Friction Stir Welding of Dissimilar 5xxx to 6xxx Al Alloys: A Review

2013 ◽  
Vol 376 ◽  
pp. 42-48 ◽  
Author(s):  
S.N. Pandya ◽  
J.V. Menghani
Keyword(s):  
Friction Stir Welding ◽  
Industrial Applications ◽  
Al Alloys ◽  
Fusion Welding ◽  
Al Alloy ◽  
Pressure Welding ◽  
Roll Bonding ◽  
Friction Stir ◽  
History Of ◽  
State Nature

Many engineering applications in aerospace and automotive field require joining of dissimilar 5xxx to 6xxx Al alloys. Dissimilar Al alloy joints are used for industrial applications due to technical & economic reasons. However, due to different metallurgical behaviour & mechanical properties, joining of dissimilar Al alloys presents a number of challenges. Due to high temperature generation most of the fusion welding techniques are not suitable. In addition, other pressure welding techniques such as – Ultrasonic welding, Roll bonding, Diffusion bonding and Friction welding have some limitation. Hence, friction stir welding (FSW) can be considered to be the most suitable method to join dissimilar Al alloys due to solid-state nature of the process. Since invention, friction stir welding has been a matter of research and investigation for years. In its history of two decades, Friction Stir welding was investigated for joining dissimilar Al alloys during the last decade. Most of studies demonstrated that good quality joints between dissimilar Al alloys can be produced by the Friction Stir Welding (FSW) process. The present study is a chronological & critical review of recent studies on joining of dissimilar 5xxx to 6xxx Al alloys by friction stir welding.

Effect of double-sided friction stir welding on the mechanical and microstructural characteristics of AA5754 aluminium alloy

2021 ◽  
Vol 63 (9) ◽  
pp. 829-835
Author(s):  
Sare Çelik ◽  
Fatmagül Tolun
Keyword(s):  
Friction Stir Welding ◽  
Al Alloys ◽  
Fusion Welding ◽  
Welding Parameters ◽  
Al Alloy ◽  
Test Results ◽  
Feeding Rates ◽  
Microstructural Characteristics ◽  
Friction Stir ◽  
Tool Tilt Angle

Abstract AA5754Al alloy is widely used in industry. However, as in the case of all Al alloys, the 5xxx series Al alloys cannot be easily joined through fusion welding techniques. To address this problem, in this study, the effect of double-sided friction stir welding at various tool rotational speeds (450, 710, and 900 rpm), feeding rates (40, 50, and 80 mm × min-1), and tool tilt angles (0°, 1°, 2°) on the welding parameters and mechanical and microstructural characteristics of AA5754 Al alloy was determined. Tensile strength tests and microhardness tests were performed to examine the mechanical properties of the welded specimens. The microstructures of the welded zone were examined by obtaining optical microscopy and scanning electron microscopy images. The tensile test results indicated that the specimens exhibited the highest welding performance of 95.17 % at a tool rotational speed, feed rate, and tool tilt angle of 450 rpm, 50 mm × min-1 and 1°, respectively.

scholarly journals Investigations on Friction Stir Welding to Improve Aluminum Alloys

2021 ◽  
Author(s):  
Bazani Shaik ◽  
Gosala Harinath Gowd ◽  
Bandaru Durga Prasad
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Coefficient Of Thermal Expansion ◽  
Research Work ◽  
Weight Ratio ◽  
Welding Process ◽  
Industrial Applications ◽  
Fusion Welding ◽  
Friction Stir

Today is an era of metals including Aluminum alloys owing to a fundamental paradigm shift in research objectives. In addition to superior performance and lightweight criteria that are used to define the innovations of yore, scientists today are compelled to take into consideration the environment-friendliness of the new and novel materials being developed due to the concerns of maintaining a sustainable and safe existence. The solid-state Friction stir welding process has immense potential in the areas of automobiles, aerospace and construction industries due to its overwhelming advantages over the conventional fusion welding process of aluminum alloys. The thesis presents an experimental investigation of friction stir welding of dissimilar aluminum alloys AA7075T651 and AA6082T651. Mathematical modeling equations are developed to predict the tensile strength, impact strength, elongation, and micro-hardness of the dissimilar FSW joints AA7075T651 and AA6082T651. The process parameters are optimized for maximum tensile strength and hardness values. Post weld heat treatment is conducted and the metallurgical properties of the FS welded AA7075T651 and AA6082T651 are presented for different combinations of tool rotational speeds. Aluminum and its alloys are widely used in nonferrous alloys for many industrial applications. Aluminum exhibits a combination of an excellent mechanical strength with lightweight and thus it is steadily replacing steel in industrial applications where the strength to weight ratio plays a significant role. In conventional welding, the joining of aluminum is mainly associated with a high coefficient of thermal expansion, solidification shrinkage and dissolution of harmful gases in the molten metal during welding. The weld joints are also associated with segregation of secondary alloys and porosities which are detrimental to the joint qualities. Friction Stir Welding (FSW) and Friction Welding (FW) are the most popular emerging solid welding techniques in aircraft and shipbuilding industries. FSW is mainly used for the joining of metal plates and FW is mainly used for the joining of rods. Both techniques are suitable for high strength material having less weight. These techniques are environmentally friendly and easy to execute. Hence, the study of these techniques can contribute much to the field of green technology. This research work is dealt with the experimental and numerical investigations on FSW and FW of aluminum alloys.

Friction Stir Welding Lap Joint Resistance Optimization Through Gradient Techniques

2007 ◽  
Vol 129 (6) ◽  
pp. 985-990 ◽  
Author(s):  
L. Fratini ◽  
V. Corona
Keyword(s):  
Friction Stir Welding ◽  
Optimization Procedure ◽  
Experimental Tests ◽  
Industrial Applications ◽  
Fusion Welding ◽  
Lap Joint ◽  
Rotating Speed ◽  
Friction Stir ◽  
Gradient Technique ◽  
Lightweight Alloys

In recent years, scientific interest on friction stir welding (FSW) has grown more and more since such a joining technique allows one to weld lightweight alloys that are rather difficult to weld or even “unweldable” with the classic fusion welding operations. Furthermore, few industrial applications of the process are already known in different manufacturing fields. In this paper, the optimization problem of a FSW lap joint for automotive applications is investigated, taking into account process parameters such as the tool rotating speed and the tool feed rate; a numerical gradient technique is applied for the optimization procedure reducing the number of experimental tests to be developed.

Microstructural Evolution during Friction Stir Welding of Ultrafine Grained Al Alloys

2006 ◽  
Vol 503-504 ◽  
pp. 169-174 ◽  
Author(s):  
Yutaka S. Sato ◽  
M. Urata ◽  
Y. Kurihara ◽  
S.H.C. Park ◽  
Hiroyuki Kokawa ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Microstructural Evolution ◽  
Al Alloys ◽  
Fusion Welding ◽  
Grain Structure ◽  
Friction Stir ◽  
Ultrafine Grained ◽  
Ultrafine Grained Materials ◽  
Welding Processes

Recently, several metallic materials with ultrafine-grained structures and characterized by high strength and toughness have been developed. When these ultrafine-grained materials are practically used, welding and joining processes are required. However, conventional fusion welding processes result in deterioration of the good mechanical properties of these ultrafine-grained materials due to the drastic grain growth of the ultrafine grains. On the other hand, friction stir welding (FSW) is a solid-state joining process having lower heat-input than fusion welding processes, enabling formation of a fine grain structure in the stir zone. Thus, this process would effectively alleviate deterioration of mechanical properties of the ultrafine-grained materials. The authors applied FSW to ultrafine-grained Al alloys and then examined the microstructural features associated with hardness in the friction stir welds. The present paper reviews microstructural evolution of ultrafine-grained Al alloys, produced by equal channel angular pressing (ECAP) and accumulative roll-bonding (ARB), during FSW.

Joining of 1100 Al Alloy to AISI 1045 Carbon Steel by Friction Stir Welding

2012 ◽  
Vol 152-154 ◽  
pp. 418-423
Author(s):  
Namdar Karimi ◽  
M. Shakeri ◽  
M. Habibnia ◽  
S. Nourouzi
Keyword(s):  
Friction Stir Welding ◽  
Carbon Steel ◽  
Rotational Speed ◽  
Dissimilar Materials ◽  
Strength Properties ◽  
Industrial Applications ◽  
Al Alloy ◽  
Friction Stir ◽  
Metallurgical Properties ◽  
Aisi 1045

Joining of dissimilar materials like Al alloy to carbon steel is attractive for industrial applications such as automotive industry. In this research, Friction Stir Welding (FSW) has been used to joint between dissimilar materials like 1100 Al alloys to AISI 1045 carbon steel. In this paper, the effect of rotational speed, feedrate and offset of tool are investigated on mechanical and metallurgical properties of the welding. The joints were evaluated by mechanical testing and metallurgical analysis. Metallurgical properties carried out by optical microscopy and Scanning Electron Microscopy (SEM) and mechanical properties conducted by the joint strength. Finally, optimum value of tool rotational speed and feedrate were obtained 710 rpm and 28 mm/min respectively and the best offset value of the tool obtained 1.5 mm in the Al alloy. Tensile strength properties of Al1100/1045 carbon steel joints were found to be approximately 20% lower than that of the Al 1100-H14 alloy base metal

Friction stir welding of ultrafine grained Al alloy 1100 produced by accumulative roll-bonding

2004 ◽  
Vol 50 (1) ◽  
pp. 57-60 ◽  
Author(s):  
Y.S. Sato ◽  
Y. Kurihara ◽  
S.H.C. Park ◽  
H. Kokawa ◽  
N. Tsuji
Keyword(s):  
Friction Stir Welding ◽  
Accumulative Roll Bonding ◽  
Al Alloy ◽  
Roll Bonding ◽  
Friction Stir ◽  
Ultrafine Grained

scholarly journals Effect of Stirring Pin Rotation Speed on Microstructure and Mechanical Properties of 2A14-T4 Alloy T-Joints Produced by Stationary Shoulder Friction Stir Welding

Materials ◽  
2021 ◽  
Vol 14 (8) ◽  
pp. 1938
Author(s):  
Haifeng Yang ◽  
Hongyun Zhao ◽  
Xinxin Xu ◽  
Li Zhou ◽  
Huihui Zhao ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Weld Nugget ◽  
Al Alloy ◽  
Nugget Zone ◽  
T Joints ◽  
Friction Stir ◽  
Stationary Shoulder ◽  
Microstructure And Mechanical Properties

In this study, 2A14-T4 Al-alloy T-joints were prepared via stationary shoulder friction stir welding (SSFSW) technology where the stirring pin’s rotation speed was set as different values. In combination with the numerical simulation results, the macro-forming, microstructure, and mechanical properties of the joints under different welding conditions were analyzed. The results show that the thermal cycle curves in the SSFSW process are featured by a steep climb and slow decreasing variation trends. As the stirring pin’s rotation speed increased, the grooves on the weld surface became more obvious. The base and rib plates exhibit W- or N-shaped hardness distribution patterns. The hardness of the weld nugget zone (WNZ) was high but was lower than that of the base material. The second weld’s annealing effect contributed to the precipitation and coarsening of the precipitated phase in the first weld nugget zone (WNZ1). The hardness of the heat affect zone (HAZ) in the vicinity of the thermo-mechanically affected zone (TMAZ) dropped to the minimum. As the stirring pin's rotation speed increased, the tensile strengths of the base and rib plates first increased and then dropped. The base and rib plates exhibited ductile and brittle/ductile fracture patterns, respectively.

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