Friction stir welding of T-joints in dissimilar materials: Influence of tool geometry and materials properties

2019 ◽  
Vol 6 (10) ◽  
pp. 106528 ◽  
Author(s):  
Neves Manuel ◽  
Claúdio Silva ◽  
José Moreira Domingos da Costa ◽  
Altino Loureiro
Keyword(s):  
Friction Stir Welding ◽  
Dissimilar Materials ◽  
Tool Geometry ◽  
T Joints ◽  
Materials Properties ◽  
Friction Stir

scholarly journals Material flow in Friction Stir Welding

2008 ◽  
Vol 14 (S3) ◽  
pp. 87-90 ◽  
Author(s):  
C. Leitão ◽  
R.M. Leal ◽  
D.M. Rodrigues ◽  
P. Vilaça ◽  
A. Loureiro
Keyword(s):  
Plastic Deformation ◽  
Friction Stir Welding ◽  
Automotive Industry ◽  
Aluminium Alloys ◽  
Material Flow ◽  
Dissimilar Materials ◽  
Tool Geometry ◽  
X Ray ◽  
Friction Stir ◽  
Solid State Joining

Friction stir welding (FSW) is a solid-state joining technique initially developed for aluminium alloys. The heat generated by a rotating tool softens the material in the vicinity of the tool. The material undergoes intense plastic deformation following quite complex paths around the tool, depending on the tool geometry, process parameters and material to be welded. The comprehension of the material flow is essential to prevent voids and other internal defects which may form during welding. Several techniques have been used for tracking material flow during FSW such as metallography, the use of a marker material as a tracer or the flow visualization by FSW of dissimilar materials or even the X-ray and computer tomography. Some of these techniques are useless in the analysis of welds in homogenous materials or welds between materials of the same group. The aim of this investigation is tracking the material flow in FSW between 1mm thick sheets in aluminium alloys AA 5182-H111 and AA 6016-T4, currently used in automotive industry.

Defects and tensile properties of 6013 aluminum alloy T-joints by friction stir welding

2014 ◽  
Vol 57 ◽  
pp. 146-155 ◽  
Author(s):  
Yong Zhao ◽  
Lilong Zhou ◽  
Qingzhao Wang ◽  
Keng Yan ◽  
Jiasheng Zou
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Tensile Properties ◽  
T Joints ◽  
Friction Stir

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．

Influence of Tool Geometry and Contact Condition on Friction Stir Welding of Al-Cu Laminated Composites

2013 ◽  
Vol 856 ◽  
pp. 16-21
Author(s):  
R. Beygi ◽  
Mohsen Kazeminezhad ◽  
A.H. Kokabi ◽  
S. Mohammad Javad Alvani ◽  
D. Verdera ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Laminated Composites ◽  
Flow Behavior ◽  
Tool Geometry ◽  
Contact Conditions ◽  
Friction Stir ◽  
Tool Geometries ◽  
Welding Procedure ◽  
Sem Analyses

In this study friction stir welding of Al-Cu laminated composites were carried out by two different tool geometries. Welding procedure was carried out from both sides of Al and Cu. Analyzing cross section of welds showed that different contact conditions between shoulder and material, offers different material flow behavior which is dependent on the tool geometry. SEM analyses showed that mixing of materials in nugget region is more pronounced in the advancing side. Also XRD results indicated that welding from Cu side, leads to intermetallic formation in mixed regions.

scholarly journals Analysis of the influence of position of welding materials on the FSW seams properties for three dissimilar aluminium alloy

2018 ◽  
Vol 178 ◽  
pp. 03003 ◽  
Author(s):  
Ana Bosneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Monica Iordache
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Workpiece Material ◽  
Friction Stir ◽  
Welding Joints ◽  
Welding Materials

Friction Stir Welding, abbreviated FSW is a new and innovative welding process. This welding process is increasingly required, more than traditional arc welding, in industrial environment such us: aeronautics, shipbuilding, aerospace, automotive, railways, general fabrication, nuclear, military, robotics and computers. FSW, more than traditional arc welding, have a lot of advantages, such us the following: it uses a non-consumable tool, realise the welding process without melting the workpiece material, can be realised in all positions (no weld pool), results of good mechanical properties, can use dissimilar materials and have a low environmental impact. This paper presents the results of experimental investigation of friction stir welding joints to three dissimilar aluminium alloy AA2024, AA6061 and AA7075. For experimenting the value of the input process parameters, the rotation speed and advancing speed were kept the same and the position of plates was variable. The exit date recorded in the time of process and after this, will be compared between them and the influence of position of plate will be identified on the welding seams properties and the best position of plates for this process parameters and materials.

Tool Geometry for Friction Stir Welding—Optimum Shoulder Diameter

2011 ◽  
Vol 42 (9) ◽  
pp. 2716-2722 ◽  
Author(s):  
M. Mehta ◽  
A. Arora ◽  
A. De ◽  
T. DebRoy
Keyword(s):  
Friction Stir Welding ◽  
Tool Geometry ◽  
Friction Stir ◽  
Shoulder Diameter

Friction Stir Welding of Aluminum 6061-T6 and Multi-Purpose Copper 11000 Alloy

2017 ◽  
Author(s):  
Lewis N. Payton
Keyword(s):  
Friction Stir Welding ◽  
Copper Alloy ◽  
Tangential Velocity ◽  
Nuclear Industry ◽  
Fusion Welding ◽  
Alternative Methods ◽  
Friction Stir Weld ◽  
Tool Geometry ◽  
Work Piece ◽  
Friction Stir

Friction Stir Welding (FSW) is a solid-state joining process invented by The Welding Institute (TWI, United Kingdom) in 1991 in partnership with the National Aeronautics Space Agency. The process is emerging as one of the preferred alternative methods to permanently join materials that are difficult to join with traditional fusion methods (e.g., MIG, TIG, etc.). The welding of various copper alloys to various aluminum alloys is of great interest to the nuclear industry and the electrical distribution industry. The very different melting points of these two alloys preclude traditional fusion welding. Since the pin tool is simultaneously rotating and traversing through the work piece, flow around the tool is asymmetrical. This has led to designating one side of the tool as advancing and the opposite side as retreating. On the advancing side of the weld, the tool has a tangential velocity in the same direction as the weld is being created. The retreating side of the weld tool is the opposite. It can be can expected that asymmetric heating and deformation will occur in the weld due to this advancing/retreating nature of the FSW pin tool. Although previous studies have been performed that have observed this asymmetric behavior in both similar and dissimilar materials, the resulting welds have been of a poor quality. Large statistical experiments were conducted locally to study the effects of tool geometry, process parameters, and material composition have upon the friction stir butt welding of aluminum alloy 6061-T6 to copper alloy 11000 using a modern conventional 3-axis CNC vertical mill. The research seeks to determine (1) which direction a dissimilar metal friction stir weld between aluminum and copper should be executed, (2) the optimal shoulder diameter to be used when friction stir welding aluminum and copper on a CNC mill, and (3) the addition of a third material to act as an aide. The extensive statistical interactions between these parameters is also documented. A weld schedule was developed that resulted in an ultimate tensile strength (UTS) surpassing (greater than 90% of the weaker, more ductile copper alloy UTS strength) what has been documented in the current literature despite the machine limitations of the CNC vertical mill. Proper optimization of the welding schedule developed may approach 100 percent of the basic copper 11000 properties across the welded zone into the aluminum 6061-T6 alloy.

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