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.

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°.

Effect of Tool pin Profile and Axial Force on Tensile Behavior in Friction Stir Welding of Dissimilar Aluminum Alloys

2011 ◽  
Vol 415-417 ◽  
pp. 1140-1146 ◽  
Author(s):  
R. Palanivel ◽  
P. Koshy Mathews ◽  
M. Balakrishnan ◽  
I. Dinaharan ◽  
N. Murugan
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Axial Force ◽  
Aluminium Alloys ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir ◽  
Tool Pin Profile ◽  
Dissimilar Aluminum Alloys ◽  
Tool Pin

Aluminium alloys generally has low weldability by traditional fusion welding process. The development of the Friction Stir Welding (FSW) has provided an alternative improved way of producing aluminium joints, in a faster and reliable manner. FSW process has several advantages, in particular the possibility to weld dissimilar aluminium alloys. This study focuses on the behavior of tensile strength of dissimilar joints of AA6351-T6 alloy to AA5083-H111 alloy produced by friction stir welding was analysed. Five different tool pin profile such as Straight Square (SS), Tapered Square (TS), Straight Hexagon (SH), Straight Octagon (SO) and Tapered Octagon (TO) with three different axial force (1tonne, 1.5tonne, 2 tonne) have been used to weld the joints. The effect of pin profiles and axial force on tensile properties and material flow behaviour of the joint was analyzed and it was found that the straight square pin profile with 1.5 tonne produced better tensile strength then other tool pin profile and axial force.

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.

Tensile Properties and Microstructure of Friction Stir Welded Joints 2195-T8 Aluminum Alloy

2016 ◽  
Vol 835 ◽  
pp. 191-196 ◽  
Author(s):  
Kookil No ◽  
Ye Rim Lee ◽  
Jong Hoon Yoon ◽  
Joon Tae Yoo ◽  
Ho Sung Lee
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Process ◽  
Tensile Tests ◽  
Fusion Welding ◽  
Homogeneous Microstructure ◽  
Rotating Speed ◽  
Friction Stir ◽  
Reactive Property

Friction stir welding is a widely used welding process for aluminum alloys because it avoids many of the problems of conventional fusion welding. This process is beneficial especially for lithium containing aluminum alloys in which the reactive property of element Li causes porosity and hot cracking during melting and solidification. In friction stir welding process, each region undergoes different thermo-mechanical cycles and produces a non-homogeneous microstructure. In the present study, the mechanical properties and microstructure of a 2195-T8 aluminum alloy joined with friction stir welding were investigated. The change in microstructure across the welded joint was found to correspond to microhardness measurement. The microstructure was characterized by the presence of severely deformed grains and fine recrystallized grains depending on the region. Tensile tests shows the optimum condition was obtained at the tool rotating speed of 600rpm and the traveling speed range from 180 to 300mm/min.

Effect of Pre and Post Weld Heat Treatment on the Mechanical Properties of Friction Stir Welded AA6061-T6 Joint

2020 ◽  
Vol 17 (2) ◽  
pp. 7882-7889 ◽  
Author(s):  
J.C. Verduzco Huarez ◽  
R. Garcia Hernandez ◽  
G. M. Dominguez Almaraz ◽  
J.J. Villalón López
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Research Work ◽  
Base Material ◽  
Welding Process ◽  
Post Weld Heat Treatment ◽  
Friction Stir

This research work focuses on the study of the improvement of mechanical properties, specifically the tensile strength of 6061-T6 aluminum alloy on prismatic specimens with 9.5 mm thickness that has been subjected to friction stir welding process and two heat treatments; solubilized and aging before or after the welding process. Three cases studied and evaluated were, welding of the base material without heat treatment (BMW), solubilized heat treatment and partial aging of the base material before welding (HTBW), and heat treatment of solubilized and aging of the base material after welding (HTAW). The obtained results show an increase of about 10% (20 MPa) of tensile strength for the HTBW process, compared to BMW case. In addition, for the case of HTAW, the obtained tensile resistance presents a joint efficiency of 96%, which is close to the tensile strength of the base material (»310 MPa).

scholarly journals An Integrated Effect of Parameters on Mechanical Properties of Friction Stir Welded Dissimilar Aluminum Alloys

2020 ◽  
Vol 8 (5) ◽  
pp. 236-244
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Tensile Properties ◽  
Welding Process ◽  
Industrial Applications ◽  
Response Surfaces ◽  
Percentage Error ◽  
Design Matrix ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Welding has been the essence of the joining processes in various industrial and domestic applications. Friction Stir Welding has emerged as a potential solid-state welding process and has been used to weld two dissimilar Aluminum alloys AA 5083 O and AA 6082 T651. Generation of an empirical model for prior prediction of tensile properties from four prominent factors of Friction Stir Welding has been done. Four factors selected are tool rotation speed, tool transverse speed, tool tilt angle and square-shaped pin size. Tensile properties have been optimized using multivariable optimization. The relative impact of various factors on the tensile properties has been analyzed. Friction Stir Welding has been performed based on Response Surface Methodology and the design matrix was generated using Central composite rotatable design which includes five levels with 31 runs. The efficacy of the empirical models has been tested with Analysis of Variance and models generated were found accurate to predict the responses up to 95%. The response surfaces and contour plots of the input and response variables were generated and analyzed. The confirmatory run for the optimum values was performed with a percentage error of less than 3 percent. This paper may be useful in various industrial applications and an enhanced understanding of Friction Stir Welding.

scholarly journals Basic Tool Design Guidelines for Friction Stir Welding of Aluminum Alloys

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 2042
Author(s):  
Elizabeth Hoyos ◽  
María Camila Serna
Keyword(s):  
Friction Stir Welding ◽  
Solid State ◽  
Aluminum Alloys ◽  
Welding Process ◽  
Design Guidelines ◽  
Fusion Welding ◽  
Basic Tool ◽  
Friction Stir ◽  
Shoulder Diameter ◽  
Welding Consumables

Friction Stir Welding (FSW) is a solid-state welding process that has multiple advantages over fusion welding. The design of tools for the FSW process is a factor of interest, considering its fundamental role in obtaining sound welds. There are some commercially available alternatives for FSW tools, but unlike conventional fusion welding consumables, their use is limited to very specific conditions. In this work, equations to act as guidelines in the design process for FSW tools are proposed for the 2XXX, 5XXX, 6XXX, and 7XXX aluminum series and any given thickness to determine: pin length, pin diameter, and shoulder diameter. Over 80 sources and 200 tests were used and detailed to generate these expressions. As a verification approach, successful welds by authors outside the scope of the original review and the tools used were evaluated under this development and used as case studies or verification for the guidelines. Variations between designs made using the guidelines and those reported by other researchers remain under 21%.

scholarly journals Effect of Tool Pin Profile and Friction Stir Welding Speed on Tensile & Hardness Properties of Friction Stir Welded Joints of AA6082 & A319 Aluminium Alloy

2019 ◽  
Vol 8 (12) ◽  
pp. 2703-2706
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminium Alloys ◽  
Welding Process ◽  
Fusion Welding ◽  
Friction Stir ◽  
Joint Properties ◽  
Tool Profile ◽  
Tool Pin ◽  
Tool Profiles

Fusion welding of aluminium alloys results in solidification cracking, porosity etc. which affects the properties of the weldment. FSW which is broadly used in welding of aluminium alloys. It overcomes the defects of fusion welding process in improving the properties of the joints. The current paper focus on studying the tensile properties of the disparate FSW of aluminium alloys AA6082 and A319 .Three dissimilar tool profiles (square, hexagonal and cylindrical) with three welding speeds (25, 30, 35 mm/min) and three tool rotational speeds (800, 1000 and 1300 rpm) have been used in studying the joint properties of the weld. Higher tensile strength was obtained for the parameters of square tool profile, 30 mm/min and 1300 rpm.

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．

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