  
YoungHwan Joo ◽  
Myungchang Kang
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloys ◽  
Heat Loss ◽  
Butt Joint ◽  
Thin Plates ◽  
Butt Welding ◽  
Friction Stir ◽  
Backing Plate ◽  
Base Materials ◽  
Tilting Angle

Thin sheets of lightweight aluminum alloys, which are increasingly used in automotive, aerospace, and electronics industries to reduce the weight of parts, are difficult to weld. When applying micro-friction stir welding (μ-FSW) to thin plates, the heat input to the base materials is considerably important to counter the heat loss to the jig and/or backing plate. In this study, three different backing-plate materials—cordierite ceramic, titanium alloy, and copper alloy—were used to evaluate the effect of heat loss on weldability in the μ-FSW process. One millimeter thick AA6061-T6 and AA5052-H32 dissimilar aluminum alloy plates were micro-friction stir welded by a butt joint. The tensile test, hardness, and microstructure of the welded joints using a tool rotational speed of 9000 rpm, a welding speed of 300 mm/min, and a tool tilting angle of 0° were evaluated. The heat loss was highly dependent on the thermal conductivity of the backing plate material, resulting in variations in the tensile strength and hardness distribution of the joints prepared using different backing plates. Consequently, the cordierite backing plate exhibited the highest tensile strength of 222.63 MPa and an elongation of 10.37%, corresponding to 86.7% and 58.4%, respectively, of those of the AA5052-H32 base metal.

scholarly journals Extension of Gap Bridgeability and Prevention of Oxide Lines in the Welding Seam through Application of Tools with Multi-Welding Pins

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1219
Author(s):  
Marcel Hatzky ◽  
Stefan Böhm
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Sheet Thickness ◽  
Dynamic Strength ◽  
Butt Joint ◽  
Surface Layers ◽  
Welding Seam ◽  
Friction Stir ◽  
Gap Width

Friction stir welding has become important in many areas of production and is increasingly used for joining aluminum components. For long welding seams, conventional tools with only one welding pin reach their technical limitations due to low gap bridgeability. When welding aluminum, the stirred in surface layers, such as oxides, lead to a decrease in static and dynamic strength since linear accumulations are formed in the welding seam. The aim of the present study is to increase the gap bridgeability using tools with various welding pins and to prevent linear accumulation in the welding seam. The results show that a gap bridgeability of up to 2 mm for 4 mm material thickness is possible for the aluminum alloys EN AW 5083 H111 and EN AW 7020 T651. With the help of multi-pin tools, no impact of the gap width on the tensile strength was observed for joint gaps of up to 0.9 mm when using butt joint with a sheet thickness of 4 mm. Furthermore, the use of multi-pin tools showed significant influence on the prevention of linear accumulations in the welding seam. In addition, the oxide layers were finely distributed in welded joints using multi-pin tools.

scholarly journals Design Analysis and Effect of Process Parameters on „Fsbw‟ of Al (2618a)-SIC Alloy

2020 ◽  
Vol 9 (3) ◽  
pp. 3408-3412
Keyword(s):  
Silicon Carbide ◽  
Tensile Strength ◽  
Process Parameters ◽  
Design Analysis ◽  
Tool Rotational Speed ◽  
Butt Welding ◽  
Plunge Depth ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Tilting Angle

The research in fabrication engineering is much focused on the new or betterment in the existing metal joining techniques. In the view of the demand in improvement of the quality , strength and efficiency of welded joins , the present research is focused on design for tensile strength and optimization of friction stir butt welding(FSBW)of aluminum(2618A) and silicon carbide alloy. The design analysis is carried out for tensile strength and hardness. . The functioning parameters such as tool rotational speed, transverse speed, plunge depth and tilting angle are considered. The Taguichi technique and ANOVA are used in optimization of process parameters. The high S/N ratios are mainly considered to analyze the results for tensile strength and hardness.

scholarly journals Investigation on the Tensile Strength of the Friction Stir Welded similar joint of Al/Al alloy using high thermal diffusivity backing plate material.

2018 ◽  
Vol 8 (2) ◽  
Author(s):  
Akshansh Mishra ◽  
Abhishek Kumar Sharma ◽  
Hardik Kapoor ◽  
Jaspreet Singh ◽  
Krishna Kumar
Keyword(s):  
Tensile Strength ◽  
Thermal Diffusivity ◽  
Welding Process ◽  
Soft Materials ◽  
Work Piece ◽  
Al Alloy ◽  
Plate Material ◽  
Friction Stir ◽  
Backing Plate ◽  
High Thermal Diffusivity

Friction Stir Welding process is a novel green solid state joining process for soft materials such as aluminium alloys. The weld quality is governed by the proper selection of parameters such as forge force rotational speed of the tool, welding speed, backing plate material etc. Thermal boundary condition at the bottom of the work piece plays an important role for obtaining the sound joint. The backing plate material governs these thermal conditions. In this case study, high thermal diffusivity backing plate material which consisted of AA2099 was used for joining of the plates of Structural Aluminium alloy. It was observed that the tensile strength was improved.

Study of Friction Stir Welding Technics and Weld Performance of Dissimilar 6063-3A21 Aluminum Alloys

2011 ◽  
Vol 299-300 ◽  
pp. 1095-1098 ◽  
Author(s):  
Lei Wang ◽  
Jian Jun Zhu ◽  
Wei Zhang ◽  
Xing Mei Feng ◽  
Zhan Ying Feng
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloys ◽  
Base Material ◽  
Post Weld Heat Treatment ◽  
Weld Strength ◽  
Welding Parameters ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Performance Results ◽  
Better Than

Several rotating rates and welding speeds were chosen to joint 6063/3A21 dissimilar aluminum alloys, tensile strength of the welds were measured to analyze effect of welding parameters on weld performance. Results show that tensile strength of the weld is better than the base material. Weld tensile strength will decrease under a too high or too low welding speed while effect of rotating rate on weld strength is relatively small. The weakest position is at heat affected zone at 3A21 side after T6 post weld heat treatment.

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.

scholarly journals Optimum Welding Parameters for Friction Stir Welded AA6063 Pipe Butt Joint Using the Taguchi Method

2021 ◽  
Vol 10 (2) ◽  
pp. 404-413
Author(s):  
Azman Ismail ◽  
Fatin Nur Zulkipli ◽  
Mokhtar Awang ◽  
Fauziah Ab Rahman ◽  
Puteri Zarina Megat Khalid ◽  
...  
Keyword(s):  
Residual Stress ◽  
Tensile Strength ◽  
Taguchi Method ◽  
Axial Force ◽  
Travel Speed ◽  
Butt Joint ◽  
Welding Parameters ◽  
Weld Quality ◽  
Joint Friction ◽  
Friction Stir

Welding parameters for pipe joint friction stir welding (FSW) have been identified based on L-9 orthogonal arrays used in the Taguchi Method. Different welding parameters, such as rotation speed, travel speed and axial force, have been used to produce several quality friction stir welded AA6063 pipe butt joints. The reliability of products obtained in the FSW process can be improved through the identification of the optimum combination of welding parameters. Weld quality was evaluated based on its tensile strength and residual stress profiles. The S/N analysis and Analysis of Variance (ANOVA) have been used to determine significant welding parameters that affect weld quality. Maximum tensile strength with acceptable residual stress was obtained at the optimum welding parameters of 1300 rpm, 5 mm/s and axial force between 5 and 6 kN. The goal of this study was to optimize welding parameters for high tensile strength and low residual stress.

Numerical Simulation of the Effect of Shoulder Rotation on the Tensile Strength of FSW Dissimilar Joints of Aluminum Alloy

2020 ◽  
Vol 402 ◽  
pp. 90-99
Author(s):  
Riswanda ◽  
Akhyar ◽  
Sugianto ◽  
Harlian Kadir ◽  
Samsul Rizal
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloys ◽  
Rotation Parameter ◽  
Maximum Temperature ◽  
Dissimilar Welding ◽  
Building Structures ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Dissimilar Weld ◽  
Weld Area

Dissimilar weld metal joints such as aluminum alloys 5083 and 6061-T6 are mostly found in the application of aircraft, railroad structures, ships, bridges, and oil platforms and building structures. However, dissimilar welding metal is relatively more difficult due to metallurgical differences and the thermophysical properties of two different materials. The purpose of this study is to study the effect of shoulder rotation variations on the Friction Stir Welding (FSW) process through numerical simulations on the mechanical properties of dissimilar weld joints between two series of aluminum alloys, and there are 5083 and 6061-T6. The FSW welding simulation process is conducted by butt joints type on 300 x 100 x 3 mm of both aluminum plates with weld distance is 300 mm. Shoulder rotation variations are carried out for this process include 1,200, 1,400 and 1,600 rpm. Results show maximum temperature distributions are 467 oC for 1,200 rpm, 499 °C for 1,400 rpm and 527 °C for 1,600 rpm, respectively. Maximum temperatures appear close to the liquid temperature of Al-6061-T6 and Al 5083 base metals, which is about 600 °C. Physical and mechanical analysis at 1,200 rpm (the rotation parameter) can be seen as the coarse weld beads on the microstructure, and the weld joint is still weak. The physical properties observed that coarse weld beads on microstructures, the tensile strength obtained 138 MPa at 1,200 rpm (the rotation parameter). The maximum hardness test occurred 47.98 (Kg/mm2 in averages) at 1,400 rpm. The tensile strength of the dissimilar FSW process is 151 MPa occurred at 1,600 rpm of shoulder rotation speed. While the fracture position occurs in the nugget weld area for all parameters and corresponds with the result of hardness tests, it shows that low hardness value for the whole weld area for all parameters.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
Anganan K ◽  
Narendran RJ ◽  
Naveen Prabhu N ◽  
Rahul Varma R ◽  
Sivasubramaniyam R
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

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