scholarly journals Dissimilar Friction Stir Welding of AA2024 and AISI 1018: Microstructure and Mechanical Properties

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 330
Author(s):  
Mohamed M. Z. Ahmed ◽  
Nabil Jouini ◽  
Bandar Alzahrani ◽  
Mohamed M. El-Sayed Seleman ◽  
Mohammad Jhaheen
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Cross Section ◽  
Heat Input ◽  
Rotation Rate ◽  
Rotation Speed ◽  
Transverse Cross Section ◽  
Traverse Speed ◽  
Friction Stir

This study investigated the effect of the friction stir welding rotation rate and welding speed on the quality and properties of the dissimilar joints between aluminum and carbon steel. Plates of 4 mm thickness from both AA2024 and AISI 1018 were successfully friction stir butt welded at rotation speeds of 200, 250, and 300 rpm and welding speeds of 25, 50, and 75 mm/min. The joint quality was investigated along the top surface and the transverse cross-sections. Further investigation using scanning electron microscopy was conducted to assess the intermetallic layers and the grain refining in the stir zone. The mechanical properties were investigated using tensile testing for two samples for each weld that wire cut perpendicular to the welding direction and the hardness profiles were obtained along the transverse cross-section. Both the top surface and the transverse cross-section macrographs indicated defect free joints at a rotation rate of 250 rpm with the different welding speeds. The intermetallic compounds (IMCs) formation was significantly affected by the heat input, where there is no formation of IMCs at the Al/steel interfaces when higher traverse speed (75 mm/min) or lower rotation speed (200 rpm) were used, which gave the maximum tensile strength of about 230 MPa at the low rotation speed (200 rpm) along with 3.2% elongation. This is attributed to the low amount of heat input (22.32 J/mm) experienced. At the low traverse speed (25 mm/min and 250 rpm), a continuous layer of Al-rich IMCs FeAl3 is formed at the joint interface due to the high heat input experienced (79.5 J/mm). The formation of the IMCs facilitates fracture and reduced the tensile strength of the joint to about 98 MPa. The fracture mechanism was found to be of mixed mode and characterized by a cleavage pattern and dimples. The hardness profiles indicated a reduction in the hardness at the aluminum side and an increase at the steel side.

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.

The Effect of Top Surface Lubrication on the Friction Stir Welding of Polycarbonate Sheets

2021 ◽  
Vol 36 (1) ◽  
pp. 94-102
Author(s):  
M. M. Z. Ahmed ◽  
A. Elnaml ◽  
M. Shazly ◽  
M. M. El-Sayed Seleman
Keyword(s):  
Tensile Strength ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Transverse Cross Section ◽  
Joint Zone ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter ◽  
Fsw Parameters ◽  
Spherulitic Structure

Abstract In this work, top surface lubrication during friction stir welding of polycarbonate sheets was applied. A homogenous layer of Paraffin wax has been placed on the top surface of the joint area with a width that ensures to cover the shoulder diameter. Then FSW was applied using conventional FSW tool with rotating pin and shoulder at different FSW parameters (Rotation speeds of 1 000, 1500, 2 000 min–1 and welding speeds of 25, 50, 75,100 mm/min). The main objective of using the wax is to act as a lubricant that reduces the friction between the shoulder and the polycarbonate surface. The joints produced were investigated in terms of surface quality, internal defects, and mechanical properties. During FSW the wax is melted and played as lubricant between the tool shoulder and the polycarbonate surface and resulted in defect-free surface with no thickness reduction of the original plate. The transverse cross-section showed defect-free joints for the majority of the FSW parameters investigated. Tensile testing results showed a reduction of the tensile strength after FSW, and an enhancement in the tensile strength with the increase of welding speed or rotation speed. The fracture occurs at the joint zone and the fracture surface investigation using SEM showed the existence of spherulitic structure in the weld joint.

Microstructure and Mechanical Properties of Friction Stir Welded Annealed Pure Copper Joints

2013 ◽  
Vol 787 ◽  
pp. 346-351
Author(s):  
Salar Salahi ◽  
Vahid Rezazadeh ◽  
Atabak Iranizad ◽  
Ali Hosseinzadeh ◽  
Amir Safari
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Welding Speed ◽  
Heat Input ◽  
Applied Load ◽  
Rotation Speed ◽  
Pure Copper ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

As a novel technique for joining materials, friction stir welding (FSW) has significant advantages over the conventional welding methods and is widely applied for joining different materials including aluminum, magnesium and copper alloys. In this research, the mechanical and microstructural characteristics of friction stir welded annealed pure copper joints were investigated. The influence of the tool rotation speed, welding speed and applied load was studied. The friction stir welding (FSW) was conducted at welding speed ranged from 30 to 70 mm/ min, rotation speed ranged from 400 to 1200rpm and applied load ranged from 1000 to 1500 kg. After welding process, tensile and Vickers hardness tests were performed. It has been found that increasing the tool rotational speed and/or reducing the welding speed increases heat input and causes grain coarsening in stir zone. High applied load refines the microstructure of NZ and increases the hardness and tensile strength of NZ. An optimum heat input condition was found to reach the best mechanical properties of the joints. The tensile characteristics of the friction stir welded tensile samples depend significantly on the tool rotation speed ,welding speed and applied load.

Microstructure and Mechanical Properties of Cu-Cr-Zr Alloy by Friction Stir Welding

2012 ◽  
Vol 602-604 ◽  
pp. 608-611
Author(s):  
Di Qiu He ◽  
Rui Lin Lai ◽  
Shao Hua Xu ◽  
Kun Yu Yang ◽  
Shao Yong Ye ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Base Material ◽  
Traverse Speed ◽  
Nugget Zone ◽  
Alloy Plate ◽  
Friction Stir ◽  
Microstructure And Mechanical Properties ◽  
Zr Alloy

In this study, Cu-Cr-Zr alloy joints are successfully fabricated by friction stir welding (FSW). Defect-free weld are produced on 12mm thick Cu-Cr-Zr alloy plate useing a non-consumable tool with a specially designed and shoulder with a constant rotation speed and a fixed traverse speed. The effect of friction stir welding (FSW) on the microstructure and mechanical properties of Cu-Cr-Zr alloy joints are investigated in details: The joints showed the presence of various zones such as nugget zone (NZ) and thermo-mechanically affected zone (TMAZ) and base metal (BM), the microhardness and the tensile strength of welded joints are lower than that of the base material.

scholarly journals Effect of Friction Stir Welding Parameters on the Microstructure and Mechanical Properties of AA2024-T4 Aluminum Alloy

2018 ◽  
Vol 8 (1) ◽  
pp. 2493-2498 ◽  
Author(s):  
A. W. El-Morsy ◽  
M. Ghanem ◽  
H. Bahaitham
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Cross Section ◽  
High Performance ◽  
Traverse Speed ◽  
Butt Joint ◽  
Welding Parameters ◽  
Friction Stir

In this work, the effects of rotational and traverse speeds on the 1.5 mm butt joint performance of friction stir welded 2024-T4 aluminum alloy sheets have been investigated. Five rotational speeds ranging from 560 to 1800 rpm and five traverse speeds ranging from 11 to 45 mm/min have been employed. The characterization of microstructure and the mechanical properties (tensile, microhardness, and bending) of the welded sheets have been studied. The results reveal that by varying the welding parameters, almost sound joints and high performance welded joints can be successfully produced at the rotational speeds of 900 rpm and 700 rpm and the traverse speed of 35 mm/min. The maximum welding performance of joints is found to be 86.3% with 900 rpm rotational speed and 35 mm/min traverse speed. The microhardness values along the cross-section of the joints show a dramatic drop in the stir zone where the lowest value reached is about 63% of the base metal due to the softening of the welded zone caused by the heat input during joining.

scholarly journals Effect of Stirring Pin Rotation Speed on Microstructure and Mechanical Properties of 2A14-T4 Alloy T-Joints Produced by Stationary Shoulder Friction Stir Welding

Materials ◽  
2021 ◽  
Vol 14 (8) ◽  
pp. 1938
Author(s):  
Haifeng Yang ◽  
Hongyun Zhao ◽  
Xinxin Xu ◽  
Li Zhou ◽  
Huihui Zhao ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Weld Nugget ◽  
Al Alloy ◽  
Nugget Zone ◽  
T Joints ◽  
Friction Stir ◽  
Stationary Shoulder ◽  
Microstructure And Mechanical Properties

In this study, 2A14-T4 Al-alloy T-joints were prepared via stationary shoulder friction stir welding (SSFSW) technology where the stirring pin’s rotation speed was set as different values. In combination with the numerical simulation results, the macro-forming, microstructure, and mechanical properties of the joints under different welding conditions were analyzed. The results show that the thermal cycle curves in the SSFSW process are featured by a steep climb and slow decreasing variation trends. As the stirring pin’s rotation speed increased, the grooves on the weld surface became more obvious. The base and rib plates exhibit W- or N-shaped hardness distribution patterns. The hardness of the weld nugget zone (WNZ) was high but was lower than that of the base material. The second weld’s annealing effect contributed to the precipitation and coarsening of the precipitated phase in the first weld nugget zone (WNZ1). The hardness of the heat affect zone (HAZ) in the vicinity of the thermo-mechanically affected zone (TMAZ) dropped to the minimum. As the stirring pin's rotation speed increased, the tensile strengths of the base and rib plates first increased and then dropped. The base and rib plates exhibited ductile and brittle/ductile fracture patterns, respectively.

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．

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.

Effect of Al2O3 nanoparticles on microstructure and mechanical properties of friction stir-welded dissimilar aluminum alloys AA7075-T6 and AA6061-T6

2021 ◽  
pp. 095440892110655
Author(s):  
Sumit Jain ◽  
R.S. Mishra
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Particle Dispersion ◽  
Al2o3 Nanoparticles ◽  
Tool Rotational Speed ◽  
Micro Hardness ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys

In this research, a defect-free dissimilar weld joint of AA7075-T6 and AA6061-T6 reinforced with Al2O3 nanoparticles was fabricated via friction stir welding (FSW). The influence of tool rotational speed (700, 900 and 1100 rpm), traverse speed (40, 50 and 60 mm/min) with varying volume fractions of Al2O3 nanoparticles (4%, 7% and 10%) on microstructural evolution and mechanical properties were investigated. The augmentation of various mechanical properties is based on the homogeneity of particle dispersion and grains refinement in the SZ of the FSWed joint. The findings revealed that the remarkable reduction in grain size in the SZ was observed owing to the incorporation of Al2O3 nanoparticles produces the pinning effect, which prevents the growth of grain boundaries by dynamic recrystallization (DRX). The increasing volume fraction of Al2O3 nanoparticles enhanced the mechanical properties such as tensile strength, % elongation and micro-hardness. Agglomeration of particles was observed in the SZ of the FSWed joints produced at lower tool rotational speed of 700 rpm and higher traverse speed of 60 mm/min due to unusual material flow. Homogenous particle dispersion and enhanced material mixing ensue at higher rotational speed of 1100 rpm and lower traverse speed of 40 mm/min exhibit higher tensile strength and micro-hardness.

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 %.

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