Friction Stir Lap Welding of Aluminium Alloys

2014 ◽  
Vol 611-612 ◽  
pp. 1421-1428
Author(s):  
Carlo Bruni ◽  
Giovanni Quercetti ◽  
Massimiliano Pieralisi
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Tensile Shear ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Tool Geometries ◽  
Lap Welding ◽  
Welding Properties ◽  
Transverse Area ◽  
Tool Rotation

The friction stir welding of lap sheets can be performed considering different variables in terms of process parameters, tool configuration, welding typology and so on. The proposed investigation deals with the friction stir welding of blanks, with the same thickness, performed under lap configuration with the sheets welded, in one-side and in both sides as well, with different tool geometries and tool rotation-wise. The double side allows to extend the weld through the whole thickness leading to better mechanical welding properties at the blank to blank interface. The weld morphology has been investigated through microstructure observations performed on the transverse area, with respect to the welding velocity, of each joint. The tensile shear strength of the joint in one-side weld is generally lower than that detected in two side weld.

scholarly journals Performance of Plunge Depth Control Methods During Friction Stir Welding

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 283 ◽  
Author(s):  
Jinyoung Yoon ◽  
Cheolhee Kim ◽  
Sehun Rhee
Keyword(s):  
Friction Stir Welding ◽  
Position Control ◽  
Longitudinal Direction ◽  
Control Methods ◽  
Friction Stir Lap Welding ◽  
Plunge Depth ◽  
Friction Stir ◽  
Compensation Control ◽  
Depth Control ◽  
Lap Welding

Friction stir welding is a preferred solid state welding process for Al/Fe joints, and in friction stir lap welding, the plunge depth is the most critical parameter for joint strength. We compared three plunge depth control methods, namely conventional position control, offset position control, and deflection compensation control in the friction stir lap welding of 3 mm-thick Al 5083-O alloy over 1.2 mm-thick DP 590 steel. The desired plunge depth was 0.2 mm into the steel sheet. However, the pin did not reach the steel surface under conventional position control due to deflection of the vertical axis of the welding system. In offset position control, an additional offset of 0.35 mm could achieve the desired plunge depth with considerable accuracy. Nevertheless, a gradual increase of the plunge depth along the longitudinal direction was unavoidable, due to an in-situ decrease of the material yield strengths. In deflection compensation control, the deflection is estimated by the coaxially measured plunging force and the force-deflection relationship, and then corrected by feedback control. Thus, the plunge depth is stabilized along the longitudinal direction and is precisely controlled with a 3.3-μm standard deviation of error during the tool traverse phase. There is also a consistent bias of 32 μm caused by the resolution of the measuring system, and it can be easily calibrated in the feedback control system.

scholarly journals PIN DIAMETER EFFECT ON MICROSTRUCTURE AND MECHANICAL PROPERTIES OF DISSIMILAR FRICTION STIR LAP WELDING ALUMINUM ALLOY 6061-T6 TO DUAL PHASE STEEL

2018 ◽  
Vol 24 (2) ◽  
pp. 163 ◽  
Author(s):  
Yazid Helal ◽  
Zakaria Boumerzoug
Keyword(s):  
Aluminum Alloy ◽  
Dual Phase Steel ◽  
Dual Phase ◽  
Tensile Shear ◽  
Friction Stir Lap Welding ◽  
Shear Tests ◽  
Friction Stir ◽  
Lap Welding ◽  
Energy Dispersive Spectroscope ◽  
Alloy 6061

<p class="AMSmaintext"> </p><p class="AMSmaintitle">Abstract</p><p class="AMSmaintext">In this work, the effect of the pin diameter on the microstructure, hardness and strength of friction stir welded 6061-T6 aluminum alloy to dual phase steel have been investigated. Microhardness measurements, tensile shear tests, optical microscopy, and scanning electron microscopy with energy dispersive spectroscope (EDS) were the main techniques used. The results showed that friction stir welding can be used for the joining of dissimilar 6061-T6 aluminum alloy to dual phase steel. We have found that the maximum strength is obtained after welding with the highest pin diameter. </p>

Friction stir welding of butt joints of 1420T1 and 1163T alloys sheets

2020 ◽  
pp. 446-453
Author(s):  
V.A. Berezina ◽  
V.V. Ovchinnikov ◽  
E.V. Luk’yanenko
Keyword(s):  
Friction Stir Welding ◽  
Ultimate Strength ◽  
Aluminium Alloys ◽  
Welded Joint ◽  
Butt Joint ◽  
Maximum Temperature ◽  
Butt Joints ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Tool Rotation

The results of the butt joint formation of 5 mm thickness sheets from 1420T1 and 1163T aluminium alloys in different combination are presented. It is established that the ultimate strength of the joints depends on the location of the welded alloys relative to the direction of the tool rotation during friction stir welding. It is shown that depending on the location of 1420T1 and 1163T alloys on the side of the run in or out of the tool, the maximum temperature at the edge of the tool shoulder is 385 or 410 °C, in the weld core the metal is heated to 490 °C. The stir zone (the weld metal) consists of two zones corresponding to welded alloys without stir with each other. Ultimate strength to welded joint 1420T1 and 1163T alloys is 0.65...0.73 of ultimate strength to the 1420T1 alloy

scholarly journals Effect of Process Factors on Tensile Shear Load Using the Definitive Screening Design in Friction Stir Lap Welding of Aluminum–Steel with a Pipe Shape

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5787
Author(s):  
Leejon Choy ◽  
Seungkyung Kim ◽  
Jeonghun Park ◽  
Myungchang Kang ◽  
Dongwon Jung
Keyword(s):  
Friction Stir Welding ◽  
Penetration Depth ◽  
Shear Load ◽  
Cast Aluminum ◽  
Tensile Shear ◽  
Plunge Depth ◽  
Friction Stir ◽  
Screening Design ◽  
Definitive Screening ◽  
Lap Welding

Recently, friction stir welding of dissimilar materials has emerged as one of the most significant issues in lightweight, eco-friendly bonding technology. In this study, we welded the torsion beam shaft—an automobile chassis component—with cast aluminum to lighten it. The study rapidly and economically investigated the effects of friction stir welding and process parameters for A357 cast aluminum and FB590 high-strength steel; 14 decomposition experiments were conducted using a definitive screening design that could simultaneously determine the effects of multiple factors. Friction stir welding experiments were conducted using an optical microscope to investigate the tensile shear load behavior in the welding zone. In addition to understanding the interactions between tool penetration depth and plunge speed and tool penetration depth and dwell time, we investigated and found that tool penetration depth positively affected the size of the hooking area and contributed to the stabilization and size reduction of the cavity. The experimental results showed that the plunge depth and tool penetration depth effects were most important; in this case, the plunge depth negatively affected the magnitude of tensile shear load, whereas the tool penetration depth had a positive effect. Therefore, when selecting a tool, it is important to consider the plunge depth and tool penetration depth in lap welding.

scholarly journals A Study of Diffusion Phenomenon in Friction Stir Lap Welding Joints for Low Carbon Steel C10 to Aluminum Alloy AA1100-H112

2018 ◽  
Vol 21 (4) ◽  
pp. 479-485
Author(s):  
Muna Khethier Abbass ◽  
Kareem Mohsen Raheef
Keyword(s):  
Carbon Steel ◽  
Low Carbon Steel ◽  
Welding Parameters ◽  
Low Carbon ◽  
Tensile Shear ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Diffusion Phenomenon ◽  
Microhardness And Microstructure ◽  
Lap Welding

In this study the friction stir lap welding was carried out by a new technique (diffusion bonding phenomenon) between (AA1100 and low carbon steel C10 sheets of 3mm and 1mm thickness respectively. These alloys have difference ranges in melting temperature and other physical properties.  Different parameters were used: tool rotation speeds (630, 1250) rpm, travel speeds (80, 32) mm/min. and pin length (2.8,3) mm  using cylindrical threaded pin. Many tests and inspections were performed such as tensile shear test and X-Ray diffraction tests. Microhardness and microstructure observations were conducted by using optical and SEM. The above tests were used to evaluate the weld quality and joint efficiency under different welding parameters. Best result for  FSLW by  diffusion phenomenon  appear in (low carbon steelC10 / AA1100-H112) joint at 1250rpm  in 32 mm/min. with 2.8mm pin length and the maximum tensile shear strength was (3.9)KN.It was found that the highest micro hardness was (138HV) at the interface between the low carbon steel and AA1100.

Micro friction stir lap welding of AISI 430 ferritic stainless steel: a study on the mechanical properties, microstructure, texture and magnetic properties

2018 ◽  
Vol 115 (3) ◽  
pp. 307
Author(s):  
Hossein Mostaan ◽  
Mehdi Safari ◽  
Arash Bakhtiari
Keyword(s):  
Stainless Steel ◽  
Magnetic Properties ◽  
Friction Stir Welding ◽  
Ferritic Stainless Steel ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Change Mechanism ◽  
Lap Welding ◽  
Field Emission Electron Microscopy ◽  
Aisi 430

In this study, the effect of friction stir welding of AISI 430 (X6Cr17, material number 1.4016) ferritic stainless steel is examined. Two thin sheets with dimensions of 0.4 × 50 × 200 mm3 are joined in lap configuration. Optical microscopy and field emission electron microscopy were used in order to microstructural evaluations and fracture analysis, respectively. Tensile test and microhardness measurements are employed in order to study the mechanical behaviors of welds. Also, vibrational sample magnetometry (VSM) is employed for characterizing magnetic properties of welded samples. Texture analysis is carried out in order to clarify the change mechanism of magnetic properties in the welded area. The results show that AISI 430 sheets are successfully joined considering both, the appearance of the welding bead and the strength of the welded joint. It is found that by friction stir welding of AISI 430 sheets, texture components with easy axes magnetization have been replaced by texture components with harder magnetization axes. VSM analysis showed that friction stir welding leads to increase in residual induction (Br) and coercivity (Hc). This increase is attributed to the grain refining due the friction stir welding and formation of texture components with harder axes of magnetizations.

scholarly journals Influence of the Aluminium Alloy Type on Defects Formation in Friction Stir Lap Welding of Thin Sheets

2018 ◽  
Vol 23 (1) ◽  
pp. 32-42 ◽  
Author(s):  
M. I. Costa ◽  
C. Leitao ◽  
D. M. Rodrigues
Keyword(s):  
Aluminium Alloys ◽  
Fatigue Behaviour ◽  
Welding Parameters ◽  
Thin Sheets ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Alloy Type ◽  
Heat Treated ◽  
Lap Welding ◽  
Applied Stresses

Abstract The weldability in Friction Stir Lap Welding (FSLW) of heat and non-heat treatable aluminium alloys, the AA6082-T6 and the AA5754-H22 aluminium alloys, respectively, are compared. For both alloys, welds were produced in very thin sheets, using the same welding parameters and procedures, and strong differences in welds morphology were found. The strength of the welds was evaluated by performing tensile-shear tests under monotonic and cyclic loading conditions. As-welded and heat-treated samples of the AA6082- T6 were tested. It was found that the heat-treatable alloy is more sensitive to defects formation, in lap welding, than the non-heat-treatable alloy. The presence of defects has a strong influence on the monotonic and fatigue behaviour of the welds. In spite of this, for very high-applied stresses, the heat-treatable alloy welds perform better in fatigue than the non-heat-treatable alloy welds.

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