Effect of friction stir welding parameters on properties and structure of 1151T alloy sheets joints

2021 ◽  
pp. 11-18
Author(s):  
V.V. Ovchinnikov ◽  
A.M. Drits ◽  
I.V. Solov’eva
Keyword(s):  
Grain Size ◽  
Tensile Strength ◽  
Corrosion Resistance ◽  
Friction Stir Welding ◽  
Welded Joint ◽  
Welding Parameters ◽  
Natural Ageing ◽  
Friction Stir ◽  
Cooling Speed ◽  
T State

The mechanical and corrosive properties of welded joints of sheets with 6 mm thickness made of the 1151 alloy of the Al—Cu—Mg system in the T state (hardening and natural ageing) obtained by friction stir welding by single, double welding and bobbin tool welding is studied. It is shown that the change in the friction stir welding scheme does not result in noticeable change in the tensile strength of the welded joint and the weld metal. The grain size in the weld increased from 4.8 µm (single welding) to 10.5 µm when bobbin tool welding. The intercrystall line corrosion resistance of all welding zones (except the base metal) increases by about 1.4 to 2 times depending on the structural area due to the higher cooling speed of single friction stir welding compared to the bobbin tool welding,

Optimization of friction stir welding parameters of dissimilar aluminium alloys 6061 and 5083 by using response surface methodology

2021 ◽  
pp. 095440622110058
Author(s):  
Sanjeev Verma ◽  
Vinod Kumar
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Tilt Angle ◽  
Feed Rate ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Industrial Sectors ◽  
Tool Pin

Aluminium and its alloys are lightweight, corrosion-resistant, affordable and high-strength material and find wide applications in shipbuilding, automotive, constructions, aerospace and other industrial sectors. In applications like aerospace, marine and automotive industries, there is a need to join components made of different aluminium alloys, viz. AA6061 and AA5083. In this study friction stir welding (FSW) is used to join dissimilar plates made of AA6061-T6 and AA5083-O. The effect of varying tool pin profile, tool rotation speed, tool feed rate and tilt angle of the tool has been investigated on the tensile strength and percentage elongation of the welded joints. Box-Behkan design, with four input parameters and three levels of each parameter has been employed to decide the set of experimental runs. The regression models have been developed to investigate the influence of welding variables on the tensile strength and elongation of the welded joint. It is revealed that with the increase in welding parameters like tool rpm, tool feed rate and tilt angle of the tool, both the mechanical properties increase, reach a maximum level, followed by a decrease with further increase in the value of parameters. Amongst different types of tool pin profiles used, the FSW tool having straight cylindrical (SC) pin profile is found to yield the maximum strength and elongation of the welded joint for different combinations of welding parameters. Multiple response optimization indicates that the maximum UTS (135.83 MPa) and TE (4.35%) are obtained for the welded joint fabricated using FSW tool having SC pin profile, tilted at 1.11° and operating at tool speed and feed rate of 1568 rpm and 39.53 mm/min., respectively.

scholarly journals Modeling and Optimization of Bobbin Friction Stir Welding for AA6061-T6 alloy Utilizing Response Surface Methodology

2018 ◽  
Vol 26 (4) ◽  
pp. 1-17
Author(s):  
Samir Ali Amin ◽  
Mohannad Yousif Hanna ◽  
Alhamza Farooq Mohamed
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Bending Force ◽  
Speed Range

Bobbin friction stir welding (BFSW) is special kind of friction stir welding. This investigation aims to develop empirical models through mathematical relationships between the welding process parameters and mechanical properties of Aluminum alloy AA6061-T6 welded joint created by using bobbin tool and to find the optimum welding parameters. The welding speed range (40-200 mm/min) and rotational speed range (340-930 rpm) were utilized (as the used input factors) to find their effects on elongation, tensile strength and maximum bending force as the main responses.  These models were built using Design of Experiment (DOE) software ‘version 10’ with Response Surface Methodology (RSM) technique. The models adequacy were tested via the (ANOVA) analysis. The obtained models appeared that as the welding speed or rotational speed increases, the elongation, tensile strength and maximum bending force of the welded joint firstly rise to a maximum value and then drop. The optimum welding parameters were rotational speed (623.949 rpm) and welding speed (128.795 mm/min) with (6.33%), (204 MPa) and (6.216 KN) of elongation, tensile strength and maximum bending force, respectively. A proper harmonization was obtained between the models predicted results and the optimized ones with actual trial with 95% level of confidence.

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．

Enhancements on dissimilar friction stir welding between AZ31 and SPHC mild steel with Al-Mg as powder additives

2021 ◽  
pp. 1-22
Author(s):  
Mohd Ridha Muhamad ◽  
Sufian Raja ◽  
Mohd Fadzil Jamaludin ◽  
Farazila Yusof ◽  
Yoshiaki Morisada ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Mild Steel ◽  
Welding Speed ◽  
Welded Joint ◽  
Microstructural Analysis ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Interface

Abstract Dissimilar materials joining between AZ31 magnesium alloy and SPHC mild steel with Al-Mg powder additives were successfully produced by friction stir welding process. Al-Mg powder additives were set in a gap between AZ31 and SPHC specimen's butt prior to welding. The experiments were performed for different weight percentages of Al-Mg powder additives at welding speeds of 25 mm/min, 50 mm/min and 100 mm/min with a constant tool rotational speed of 500 rpm. The effect of powder additives and welding speed on tensile strength, microhardness, characterization across welding interface and fracture morphology were investigated. Tensile test results showed significant enhancement of tensile strength of 150 MPa for 10% Al and Mg (balance) powder additives welded joint as compared to the tensile strength of 125 MPa obtained for welded joint without powder additives. The loss of aluminium in the alloy is compensated by Al-Mg powder addition during welding under a suitable heat input condition identified by varying welding speeds. Microstructural analysis revealed that the Al-Mg powder was well mixed and dispersed at the interface of the joint at a welding speed of 50 mm/min. Intermetallic compound detected in the welding interface contributed to the welding strength.

Features for friction stir welding of butt joints of casting VAL8 alloy with wrought 1565chN2 and AMg6M alloys

2021 ◽  
pp. 441-449
Author(s):  
V.A. Berezina ◽  
V.V. Ovchinnikov ◽  
E.V. Luk'yanenko
Keyword(s):  
Grain Size ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Chemical Composition ◽  
Arc Welding ◽  
Butt Joints ◽  
Friction Stir ◽  
Discrete Nature ◽  
Casting Aluminum ◽  
Tool Rotation

The results of technological features for friction stir welding of butt joints of sheet blanks with thickness of 3 mm made of casting aluminum V AL8 alloy with wrought magnalium group 1565chN2 and AMg6M alloys are presented. It is established that the time resistance of the joints depends on the location of the welded alloys relative to the direction of tool rotation during friction stir welding. The ultimate strength of welded joints of VAL8 alloy with 1565chN2 and AMg6 alloys in automatic argon-arc welding is 0.82...0.84 of the ultimate tensile strength of VAL8 alloy. The grain size in the stir zone practically does not depend on the initial grain size in the alloys to be joined. The destruction of the joints made of VAL8 + 1565chH2 alloys under cyclic loading has multi-focal character and is initiated from irregularities on the surface of the weld. The discrete nature of the change in the chemical composition of the weld metal along the axis of the weld is revealed. The weld is formed by alternating strips of connected alloys with width of 30...90 microns.

scholarly journals Innovate Method for Friction Stir Welding of Al-Mg-Si Alloy Thin Plate

2019 ◽  
Vol 269 ◽  
pp. 02006
Author(s):  
Li Fu ◽  
Fenjun Liu
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Base Metal ◽  
High Speed ◽  
Thick Plate ◽  
Welding Parameters ◽  
Butt Joints ◽  
Friction Stir ◽  
High Rotation Speed ◽  
Precipitated Phases

Al-Mg-Si (6061-T6) alloy with 0.8 mm thick plate was welded successfully by use of high speed friction stir welding (FSW) technology. The microstructural characteristics and mechanical property of the butt joints prepared by high speed FSW were analyzed in detail, the influence of welding parameters, fixture condition and after welding heat treatment were also explored. The results shown that sound surface topography and defect-free bonding interface were observed in the nugget zone (NZ). The microhardness of the as-welded joint was lower than that of the base metal because of the welding heat effect. Compared with the conventional speed FSW, the number of β-Mg2Si, Al2CuMg and Al8Fe2Si precipitated phases existed in the high speed FSWed NZ increased, which made the microhardness in the NZ improved significantly. The rod-shaped precipitates (Mg2Si) have the greatest influence on the microhardness distributions. The maximum tensile strength of 301.8 MPa, which was 85.8% of the base metal, was obtained at high rotation speed of 8000 rpm and fast welding speed of 1500 mm/min. The tensile strength of the ultra-high speed FSWed butt joints were improved significantly by post-weld artificial aging, with a maximum joint efficiency of 90.4%.

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.

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