Friction Stir Welding of Dissimilar AA7075-T6 to AZ31B-H24 Alloys

MRS Advances ◽  
2017 ◽  
Vol 2 (64) ◽  
pp. 4055-4063 ◽  
Author(s):  
D. Hernández-García ◽  
R. Saldaña-Garcés ◽  
F. García-Vázquez ◽  
E.J. Gutiérrez-Castañeda ◽  
R. Deaquino-Lara ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Joint Line ◽  
Friction Stir ◽  
Tool Offset ◽  
Tool Tilt Angle

AbstractIn the present investigation, AA7075-T6 alloys and AZ31B-H24 were joined by the FSW process using the following range of parameters: rotational speed between 200 and 800 rpm, welding speed from 30 to 60 mm/min and a tilt angle from 1° to 3°. In some cases, a tool offset of 1 mm was used into Mg-based alloy. The experimental results show that sound and good joints can be obtained by positioning the tool in the middle of the joint-line using a rotational speed of 200 rpm, a welding speed of 30 mm/min and a tool tilt angle of 1°. The hardness and ultimate tensile strength in the stir zone were 122 Hv and 61.35 MPa, respectively. Also, it is important to mention that the Al3Mg2 and Al12Mg17 intermetallics compounds were observed in the this zone besides some defects like cavities and tunnel.

scholarly journals Friction Stir Welding of Dissimilar AA6061-T6 to AZ31B-H24 Alloys

2020 ◽  
Vol 25 ◽  
Author(s):  
Rocio Saldaña-Garcés ◽  
Daniela Hernández-García ◽  
Felipe García-Vázquez ◽  
Emmanuel José Gutiérrez-Castañeda ◽  
David Verdera ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Workpiece Material ◽  
Friction Stir ◽  
Tool Offset ◽  
Dissimilar Welds ◽  
Aluminum And Magnesium Alloys ◽  
Solid State Joining

Abstract: Friction Stir Welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material. FSW is predominantly used for welding lightweight materials such as aluminum and magnesium alloys. In the present investigation, AA6061-T6 and AZ31B-H24 alloys were joined by FSW using the following parameters: rotational speed of 400, 800, 1200 and 1600 rpm, welding speed of 30 and 60 mm/min and tilt angle of 1° and 3°. In some cases, a tool offset of 1 mm was used into the Mg-based alloy. Microstructural characteristics of the weld joints were analyzed by optical microscopy and scanning electron microscopy. The experimental results show that dissimilar welds can be obtained by placing the AA6061-T6 alloy on the advancing side under two processing conditions: i) without a tool offset using a welding speed of 30 mm/min, a rotational speed of 400 rpm and a tilt angle of 1° (M7) and ii) with a tool offset and a welding speed of 30 mm/min, using a rotational speed of 1200 rpm and a tilt angle of 3° (M3). Al3Mg2 and Al12Mg17 intermetallic compounds were observed in the stir zone. Hardness and tensile strength of joints M7 varied from 76 to 129 HV, and 88.2 MPa respectively, and these properties varied from 95 to 153 HV, and 18.95 MPa in joints M3.

Procedure to find out the optimal ranges of process parameters for friction stir welding

2021 ◽  
pp. 146442072199314
Author(s):  
Shubham Verma ◽  
Joy Prakash Misra ◽  
Meenu Gupta
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Optical Microscope ◽  
Graphical Analysis ◽  
Friction Stir ◽  
Steepest Ascent ◽  
Vertical Milling Machine

The present study deals with the application of sequential procedure (i.e. steepest ascent) to obtain the optimum values of process parameters for conducting friction stir welding (FSW) experiments. A vertical milling machine is modified by fabricating fixture and tool ( H13 material) for performing FSW operation to join AA7039 plates. The steepest ascent technique is employed to design the experiments at different rotational speed, welding speed, and tilt angle. The ultimate tensile strength is considered as a performance characteristic for deciding the optimal levels. The mechanical and metallurgical characteristics of the joints are studied by executing tensile and microhardness tests. It is concluded from the graphical analysis of the steepest ascent technique that the optimal maximum and minimum values are 1812–1325 r/min for rotational speed, 43–26 mm/min for welding speed, and 2°–1.3° for tilt angle, respectively. Besides, optical microscope and scanning electron microscope are utilized for microstructural and fractographic analyses for a better understanding of the process.

Process Parameters Optimization of Friction Stir Welding in Aluminium Alloy 6063-T6 by Taguchi Method

2017 ◽  
Vol 867 ◽  
pp. 97-104 ◽  
Author(s):  
T. Ganapathy ◽  
K. Lenin ◽  
K. Pannerselvam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Taguchi Method ◽  
Axial Force ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Process Parameter ◽  
Main Process ◽  
Friction Stir

This paper deals with the effective application of friction stir welding similar to butt joining technique.AL6063 T-6 alloys prepared in 125x 100 x 7mm thickness plate and FSW tool setup were H13 of diameter 25mm rotary tool with straight cylindrical pin profile. The maximum strength was considered for selection of combined process parameter. The process parameters were optimized using Taguchi method. The Rotational speed, welding speed, and axial speed are the main process parameter which taken into our consideration. The optimum process parameters are determined with reference to tensile strength of the joint. From the experiments, it was found the effects of welding parameter are the axial force is highest substantial parameter to determining the tensile strength of the joint. The paper which revealed the optimal values of process parameter are to acquire a maximum tensile strength of friction stir welded AL6063-T6 plates is 101.6Mpa with the combination level of rotational speed, welding speed and axial force are found to be 1100 RPM, 60 mm/min and 12.5 KN. validation test was carried out and results were nearer to the optimized results confirmed by the optimum results.

scholarly journals Combined Response Surface Method and Modified Differential Evolution for Parameter Optimization of Friction Stir Welding

Processes ◽  
2020 ◽  
Vol 8 (9) ◽  
pp. 1080
Author(s):  
Thanatkij Srichok ◽  
Rapeepan Pitakaso ◽  
Kanchana Sethanan ◽  
Worapot Sirirak ◽  
Parama Kwangmuang
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Ultimate Tensile Strength ◽  
Differential Evolution ◽  
Welding Speed ◽  
Tool Material ◽  
Optimal Parameters ◽  
Friction Stir ◽  
Surface Method ◽  
Tool Pin

In this study, we constructed a new algorithm to determine the optimal parameters for friction stir welding including rotational speed, welding speed, axial force, tool pin profile, and tool material. The objective of welding is to maximize the ultimate tensile strength of the welded aluminum. The proposed method combines the response surface method and the modified differential evolution algorithm (RSM-MDE). RSM-MDE is a method that involves both experimental and simulation procedures. It is composed of four steps: (1) finding the number of parameters and their levels that affect the efficiency of the friction stir welding, (2) using RSM to formulate the regression model, (3) using the MDE algorithm to find the optimal parameter of the regression model obtained from (2), and (4) verifying the results obtained from step (3). The optimal parameters generated by the RSM-MDE method were a rotation speed of 1417.68 rpm, a welding speed of 60.21 mm/min, an axial force of 8.44 kN, a hexagon-tapered tool pin profile, and the SKD 11 tool material. The ultimate tensile strength obtained from this set of parameters was 294.84 MPa, which was better than that of the RSM by 1.48%.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
Anganan K ◽  
Narendran RJ ◽  
Naveen Prabhu N ◽  
Rahul Varma R ◽  
Sivasubramaniyam R
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

scholarly journals Modeling and Optimization of Bobbin Friction Stir Welding for AA6061-T6 alloy Utilizing Response Surface Methodology

2018 ◽  
Vol 26 (4) ◽  
pp. 1-17
Author(s):  
Samir Ali Amin ◽  
Mohannad Yousif Hanna ◽  
Alhamza Farooq Mohamed
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Rotational Speed ◽  
Welded Joint ◽  
Welding Parameters ◽  
Friction Stir ◽  
Bending Force ◽  
Speed Range

Bobbin friction stir welding (BFSW) is special kind of friction stir welding. This investigation aims to develop empirical models through mathematical relationships between the welding process parameters and mechanical properties of Aluminum alloy AA6061-T6 welded joint created by using bobbin tool and to find the optimum welding parameters. The welding speed range (40-200 mm/min) and rotational speed range (340-930 rpm) were utilized (as the used input factors) to find their effects on elongation, tensile strength and maximum bending force as the main responses.  These models were built using Design of Experiment (DOE) software ‘version 10’ with Response Surface Methodology (RSM) technique. The models adequacy were tested via the (ANOVA) analysis. The obtained models appeared that as the welding speed or rotational speed increases, the elongation, tensile strength and maximum bending force of the welded joint firstly rise to a maximum value and then drop. The optimum welding parameters were rotational speed (623.949 rpm) and welding speed (128.795 mm/min) with (6.33%), (204 MPa) and (6.216 KN) of elongation, tensile strength and maximum bending force, respectively. A proper harmonization was obtained between the models predicted results and the optimized ones with actual trial with 95% level of confidence.

Optimization and Mechanical Characterization of AA5083 and AA7075 Dissimilar Aluminium Alloy Joints Produced by Friction Stir Welding

2021 ◽  
Vol 13 (3) ◽  
Author(s):  
S. Rajeshkannan ◽  
M. Vigneshkumar ◽  
V. Gopal ◽  
S. Ramesh
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Axial Force ◽  
Welding Speed ◽  
Rotational Speed ◽  
Frictional Heat ◽  
Friction Stir ◽  
Welding Method ◽  
The Impact

In this research work the aluminium alloys including AA7075 and AA5083 are combined with friction stir welding method. This contrasts with factors such as alloy segregation, hot cracking and porosity which result from fusion welding process in the welded area. In order to generate high quality joint of aluminium alloy, friction-stir welding (FSW) an assuring welding method is followed. To achieve the determined strength, an entire control over the relevant process is needed to increase the tensile vitality. The welding factors like welding speed (WS), axial force (AF) and rotational speed (RS) are examined for optimisation. In order to measure the impact of the factors on tensile strength of FS welded joints, Taguchi L9 orthogonal array technique is employed. The amount of involvement of these factors on weld quality is determined by means of analysis of variance (ANOVA). The utmost ultimate tensile strength (UTS) attained for AA7075 and AA5083 joint is 256MPa. ANOVA results show that the quality-wise effectiveness of the weld as welding speed (5.48percent), axial force (15.18percent), then the rotational speed (79.32percent). This is due to the presence of fine equiaxed grains in the microstructures of the stir zones at different FS welding circumstances. However, a decrease in the grain size of the process zone is observed when the frictional heat flow is decreased while friction-stir welding.

Experimental Analysis on Mechanical Properties of Friction Stir Welding in Dissimilar Aluminum Alloys

2020 ◽  
pp. 64-68
Author(s):  
K. Anganan ◽  
R.J . Narendran ◽  
N Naveen Prabhu ◽  
R Rahul Varma ◽  
R Sivasubramaniyam
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Speed ◽  
Rotational Speed ◽  
Copper Alloys ◽  
Welding Parameters ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

Friction stir welding (FSW) is an innovative solid state joining technique and has been employed in industries for joining aluminum, magnesium, zinc and copper alloys. The FSW process parameters such as tool, rotational speed, welding speed, axial force, etc play major role in deciding the weld quality. A mathematical modeling was developed based on experiments to predict the tensile strength of dissimilar FSW aluminum alloys. The maximum tensile strength of 210 MPa can be obtained at the tool rotational speed of 1100 rpm, welding speed of 35mm/min and an axial load of 7 kN is the Optimum welding parameters.

Effect of Tool Tilt Angle and Tool Plunge Depth on Mechanical Properties of Friction Stir Welded AA 5083 Joints

2014 ◽  
Vol 493 ◽  
pp. 709-714 ◽  
Author(s):  
Nurul Muhayat ◽  
Achmad Zubaydi ◽  
Sulistijono ◽  
M. Zaed Yuliadi
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Tilt Angle ◽  
Welding Speed ◽  
Tensile Testing ◽  
Welding Temperature ◽  
Plunge Depth ◽  
Friction Stir ◽  
Hole Defect ◽  
Tool Tilt Angle

The influences of tool tilt angle and tool plunge depth on tensile properties of friction stir welded AA 5083-H116 with the thickness of 4 mm were studied. Four different values of tool tilt angle of 1΀ 2°, 3°, and 4° were used to fabricate the joints. The tool plunge depths were choosen 3.85 mm, 3.90 mm and 3.95 mm. The FSW rotational speed and welding speed were 1125 rpm and 30 mm/min, respectively. The temperature, macrostructure, hardness and tensile strength of joints were compared and discussed. Results show that the increase of tool tilt angle and tool plunge depth resulted the welding temperature increase. Due to the increase of welding temperature, the hole defect become smaller. Tensile testing results indicated that the tensile strength of joints increased with increasing both the tool tilt angle and tool plunge depth.

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