Friction Stir Blind Riveting for Dissimilar Cast MG AM60 and Al Alloy Sheets

2014 ◽  
Author(s):  
Junying Min ◽  
Jingjing Li ◽  
Weiming Wang ◽  
Blair E. Carlson ◽  
Yongqiang Li ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Joint Strength ◽  
Tensile Load ◽  
Frictional Heat ◽  
Process Window ◽  
Al Alloy ◽  
Dissimilar Metals ◽  
Friction Stir ◽  
Lap Shear ◽  
Process Material

A new one-sided joining method, friction stirring blind riveting (FSBR) was successfully implemented to form lap-shear joints for dissimilar metals from pairs of 3.05mm thick cast Mg AM60, rolled 1.5mm thick Al AA6022 and extruded 3.15mm thick Al AA6082 specimens. The concept of this process is riveting the two workpieces with reduced force under frictional heat and fastening the workpieces through blind riveting once the rivet is fully inserted. In this research the process was experimentally analyzed and optimized for four joint combinations. It was demonstrated that switching the positions of Mg and Al alloy specimens has a significant effect on the process window and maximum tensile load of the joints. Three quality issues of the FSBR joints were observed and discussed. The mechanisms associated with joint strength were discussed and explain the effects of FSBR process, material matching and sheet position on the joint tensile strength.

Friction Stir Blind Riveting for Joining Dissimilar Cast Mg AM60 and Al Alloy Sheets

2015 ◽  
Vol 137 (5) ◽  
Author(s):  
Junying Min ◽  
Jingjing Li ◽  
Blair E. Carlson ◽  
Yongqiang Li ◽  
James F. Quinn ◽  
...  
Keyword(s):  
Loading Condition ◽  
Tensile Load ◽  
Strengthening Mechanism ◽  
Frictional Heat ◽  
Process Window ◽  
Al Alloy ◽  
Forming Process ◽  
Friction Stir ◽  
Lap Shear ◽  
Riveting Process

A new one-sided joining method, friction stirring blind riveting (FSBR) was successfully implemented to form lap-shear joints for dissimilar metals from pairs of 3.05 mm thick cast Mg AM60, rolled 1.5 mm thick Al AA6022, and extruded 3.15 mm thick Al AA6082 specimens. The concept of this process is riveting the two workpieces with reduced force under frictional heat and fastening the workpieces through blind riveting once the rivet is fully inserted. In this research, the process was experimentally analyzed and optimized for four joint combinations. It was demonstrated that switching the positions of Mg and Al alloy specimens has a significant effect on the process window and maximum tensile load of the joints. Three quality issues of the FSBR joints were observed and discussed. During tensile testing, the sheet closer to the rivet tail work-hardens due to tail forming process but has worse loading condition than the sheet closer to the rivet head. For AA6xxx sheets, precipitate hardening due to frictional heat is another strengthening mechanism in FSBR compared to the conventional riveting process, which leads to higher tensile loads in FSBR joints.

Friction Stir Welding between Dissimilar Metalswith Circular Weld Line

2014 ◽  
Vol 622-623 ◽  
pp. 501-507
Author(s):  
Masahiro Fukumoto ◽  
Hiroki Mizushima ◽  
Toshiaki Yasui
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
High Performance ◽  
Weld Line ◽  
Hybrid Structure ◽  
Light Metal ◽  
Al Alloy ◽  
Dissimilar Metals ◽  
Bottom Part ◽  
Friction Stir

Hybrid metallic structure, which is composed of aluminum alloy as a representative of light metal and steel as that of high strength metal, has been paid attention remarkably in these days, especially in the transportation vehicle industry from the energy saving viewpoint. To perform the hybrid structure, friction stir welding FSW has been recognized to be an effective way for the welding between dissimilar metals, like between steel and Al alloy. Based on our previous findings on the butt welding between dissimilar metals with straight weld line, welding between dissimilar metals with circular weld line has been tried to open a new application field of FSW. The objective of this research is to get a fundamental finding on the welding between dissimilar metals with circular weld line and to clarify the effect of material character of Al alloy and tool design on the FSW between dissimilar metals. Typical results obtained in this study are summarized as follows: 1) Macroscopic defects often observed at the bottom part of the welding in case of ADC12 material. It indicates that insufficient stirring was given in the stirring zone due to the higher thermo-mechanical property of ADC12. 2) Tensile strength of the specimen welded with scroll shoulder tool was 266 MPa, while that with flat shoulder tool was 161 MPa. Tensile strength of the weld joint was improved by a factor of 1.65 by introducing the scroll onto the tool shoulder with normal thread probe. 3) High performance defect free ADC12/S45C weld structure with circular weld line could be fabricated by the tool with combination of scroll shoulder and thread probe.

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.

scholarly journals Investigation on the Tensile Strength of the Friction Stir Welded similar joint of Al/Al alloy using high thermal diffusivity backing plate material.

2018 ◽  
Vol 8 (2) ◽  
Author(s):  
Akshansh Mishra ◽  
Abhishek Kumar Sharma ◽  
Hardik Kapoor ◽  
Jaspreet Singh ◽  
Krishna Kumar
Keyword(s):  
Tensile Strength ◽  
Thermal Diffusivity ◽  
Welding Process ◽  
Soft Materials ◽  
Work Piece ◽  
Al Alloy ◽  
Plate Material ◽  
Friction Stir ◽  
Backing Plate ◽  
High Thermal Diffusivity

Friction Stir Welding process is a novel green solid state joining process for soft materials such as aluminium alloys. The weld quality is governed by the proper selection of parameters such as forge force rotational speed of the tool, welding speed, backing plate material etc. Thermal boundary condition at the bottom of the work piece plays an important role for obtaining the sound joint. The backing plate material governs these thermal conditions. In this case study, high thermal diffusivity backing plate material which consisted of AA2099 was used for joining of the plates of Structural Aluminium alloy. It was observed that the tensile strength was improved.

Joint Strength and its Improvement of Friction Welded Joint Between Ductile Cast Iron and 5052 Al Alloy

2020 ◽  
Author(s):  
Masaaki Kimura ◽  
Akira Yoneda ◽  
Masahiro Kusaka ◽  
Koichi Kaizu ◽  
Kazuhiro Hayashida ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Cast Iron ◽  
Base Metal ◽  
Joint Strength ◽  
Welded Joint ◽  
Weld Interface ◽  
Ductile Cast Iron ◽  
Al Alloy ◽  
High Tensile Strength ◽  
Graphite Particles

Abstract To obtain dissimilar joint for easily making multi-material structures, the characteristics of friction welded joint between ductile cast iron (FCD400) and 5052 Al alloy (A5052) was investigated. The relatively high tensile strength of joint was obtained when that was made with a friction speed of 27.5 s−1, a friction pressure of 20 MPa, a friction time of 1.5 s, and a forge pressure of 270 MPa, respectively. However, this joint had approximately 77% in the tensile strength of the A5052 base metal and that was fractured at the weld interface. Although the weld interface had no intermetallic compound layer, the fractured surface at the A5052 side had some graphite particles that were supplied from the FCD400 side. To improve the joint strength, the graphite particles were reduced from the weld faying surface at the FCD400 side by decarburization treatment. The joint had approximately 96% in the tensile strength of the A5052 base metal and that was fractured between the A5052 side and the weld interface. The joint with high tensile strength as well as the possibility improving the fractured point of that were obtained when those were made with opportune friction welding condition and no graphite particles at the weld faying surface of the FCD400 side.

Joint Characteristics of Spot Friction Stir Welded 5052 Al Alloy Sheet

2006 ◽  
Vol 15-17 ◽  
pp. 345-350 ◽  
Author(s):  
Chang Yong Lee ◽  
Won Bae Lee ◽  
Yun Mo Yeon ◽  
Keun Song ◽  
Jeong Hoon Moon ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fracture Mode ◽  
Shear Fracture ◽  
Alloy Sheet ◽  
Al Alloy ◽  
Shear Load ◽  
Insertion Depth ◽  
Friction Stir ◽  
Lap Shear ◽  
Joint Characteristics

The microstructure and mechanical properties of spot friction stir welded A 5052 alloy were investigated with insertion depth of welding tool. As the insertion depth of welding tool increased, the size of stirring zone increased and the thickness of upper sheet decreased. The value of shear load was the lowest at the shallowest insertion depth and increased to the highest value of 3.35 kN at a 1.6mm of insertion depth. An increase in the pin insertion depth beyond 1.6mm did not result in further increase in the lap shear load. Spot friction stir welded joints showed shear fracture mode at shallower insertion depths and fracture mode changed to plug fracture mode as the insertion depth was deeper.

Effect of Welding Speed on Mechanical Properties of Friction Stir Welded AA 6082-T6 Al Alloy

2018 ◽  
Vol 877 ◽  
pp. 98-103
Author(s):  
Dhananjayulu Avula ◽  
D.K. Dwivedi
Keyword(s):  
Tensile Strength ◽  
Welding Speed ◽  
Welded Joint ◽  
Al Alloy ◽  
Microstructural Properties ◽  
Nugget Zone ◽  
Percentage Elongation ◽  
Friction Stir ◽  
Mechanical And Microstructural Properties ◽  
Hardness Values

In this study the effect of process parameters on mechanical and microstructural properties of similar AA6082-T6 joints produced by friction stir welding was investigated. Different samples were produced by varying the transverse welding speeds of the tool from 19 to 75 mm/min and a fixed rotational speed of 635 rpm. A more uniform hardness values in the nugget zone were observed at 48 mm/min welding speed. The lowest hardness values were recorded on nugget zone at all the welding speeds. The increase in welding speed increases ultimate tensile strength and reaches maximum and further increase in welding speed results decrease in tensile strength were observed. The welded joint has highest joint efficiency (52.33 %) obtained at the welding speed of 48 mm/min. Similarly with the increase in welding speed decrease in the percentage elongation were recorded.

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