scholarly journals Dissimilar Friction Stir Butt Welding of Aluminum and Copper with Cross-Section Adjustment for Current-Carrying Components

Metals ◽  
2018 ◽  
Vol 8 (9) ◽  
pp. 661 ◽  
Author(s):  
Nima Eslami ◽  
Alexander Harms ◽  
Johann Deringer ◽  
Andreas Fricke ◽  
Stefan Böhm
Keyword(s):  
Friction Stir Welding ◽  
Cross Section ◽  
Tensile Force ◽  
Base Material ◽  
Metallographic Analysis ◽  
Dissimilar Joints ◽  
Butt Welding ◽  
Friction Stir ◽  
Aluminum Base ◽  
Electrical Conductors

Manufacturing dissimilar joints of aluminum and copper is a challenging task. However, friction stir welding (FSW) was found to be a suitable technique to produce aluminum–copper joints. Due to different electrical conductivities between aluminum and copper, an adjustment of the cross-section is required to realize electrical conductors free of resistive losses. Taking this into account, this paper presents initial results on the mechanical and electrical properties of friction stir butt welded aluminum and copper blanks having thicknesses of 4.7 mm and 3 mm, respectively. Three different approaches were investigated with the aim to produce sound welds with properties similar to those of the used base materials. Friction stir welding has been conducted at a welding speed of 450 mm/min. Subsequently, the welded specimens were subjected to metallographic analysis, tensile testing, and measurements of the electrical conductivity. The ultimate tensile force of the best joints was about 10 kN, which corresponds to joint efficiencies of approximately 72% of the aluminum base material. The analysis of electrical joint properties led to very promising results, so that the potential of FSW of Al–Cu butt joints with sheets having different thicknesses could be confirmed by the investigations carried out.

scholarly journals Analysis of the Oscillation Behavior of Hybrid Aluminum/Steel Joints Realized by Ultrasound Enhanced Friction Stir Welding

Metals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 1079
Author(s):  
Marco Thomä ◽  
Andreas Gester ◽  
Guntram Wagner ◽  
Marco Fritzsche
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Fusion Welding ◽  
Laser Vibrometer ◽  
Particle Volume ◽  
Dissimilar Joints ◽  
Additional Energy ◽  
Power Ultrasound ◽  
Friction Stir ◽  
Ultrasound Enhancement

Friction stir welding (FSW) is an innovative solid-state joining process, which is suitable for joining dissimilar materials with strongly differing physical and chemical properties such as aluminum and steel. Where other joining methods such as fusion welding struggle to achieve appropriate joint strengths due to the excessive formation of brittle aluminum-rich intermetallic phases (IMP), FSW joints of aluminum and steel only show small layers of IMP, thus, sufficient tensile strengths in proximity to the maximum tensile strength of the weaker aluminum base material can be reached. With the aim to optimize the mechanical and microstructural properties of such dissimilar joints for widening the field for possible industrial applications, several hybrid friction stir welding methods have been developed which include an additional energy input, whereas the ultrasound enhancement (USE-FSW) is one of the most promising. The current work was carried out on AA6061/DC04 joints which were successfully friction stir welded with and without ultrasound support, in respect to the influence of varying the ultrasound transmission side. The functionality of the USE-FSW setup could be verified by multi point laser vibrometer measurements. Additionally, a higher proportion of transversal oscillation for the transmission of power ultrasound into aluminum could be detected using a scanning vibrometer. In comparison to the conventionally friction stir welded joints the ultrasound enhancement led to an avoidance of weld defects and an increase of the steel particle volume in the stir zone. The joint produced with power ultrasound transmission via aluminum resulted in a more uniform interface.

Temperature Distribution of Aluminum Alloys under Friction Stir Welding

2011 ◽  
Vol 264-265 ◽  
pp. 217-222 ◽  
Author(s):  
Ben Yuan Lin ◽  
P. Yuan ◽  
Ju Jen Liu
Keyword(s):  
Numerical Simulation ◽  
Temperature Distribution ◽  
Cross Section ◽  
Base Material ◽  
Welding Process ◽  
Measuring System ◽  
Close Correspondence ◽  
Distribution Profile ◽  
Butt Welding ◽  
Friction Stir

The temperature distribution of 6061-T6 aluminum alloy plates under a friction stir butt-welding was investigated by using experiment and numerical simulation. A real-time temperature measuring system was used to measure the temperature change in the welding process. Vickers hardness profiles were made on the cross-section of the weld after welding. A commercial software of FlexPDE, a solver for partial different equations with finite element method, was used to simulate the experimental welding process of this study. Comparison the experimental and numerical results, the temperature cycles calculated by numerical are similar to those measured by experiment. The temperature distribution profile obtained from the numerical simulation is symmetrical to the weld center and has a close correspondence with the hardness configuration and the microstructure of the weld. The region with the temperature over 300 °C is the zone of softening within the boundaries of base material and HAZ. The regions of 350 °C with minimum hardness are located near the boundary of HAZ and TMAZ. The maxima temperature about 500 °C distributes around the upper part of the weld center. However, the region above 400 °C only matches with the upper half of the weld nugget.

Influence of the Process Temperature on the Properties of Friction Stir Welded Blanks Made of Mild Steel and Aluminum

2014 ◽  
Vol 611-612 ◽  
pp. 1429-1436 ◽  
Author(s):  
Chris Mertin ◽  
Andreas Naumov ◽  
Linda Mosecker ◽  
Markus Bambach ◽  
Gerhard Hirt
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Mild Steel ◽  
Base Material ◽  
Welding Process ◽  
Process Temperature ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Temperature Range ◽  
Aluminum Base

Hybrid components made of steel and aluminum sheet metal are a promising approach for weight reduction for automotive applications. However, lightweight components made of steel and aluminum require suitable joining technologies, particularly if forming operations follow after the welding process. Friction Stir Welding (FSW) is a promising solid-state welding technology for producing dissimilar joints of steel and aluminum. Within this work dissimilar butt joints were produced using sheet metals of mild steel DC04 and the aluminum alloy AA6016 with a thickness of about 1 mm. The FSW joints show approximately 85 % of the tensile strength of the aluminum base material. In metallographic investigations of the produced FSW blanks it was found that the microstructure in the area of the weld seam changes in the aluminum alloy due to the process temperature and plastic deformation. Due to temperature dependent changes of precipitations of the aluminum alloy, temperature measurements have been carried out during the welding process. To find an explanation of the reduction in tensile strength of the FSW joints, short time heat treatment experiments in the temperature range between 250 °C and 450 °C were performed using the aluminum base material. Heat treatments in the temperature range of the measured process temperature result in a reduction of the tensile strength of about 20 % regardless the annealing time.

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.

The Effect of Tool Rotation Speed on Hardness, Tensile Strength, and Microstructure of Dissimilar Friction Stir Welding of Dissimilar AA5083 and AA6061-T6 Alloys

2021 ◽  
Vol 892 ◽  
pp. 159-168
Author(s):  
Arif Wahyudianto ◽  
Mochammad Noer Ilman ◽  
Priyo Tri Iswanto ◽  
Kusmono ◽  
Akhyar Akhyar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Base Material ◽  
Metallographic Analysis ◽  
Friction Stir ◽  
Dissimilar Alloys ◽  
Dissimilar Friction Stir Welding ◽  
Solid State Joining ◽  
Tool Rotation

The welding between two different grades of aluminum alloy, specifically AA5083 and AA6061-T6, is very difficult to obtain optimal results when using conventional welding methods such as TIG/MIG welding. Therefore, a solid-state joining technique is highly recommended to overcome these problems, one of which is friction stir welding (FSW). The effect of rotation speed on microstructure, microhardness, and tensile properties of dissimilar Friction Stir welded AA5083 and AA6061-T6 aluminum alloys were investigated. Three different rotation speeds (910, 1500, and 2280 rpm) were used to weld the dissimilar alloys. The metallographic analysis of joints showed the presence of various zones such as BM (base material), HAZ (heat affected zone), TMAZ (thermo-mechanically affected zone), and NZ (nugget zone) were observed and analyzed by mean of optical and scanning electron microscope. The results showed that increasing the rotation speed from 900 to 2280 rpm made grain coarsening in NZ and the mass distribution of the material is more evenly distributed, as well as increased hardness and tensile strength of the joint. The highest values in microhardness in NZ and tensile strength at the join were founded at the speed of 2280 rpm and 1500 rpm which was similar to 2280 rpm, respectively.

Effect of Friction Stir Welding Parameters on Thermal and Tensile Behavior of Aluminum Weldments Using Double Shoulder Tools

2012 ◽  
Vol 622-623 ◽  
pp. 323-329
Author(s):  
Ebtisam F. Abdel-Gwad ◽  
A. Shahenda ◽  
S. Soher
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Tensile Behavior ◽  
Frictional Heat ◽  
Welding Parameters ◽  
Friction Stir ◽  
Aluminum Base ◽  
Tool Pin ◽  
Strength And Ductility

Friction stir welding (FSW) process is a solid state welding process in which the material being welded does not melt or recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The welding parameters and tool pin profile play major roles in deciding the weld quality. In this investigation, an attempt has been made to understand effects of process parameters include rotation speeds, welding speeds, and pin diameters on al.uminum weldment using double shoulder tools. Thermal and tensile behavior responses were examined. In this direction temperatures distribution across the friction stir aluminum weldment were measured, besides tensile strength and ductility were recorded and evaluated compared with both single shoulder and aluminum base metal.

Influence of Friction Stir Welding Process on the Weld Formation and Tensile Strength of Titanium and Aluminum Dissimilar Alloys Welded Joint

2011 ◽  
Vol 189-193 ◽  
pp. 3266-3269 ◽  
Author(s):  
Yu Hua Chen ◽  
Peng Wei ◽  
Quan Ni ◽  
Li Ming Ke
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Welded Joint ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Influence Of Process Parameters ◽  
Friction Stir ◽  
Dissimilar Alloys ◽  
Titanium Aluminum

Titanium alloy TC1 and Aluminum alloy LF6 were jointed by friction stir welding (FSW), and the influence of process parameters on formation of weld surface, cross-section morphology and tensile strength were studied. The results show that, Titanium and Aluminum dissimilar alloy is difficult to be joined by FSW, and some defects such as cracks and grooves are easy to occur. When the rotational speed of stir head(n) is 750r/min and 950r/min, the welding speed(v) is 118mm/min or 150mm/min, a good formation of weld surface can be obtained, but the bonding of titanium/aluminum interface in the cross-section of weld joint is bad when n is 750r/min which results in a low strength joint. When n is 950r/min and v is 118mm/min，the strength of the FSW joint of Titanium/Aluminum dissimilar materials is 131MPa which is the highest．

The Use of Bobbin Tools for Friction Stir Welding of Aluminium Alloys

2010 ◽  
Vol 638-642 ◽  
pp. 1179-1184 ◽  
Author(s):  
Philip L. Threadgill ◽  
M.M.Z. Ahmed ◽  
Jonathan P. Martin ◽  
Jonathan G. Perrett ◽  
Bradley P. Wynne
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Axial Force ◽  
Aluminium Alloys ◽  
Processing Parameters ◽  
Machine Design ◽  
Friction Stir ◽  
Triangular Zone

The use of a double sided friction stir welding tool (known as a bobbin tool) has the advantage of giving a processed zone in the workpiece which is more or less rectangular in cross section, as opposed the triangular zone which is more typically found when conventional friction stir welding tool designs are used. In addition, the net axial force on the workpiece is almost zero, which has significant beneficial implications in machine design and cost. However, the response of these tools in generating fine microstructures in the nugget area has not been established. The paper presents detailed metallographic analyses of microstructures produced in 25mm AA6082-T6 aluminium wrought alloy, and examines grain size, texture and mechanical properties as a function of processing parameters and tool design, and offers comparison with data from welds made with conventional tools.

scholarly journals Influence of Mx-Trivex, A-Skew, Three Flat Threaded and Concave Shouldered Mx-Triflute Tool Pin Profiles on Tensile Properties and Fractural Behaviour of Aa 6082-T6 Weldments During Friction Stir Welding

2020 ◽  
Vol 9 (4) ◽  
pp. 1376-1384
Keyword(s):  
Friction Stir Welding ◽  
Tensile Test ◽  
Weld Zone ◽  
Base Material ◽  
Traverse Speed ◽  
Friction Stir ◽  
Tool Pin ◽  
Solid State Joining ◽  
Joining Process ◽  
Brass Wire

Friction Stir Welding (FSW) is a topical and propitious solid-state joining process producing economical and strengthened joints of age-hardened and heat-treatable Aluminium Alloy AA 6082-T6. Mechanical and fractural behaviour of weldments were investigated in order to find crack initiation and necking on the weld zone thereby perceiving the complete behaviour of fracture occurred near the weld zone. Weldments are fabricated by employing four tool pin profiles namely MX-TRIVEX, A-SKEW, Three flat threaded and Concave shouldered MX-TRIFLUTE tools at various rotational speeds 1000 rpm, 1200 rpm and 1400 rpm at single traverse speed 25 mm/min. EXCETEX-EX-40 CNC wire cut EDM with 0.25 mm brass wire diameter has been employed to perform the extraction of tensile test specimens from the weldments according to ASTM E8M-04 standard. Tensile test was performed on elctromechanically servo controlled TUE-C-200 (UTM machine) according to ASTM B557-16 standards Maximum Ultimate Tensile Strength (UTS) of 172.33 MPa (55.5% of base material) and 0.2% Yield Stress (YS) of 134.10 MPa (51.5% of base material) were obtained by using A-SKEW at 1400 rpm, 25 mm/min and maximum % Elongation (%El) of 11.33 (113.3% of base material) was obtained at MX-TRIVEX at 1000 rpm, 25 mm/min. Minimum UTS of 131.16 MPa (42.30% of base material) and 0.2% YS of 105.207 MPa (40.46% of base material )were obtained by using Concave shouldered MX-TRIFLUTE at 1400 rpm, 25 mm/min. Minimum % El of 5.42 ( 54.2% of base material) was obtained by using A-SKEW at 1000 rpm, 25 mm/min.

Superplastic Behavior and Microstructure of Titanium (Ti-6Al-4V) Friction Stir Welds Made under a Variety of Processing Conditions

2010 ◽  
Vol 433 ◽  
pp. 169-176 ◽  
Author(s):  
Paul Edwards ◽  
Mamidala Ramulu ◽  
Daniel G. Sanders
Keyword(s):  
Friction Stir Welding ◽  
Base Material ◽  
Superplastic Forming ◽  
Spindle Speed ◽  
Processing Conditions ◽  
Superplastic Behavior ◽  
Friction Stir ◽  
Fine Grained ◽  
Weld Parameters

Friction Stir Welding of Ti-6Al-4V was performed on 5 mm thickness plate in order to assess the affect of welding conditions on the resulting microstructure and superplastic forming behavior of the joints. A variety of welding conditions were tested and all welds were subsequently Superplastically formed. It was found that the weld parameters do influence the microstructure and degree of superplastic performance of the joints. Spindle speed was found to have the most dominant affect on the resulting microstructure and superplastic forming behavior. Low spindle speed welds lead to fine grained microstructures and highly superplastic welds, relative to the base material, while high spindle speed welds larger grained microstructures and less superplastic welds.

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