scholarly journals Friction Stir Welding of Dissimilar Aluminum Alloy Combinations: State-of-the-Art

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 270 ◽  
Author(s):  
Vivek Patel ◽  
Wenya Li ◽  
Guoqing Wang ◽  
Feifan Wang ◽  
Achilles Vairis ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Great Success ◽  
Lightweight Structures ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
And Performance

Friction stir welding (FSW) has enjoyed great success in joining aluminum alloys. As lightweight structures are designed in higher numbers, it is only natural that FSW is being explored to join dissimilar aluminum alloys. The use of different aluminum alloy combinations in applications offers the combined benefit of cost and performance in the same component. This review focuses on the application of FSW in dissimilar aluminum alloy combinations in order to disseminate research this topic. The review details published works on FSWed dissimilar aluminum alloys. The detailed summary of literature lists welding parameters for the different aluminum alloy combinations. Furthermore, auxiliary welding parameters such as positioning of the alloy, tool rotation speed, welding speed and tool geometry are discussed. Microstructural features together with joint mechanical properties, like hardness and tensile strength measurements, are presented. At the end, new directions for the joining of dissimilar aluminum alloy combinations should guide further research to extend as well as to improve the process, which is expected to raise further interest on the topic.

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.

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

2020 ◽  
pp. 64-68
Author(s):  
K. Anganan ◽  
R.J . Narendran ◽  
N Naveen Prabhu ◽  
R Rahul Varma ◽  
R Sivasubramaniyam
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.

Localized Corrosion Resistance of Dissimilar Aluminum Alloys Joined by Friction Stir Welding (FSW)

2016 ◽  
Vol 710 ◽  
pp. 41-46 ◽  
Author(s):  
Aline F.S. Bugarin ◽  
Fernanda Martins Queiroz ◽  
Maysa Terada ◽  
Hercílio G. De Melo ◽  
Isolda Costa
Keyword(s):  
Corrosion Resistance ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Weight Ratio ◽  
Base Material ◽  
High Strength ◽  
Localized Corrosion ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

2XXX and 7XXX high strength aluminum alloys are the most used materials for structural parts of aircrafts due to their high strength/weight ratio. Their joining procedure is an engineering challenge since they present low weldability. Friction Stir Welding (FSW) is a joining technology developed in the early 90 ́s. It is a solid-state welding process, without the use of fillers or gas shield, that eliminates conventional welding defects and has been considered of great interest for application in the aircraft industry. FSW of aluminum alloys results in four regions of different microstructures, specifically: the base material (BM), the heat affected zone (HAZ), the thermo-mechanically affected zone (TMAZ), and the nugget zone (NZ). The complex microstructure of the weld region leads to higher susceptibility to localized corrosion as compared to the BM even when similar alloys are joined. The welding of dissimilar alloys in its turn results in even more complex microstructures as materials with intrinsically different composition, microstructures and electrochemical properties are put in close contact. Despite the great interest in FSW, up to now, only few corrosion studies have been carried out for characterization of the corrosion resistance of dissimilar Al alloys welded by FSW. The aim of this study is to investigate the corrosion behavior of aluminum alloy 2024-T3 (AA2024-T3) welded to aluminum alloy 7475-T761 (AA7475-T761) by FSW. The evaluation was performed in 0.01 mol.L-1 by means of open circuit potential measurements, polarization techniques and surface observation after corrosion tests.

scholarly journals Relationship between micro-structure and mechanical properties of dissimilar aluminum alloy plates by friction stir welding

2018 ◽  
Vol 22 (Suppl. 1) ◽  
pp. 55-66 ◽  
Author(s):  
Furkan Sarsilmaz
Keyword(s):  
Electron Microscopy ◽  
Mechanical Properties ◽  
Scanning Electron Microscopy ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Parameters ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Wide Range ◽  
Scanning Electron

Friction stir welding can be applied to weld dissimilar aluminum alloys which have different chemical and mechanical properties without causing any weld defects under a wide range of welding conditions. In this study, AA2024-T3 and AA6063-T6 aluminum alloys were selected and successfully welded in butt position together using by friction stir welding. The welding trials were conducted using different rotational speed and traverse speed conditions also investigating their effect on mechanical and micro-structural behavior of friction stir welding joints. The micro-structural evolution of the material was analyzed by optical observations and scanning electron microscopy inspections of the weld cross-sections. Tension and fatigue studies were also employed to the study. On the other hand, the fracture characterizations of samples were examined by scanning electron microscopy. Fatigue tests were performed by using a resonant electro-mechanical fatigue testing machine by axial bending fatigue test procedure. The fatigue strength has been analyzed drawing S-N curves. Experimental results indicate that micro-structural and mechanical properties are significantly affected by changing welding parameters within the chosen range of welding conditions.

scholarly journals Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 610 ◽  
Author(s):  
Mian Wasif Safeen ◽  
Pasquale Russo Spena
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Intermetallic Compounds ◽  
Crack Nucleation ◽  
Weld Strength ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Friction Stir ◽  
Stress Concentration Factors ◽  
As Stress

Joining of aluminum alloys through friction stir welding (FSW) is effectively employed in several industries (e.g., aeronautics and aerospace) since it guarantees proper weld strength as compared to other joining technologies. Contrarily, dissimilar FSW of aluminum alloys and steels often poses important issues in the selection of welding parameters due to the difficulty to join different materials. Improper welding parameters give rise to the formation of intermetallic compounds, and internal and external defects (e.g., tunnel formation, voids, surface grooves, and flash). Intermetallic compounds are brittle precipitates of Al/Fe, which chiefly initiate crack nucleation, whereas internal and external defects mainly act as stress concentration factors. All these features significantly reduce joint strength under static and dynamic loading conditions. With reference to the literature, the influence of main welding parameters (rotational speed, welding speed, tool geometry, tilt angle, offset distance, and plunge depth) on the formation of intermetallic compounds and defects in FSW of aluminum alloys and steels is discussed here. Possible countermeasures to avoid or limit the above-mentioned issues are also summarily reported.

scholarly journals Identifying Combination of Friction Stir Welding Parameters to Maximize Strength of Lap Joints of AA2014-T6 Aluminum Alloy

2017 ◽  
Vol 37 (1) ◽  
pp. 6-21 ◽  
Author(s):  
C. Rajendrana ◽  
K. Srinivasan ◽  
V. Balasubramanian ◽  
H. Balaji ◽  
P. Selvaraj
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Weight Ratio ◽  
Welding Process ◽  
Lap Joints ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Friction Stir

AbstractAA2014 aluminum alloy (Al-Cu alloy) has been widely utilized in fabrication of lightweight structures like aircraft structures, demanding high strength to weight ratio and good corrosion resistance. The fusion welding of these alloys will lead to solidification problems such as hot cracking. Friction stir welding is a new solid state welding process, in which the material being welded does not melt and recast. Lot of research works have been carried out by many researchers to optimize process parameters and establish empirical relationships to predict tensile strength of friction stir welded butt joints of aluminum alloys. However, very few investigations have been carried out on friction stir welded lap joints of aluminum alloys. Hence, in this investigation, an attempt has been made to optimize friction stir lap welding (FSLW) parameters to attain maximum tensile strength using statistical tools such as design of experiment (DoE), analysis of variance (ANOVA), response graph and contour plots. By this method, it is found that maximum tensile shear fracture load of 12.76 kN can be achieved if a joint is made using tool rotational speed of 900 rpm, welding speed of 110 mm/min, tool shoulder diameter of 12 mm and tool tilt angle of 1.5°.

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