Effect of Ultrasonic Application during Friction Stir Welding on Microstructure and Properties of AA2024 Fixed Joints

2016 ◽  
Vol 683 ◽  
pp. 227-231 ◽  
Author(s):  
Alexander A. Eliseev ◽  
Sergei Yu. Tarasov ◽  
Sergey Fortuna ◽  
Valery E. Rubtsov ◽  
Tatiana Kalashnikova
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultrasonic Vibration ◽  
Friction Stir ◽  
Vibration Effect ◽  
Ultrasonic Assisted ◽  
Aluminum Alloy 2024 ◽  
Joint Quality

Microstructure and mechanical properties of aluminum alloy 2024 fixed joint produced by ultrasonic assisted friction stir welding are described. Tensile strength, microhardness, grain size and zone area are measured and compared with ones of joint produced without ultrasonic vibration. Analyzing this data authors make conclusion about ultrasonic vibration effect on friction stir welding joint quality.

Effect of Preheat Temperature on Friction Stir Welded Aluminum Alloy 5052 Joints

2014 ◽  
Vol 597 ◽  
pp. 253-256 ◽  
Author(s):  
Nurul Muhayat ◽  
Triyono ◽  
Bambang Kusharjanta ◽  
Radian T. Handika
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Preheat Temperature ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Heated Air

The effects of preheat temperature on mechanical properties and the microstructure of friction stir welded (FSW) aluminum alloy 5052 joints were studied in the present work. Heated air from Hot Gun was applied in front of the FSW tool to give the preheat on friction stir welding process. Preheat temperature was set 150°C, 250°C and 300°C. Mechanical properties were correlated and analyzed according to tensile strength, macro and microstructure. Defect free weldswere obtained at all preheat variations. The increasing preheat temperature produced the coarser grain size, it influencedthe little decrease both the tensile strength and hardness of joints.

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.

Stir zone material flow patterns during friction stir welding of heavy gauge AA5056 workpieces and stability of its mechanical properties

2021 ◽  
Vol 23 (4) ◽  
pp. 140-154
Author(s):  
Tatiana Kalashnikova ◽  
◽  
Vladimir Beloborodov ◽  
Kseniya Osipovich ◽  
Andrey Vorontsov ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Elevated Temperatures ◽  
Thin Sheet ◽  
Stir Zone ◽  
Clear Correlation ◽  
Material Structure ◽  
Friction Stir ◽  
Significant Difference

Introduction. Friction stir welding and processing are almost identical processes of severe plastic deformation at elevated temperatures. These technologies differ mainly in the purpose of its use: the formation of a hardened surface layer or producing a welded joint. However, it is known that both during welding and during processing of heavy gauge workpieces temperature gradients occur. As a result, the conditions of adhesive interaction, material plastic flow, and the formation of the stir zone change as compared to thin-sheet workpieces with fundamentally different heat dissipation rates. In this connection, the purpose of the work is to determine the regularities of the structure formation and stability of the mechanical properties in different directions in the material of 35-mm-thick aluminum-magnesium alloy samples produced by friction stir welding/processing. Research Methodology. The technique and modes of friction stir welding and processing of AA5056 alloy workpieces with a thickness of 35 mm are described. Data on the equipment used for mechanical tests and structural research are given. Results and discussion. The data obtained show the excess mechanical properties of the processing zone material over the base metal ones in all studied directions. Material structure heterogeneities after friction stir welding/processing of heavy gauge workpieces have no determining effect on the stir zone properties. At the same time, there is no clear correlation between the tensile strength values and the load application direction, nor is there any significant difference in mechanical properties depending on the location of the samples inside the stir zone. The average ultimate tensile strength values in the vertical, transverse, and longitudinal directions are 302, 295 and 303 MPa, respectively, with the yield strength values of 155, 153 and 152 MPa, and the relative elongation of 27.2, 27.5, 28.7 %.

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 Interface Characteristics and Mechanical Properties of Ultrasonic-Assisted Friction Stir Lap Welded 7075-T6 Aluminium Alloy

Materials ◽  
2020 ◽  
Vol 13 (23) ◽  
pp. 5335 ◽  
Author(s):  
Changshu He ◽  
Zhiqiang Zhang ◽  
Ying Li ◽  
Jingxun Wei ◽  
Menggang Zhai ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Ultrasonic Vibration ◽  
Fracture Mode ◽  
Fracture Strength ◽  
Shear Fracture ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Ultrasonic Assisted ◽  
Lap Welding ◽  
Cold Lap

In this work, friction stir lap welding (FSLW) and ultrasonic-assisted friction stir lap welding (UAFSLW) was applied to 6-mm-thick 7075-T6 alloy sheets using three welding tools with the same process parameters. The joint formation, microstructural characteristics, and mechanical properties of the resulting lap joints were then investigated. The results showed that ultrasonic vibration significantly promoted the flow of metal at the interface, enlarged the size of the stirred zone (SZ), and reduced the angle between the hook defect and the interface. During lap shear testing, the FSLW and UAFSLW joints fractured in a similar manner. The fracture modes included tensile fracture, shear fracture, and a mixture of both. Cold lap and hook defects may have served as crack-initiation zones within the joint. Under configuration A (i.e., upper sheet on the retreating side (RS)), all joints failed in the shear-fracture mode. The effective lap width (ELW) of the joint welded using tool T2 was the greatest. This resulted in a higher shear fracture strength. The maximum shear fracture strength of the UAFSLW joint was 663.1 N/mm. Under configuration B (i.e., upper sheet on the advancing side (AS)), the shear fracture strength was greatly affected by the fracture mode. The highest shear fracture strength of the UAFSLW joint, 543.7 N/mm, was welded by tool T3. Thus, under otherwise identical conditions, UAFSLW joints can withstand a greater fracture shear strength than FSLW joints, as ultrasonic vibration helps to mix the material at the interface, thus, enlarging the SZ and diminishing the cold lap defects.

Evaluating the Strength of the Friction Stir Welded Joints at Various Rotational Speeds

2013 ◽  
Vol 446-447 ◽  
pp. 312-315
Author(s):  
Ramaraju Ramgopal Varma ◽  
Abdullah Bin Ibrahim ◽  
B. Ravinder Reddy
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Yield Strength ◽  
Welded Joints ◽  
Rotational Speed ◽  
Testing Machine ◽  
Friction Stir ◽  
Universal Testing ◽  
Welding Technique

The present research paper aims in evaluating the strength of the welded AA6351 alloy plates of 6 mm thick by using friction stir welding technique at different rotational speeds The applied welding technique is capable of achieving the mechanical properties of the alloy close to that of the original alloy. In the present investigation, the speeds of the spindle were varied from 1100 rpm to 1500 rpm with a constant transverse speed of 20 mm/min. The tensile strength of the joints is determined by an universal testing machine. The results from the present investigation show that the values of the yield strength were very much closer to the values of the AA6351Alloy prior to welding. It has been found from the experiments that the strength of the joints increases with the increase in the rotational speed; however, the same is decreasing after achieving certain speed.

Prediction and optimization of the mechanical properties of dissimilar friction stir welding of aluminum alloys using design of experiments

2016 ◽  
Vol 232 (8) ◽  
pp. 1384-1394 ◽  
Author(s):  
R Palanivel ◽  
RF Laubscher ◽  
S Vigneshwaran ◽  
I Dinaharan
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Ultimate Tensile Strength ◽  
Design Of Experiments ◽  
Process Parameters ◽  
Welding Process ◽  
Friction Stir ◽  
Friction Stir Welding Process

Friction stir welding is a solid-state welding technique for joining metals such as aluminum alloys quickly and reliably. This article presents a design of experiments approach (central composite face–centered factorial design) for predicting and optimizing the process parameters of dissimilar friction stir welded AA6351–AA5083. Three weld parameters that influence weld quality were considered, namely, tool shoulder profile (flat grooved, partial impeller and full impeller), rotational speed and welding speed. Experimental results detailing the variation of the ultimate tensile strength as a function of the friction stir welding process parameters are presented and analyzed. An empirical model that relates the friction stir welding process parameters and the ultimate tensile strength was obtained by utilizing a design of experiments technique. The models developed were validated by an analysis of variance. In general, the full impeller shoulder profile displayed the best mechanical properties when compared to the other profiles. Electron backscatter diffraction maps were used to correlate the metallurgical properties of the dissimilar joints with the joint mechanical properties as obtained experimentally and subsequently modeled. The optimal friction stir welding process parameters, to maximize ultimate tensile strength, are identified and reported.

Investigation of Microstructure and Mechanical Properties of Friction Stir Lap Jointed Ni Base Superalloy

2012 ◽  
Vol 724 ◽  
pp. 481-485
Author(s):  
Kuk Hyun Song ◽  
Kazuhiro Nakata
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Friction Stir Welding ◽  
Base Material ◽  
Lap Joints ◽  
Stir Zone ◽  
Inconel 600 ◽  
Friction Stir ◽  
Microstructure And Mechanical Properties ◽  
Average Grain Size

This study evaluated the microstructure and mechanical properties of friction stir welded lap joints. Inconel 600 and SS 400 as experimental materials were selected, and friction stir welding was carried out at tool rotation speed of 200 rpm and welding speed of 100 mm/min. Applying the friction stir welding was notably effective to reduce the grain size of the stir zone, as a result, the average grain size of Inconel 600 was reduced from 20 μm in the base material to 8.5 μm in the stir zone. Joint interface between Inconel 600 and SS 400 showed a sound weld without voids and cracks. Also, the hook, along the Inconel 600 alloy from SS 400, was formed at advancing side, which directly affected an increase in peel strength. In this study, we systematically discussed the evolution on microstructure and mechanical properties of friction stir lap jointed Inconel 600 and SS 400.

Residual stress, tensile strength, and macrostructure investigations on ultrasonic assisted friction stir welding of AA 6061-T6

2018 ◽  
Vol 53 (7) ◽  
pp. 494-503 ◽  
Author(s):  
Iman Alinaghian ◽  
Saeid Amini ◽  
Mohammad Honarpisheh
Keyword(s):  
Residual Stress ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Weld Zone ◽  
Ultrasonic Power ◽  
Ultrasonic Vibrations ◽  
Friction Stir ◽  
Longitudinal Residual Stress ◽  
Ultrasonic Assisted

In recent decades, ultrasonic vibrations are used in manufacturing processes because they can improve tool life, material performance, and quality. One of them which can be integrated with ultrasonic vibrations is friction stir welding called ultrasonic assisted friction stir welding. In previous studies, the effect of ultrasonic vibrations on the mechanical, metallurgical, and thermal properties was investigated and there is not any residual stress investigations on ultrasonic assisted friction stir welding. Since residual stress plays an important role in performance and stability of components, the influence of ultrasonic power on the longitudinal residual stress in friction stir welding is investigated in this work. In spite of residual stress, tensile strength and quality of weldment were investigated as complementary terms to ensure successful performance of ultrasonic assisted friction stir welding. The findings indicated that high-frequency vibrations with power of 200 W can reduce the maximum tensile residual stress about 45% and significantly increase tensile strength. Also, ultrasonic vibrations prevent defect such has voids and tunnel in weld zone due to peening effect in ultrasonic assisted friction stir welding.

scholarly journals Effect of Tool Rotation Speed on Mechanical Properties and Microstructure as the Results of Friction Stir Welding Method on Aluminium 5083-7075

2016 ◽  
Vol 27 (1) ◽  
pp. 9-17
Author(s):  
Maryati Maryati ◽  
Bambang Soegijono ◽  
M Yudi Masduky ◽  
Tarmizi Tarmizi
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Incomplete Fusion ◽  
Connection Form ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Speed Rotation ◽  
Tool Rotation

Friction Stir Welding (FSW) is a new method of welding process which is affordable and provide good quality. Aluminium 5083-7075 has been connected successfully by using friction stir welding (FSW) method into butt joint connection form. Tool rotation speed is one of the important parameters in FSW. The changes of rotation speed will affect the characteristics of mechanical properties and microstructure. The parameters of welding being used are welding speed of 29 mm/minutes by varying the speed rotation of 525 rpm, 680 rpm, 910 rpm, and 1555 rpm. In order to find out the mechanical strength of welds, tensile strength and hardness testing is done while finding out the microstructure will be done by using optical microscope and Scanning Electron Microscope (SEM). The result of the research showed that the highest tensile strength obtained at 910 rpm speed rotation about 244.85 MPa and the greatest hardness values was found on aluminium 5083 around the wheel zone area about 96 HV with rotary speed of 525 rpm. Then, the result of testing the macro and microstructure on all samples indicated defect which is seen as incomplete fusion and penetration causing the formation of onion rings. In other words, it is which showed that the result of stirring and tacking in the welding area is less than perfect.

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