scholarly journals Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 610 ◽  
Author(s):  
Mian Wasif Safeen ◽  
Pasquale Russo Spena
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Intermetallic Compounds ◽  
Crack Nucleation ◽  
Weld Strength ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Friction Stir ◽  
Stress Concentration Factors ◽  
As Stress

Joining of aluminum alloys through friction stir welding (FSW) is effectively employed in several industries (e.g., aeronautics and aerospace) since it guarantees proper weld strength as compared to other joining technologies. Contrarily, dissimilar FSW of aluminum alloys and steels often poses important issues in the selection of welding parameters due to the difficulty to join different materials. Improper welding parameters give rise to the formation of intermetallic compounds, and internal and external defects (e.g., tunnel formation, voids, surface grooves, and flash). Intermetallic compounds are brittle precipitates of Al/Fe, which chiefly initiate crack nucleation, whereas internal and external defects mainly act as stress concentration factors. All these features significantly reduce joint strength under static and dynamic loading conditions. With reference to the literature, the influence of main welding parameters (rotational speed, welding speed, tool geometry, tilt angle, offset distance, and plunge depth) on the formation of intermetallic compounds and defects in FSW of aluminum alloys and steels is discussed here. Possible countermeasures to avoid or limit the above-mentioned issues are also summarily reported.

scholarly journals Friction Stir Welding of Dissimilar Aluminum Alloy Combinations: State-of-the-Art

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 270 ◽  
Author(s):  
Vivek Patel ◽  
Wenya Li ◽  
Guoqing Wang ◽  
Feifan Wang ◽  
Achilles Vairis ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Great Success ◽  
Lightweight Structures ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
And Performance

Friction stir welding (FSW) has enjoyed great success in joining aluminum alloys. As lightweight structures are designed in higher numbers, it is only natural that FSW is being explored to join dissimilar aluminum alloys. The use of different aluminum alloy combinations in applications offers the combined benefit of cost and performance in the same component. This review focuses on the application of FSW in dissimilar aluminum alloy combinations in order to disseminate research this topic. The review details published works on FSWed dissimilar aluminum alloys. The detailed summary of literature lists welding parameters for the different aluminum alloy combinations. Furthermore, auxiliary welding parameters such as positioning of the alloy, tool rotation speed, welding speed and tool geometry are discussed. Microstructural features together with joint mechanical properties, like hardness and tensile strength measurements, are presented. At the end, new directions for the joining of dissimilar aluminum alloy combinations should guide further research to extend as well as to improve the process, which is expected to raise further interest on the topic.

Study of Friction Stir Welding Technics and Weld Performance of Dissimilar 6063-3A21 Aluminum Alloys

2011 ◽  
Vol 299-300 ◽  
pp. 1095-1098 ◽  
Author(s):  
Lei Wang ◽  
Jian Jun Zhu ◽  
Wei Zhang ◽  
Xing Mei Feng ◽  
Zhan Ying Feng
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloys ◽  
Base Material ◽  
Post Weld Heat Treatment ◽  
Weld Strength ◽  
Welding Parameters ◽  
Friction Stir ◽  
Dissimilar Aluminum Alloys ◽  
Performance Results ◽  
Better Than

Several rotating rates and welding speeds were chosen to joint 6063/3A21 dissimilar aluminum alloys, tensile strength of the welds were measured to analyze effect of welding parameters on weld performance. Results show that tensile strength of the weld is better than the base material. Weld tensile strength will decrease under a too high or too low welding speed while effect of rotating rate on weld strength is relatively small. The weakest position is at heat affected zone at 3A21 side after T6 post weld heat treatment.

Numerical Simulation of Friction Stir Welding of Aluminum Alloys: A Brief Review

2015 ◽  
Vol 809-810 ◽  
pp. 467-472
Author(s):  
Marius Adrian Constantin ◽  
Ana Boşneag ◽  
Monica Iordache ◽  
Eduard Niţu ◽  
Doina Iacomi
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Copper Alloys ◽  
Tool Geometry ◽  
Friction Stir ◽  
Complex Process ◽  
Scientific Papers ◽  
Fsw Simulation ◽  
Aluminum And Magnesium Alloys

Friction Stir Welding (FSW) is the latest innovative and most complex process which is widely applied to the welding of lightweight alloys, such as aluminum and magnesium alloys, and most recently, titanium alloys, copper alloys, steels and super-alloys. Friction stir welding is a highly complex process comprising several highly coupled physical phenomena. The experiments are often time consuming and costly. To overcome these problems, numerical analysis has frequently been used in the last ten years. In this paper is presented a brief review of scientific papers in recent years on numerical simulation of Friction Stir Welding of aluminum alloys. The main elements analyzed by FSW simulation, and briefly in this paper are: temperature and residual stress distribution; work tool geometry (size and shape of the pin); distribution of equivalent plastic deformation; main areas resulted after welding; distribution of microstructure (grain size); parameters and optimization of the FSW process.

Optimization of friction stir welding parameters for joining Aluminum alloys using RSM

2013 ◽  
Vol 6 ◽  
pp. 13-26 ◽  
Author(s):  
Jawdat A. Al-Jarrah ◽  
Sallameh Swalha ◽  
Talal Abu Mansour ◽  
Masoud Ibrahim ◽  
Maen Al-Rashdan ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Welding Parameters ◽  
Friction Stir

The Effects of Friction Stir Welding Parameters on the Characteristics of Banded Structure for Aluminum Alloys

2016 ◽  
Vol 710 ◽  
pp. 155-159
Author(s):  
Mariem Zoghlami ◽  
Mohammad Jahazi ◽  
Victor Songmene
Keyword(s):  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Process Parameters ◽  
Mechanical Characteristics ◽  
Research Work ◽  
Welding Parameters ◽  
Processing Conditions ◽  
Influence Of Process Parameters ◽  
Friction Stir

Since the invention of the friction stir welding, several studies have been conducted to understand the influence of process parameters on the microstructural, thermal and mechanical characteristics to improve the weld quality. Banded structures better known under the name of "onion rings" are one of phenomena that appear in the microstructure during this process. The welding parameters leading to their appearance as well as their effect on the quality of the joint are still subject to much research with different conclusions. In this context, the objective of this research work is to determine various characteristics of the ‘onion rings’ and correlate them to processing conditions.

scholarly journals Effect of Tool Geometry and Process Parameters on Microstructure and Mechanical Properties of Friction Stir Spot Welded 2024-T3 Aluminum Alloy Sheets

2016 ◽  
Author(s):  
Memduh Murtulmuş
Keyword(s):  
Aluminum Alloy ◽  
Penetration Depth ◽  
Rotational Speed ◽  
Stir Zone ◽  
Weld Strength ◽  
Tool Geometry ◽  
Welding Parameters ◽  
Tensile Shear ◽  
Shear Tests ◽  
Friction Stir

Aluminum alloy Al 2024-T3 were successfully joined using friction stir spot jwelding joining (FSSW). Satisfactory joint strengths were obtained at different welding parameters (tool rotational speed, tool plunge depth, dwell time) and tool pin profile (straight cylindrical, triangular and tapered cylindrical). Resulting joints were welded with welded zone. The different tools significantly influenced the evolution on the stir zone in the welds. Lap-shear tests were carried out to find the weld strength. Weld cross section appearance observations were also done. The macrostructure shows that the welding parameters have a determinant effect on the weld strength (x: the nugget thickness, y: the thickness of the upper sheet and SZ: stir zone). The main fracture mode was pull out fracture modes in the tensile shear test of joints. The results of tensile shear tests showed that the tensile-shear load increased with increasing rotational speed in the shoulder penetration depth of 0.2 mm. Failure joints were obrerved in the weld high shoulder penetration depth and insufficient tool rotation.

Effect of welding parameters on mechanical properties and microstructure of friction stir welded brass joints

2018 ◽  
Vol 106 (6) ◽  
pp. 606 ◽  
Author(s):  
İnan Geçmen ◽  
Zarif Çatalgöl ◽  
Mustafa Kemal Bilici
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Rotation Speed ◽  
Stir Zone ◽  
Weld Strength ◽  
Welding Parameters ◽  
Feed Speed ◽  
Friction Stir ◽  
Tool Rotation Speed ◽  
Tool Rotation

Friction stir welding is a method developed for the welding of high-alloy aluminum materials which are difficult to combine with conventional welding methods. Friction stir welding of MS 63 (brass) plates used different tools (tapered cylindrical, tapered threaded cylindrical), tool rotational speeds (1040, 1500, 2080 rpm) and traverse speeds (30,45,75,113 mm.min−1). Tensile, bending, radiography and microstructure tests were carried out to determine the mechanical properties of brass plates joined by friction stir welding technique. Microstructure characterization studies were based on optical microscope and SEM analysis techniques. In addition, after joining operations, radiographs were taken to see the internal structure failure. Brass sheets were successfully joined to the forehead in the macrostructure study. In the evaluation of the microstructure, it was determined that there were four regions of base metal, thermomechanically affected zone (TMEB), heat-affected zone (HAZ) and stir zone. In both welding tools, the weld strength increased with increasing tool rotation speed. The particles in the stir zone are reduced by increasing of the tool rotation speed. Given the strength and % elongation values, the highest weld strength was achieved with tapered pin tool with a tool rotation speed of 1040 rpm and a tool feed speed of 113 min−1.

Underwater dissimilar friction stir welding of aluminum alloys: Elucidating the grain size and hardness of the joints

2017 ◽  
Vol 233 (4) ◽  
pp. 763-775 ◽  
Author(s):  
Khosro Bijanrostami ◽  
Reza Vatankhah Barenji
Keyword(s):  
Grain Size ◽  
Friction Stir Welding ◽  
Aluminum Alloys ◽  
Classical Equation ◽  
Hardness Test ◽  
Traverse Speed ◽  
Welding Parameters ◽  
Friction Stir ◽  
Dissimilar Friction Stir Welding ◽  
Electron Microscopes

Underwater dissimilar friction stir welding of the AA6061 and AA7075 aluminum alloys was performed in this study. The effect of friction stir welding parameters on the grain size and hardness of the joints was studied using empirical models. The microstructure of the joints was characterized by means of light and transmission electron microscopes. The Vickers hardness test was conducted to measure the hardness of the joints. In addition, the process parameters including traverse and rotational speeds, grain size and hardness of the joints were correlated. The results revealed that the developed models predicted the hardness and grain size of the joints, precisely. Higher traverse speed and lower rotational speeds resulted in finer grain size and larger hardness. The grain boundaries and dislocations were identified as responsible for the higher hardness of the joints welded at lower heat input conditions. Moreover, the Hall–Petch relationship showed a deviation from its linear classical equation, which was due to the formation of substructures such as dislocations inside the grains.

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