scholarly journals Systematic Evaluation of the Advantages of Static Shoulder FSW for Joining Aluminium

2014 ◽  
Vol 794-796 ◽  
pp. 407-412 ◽  
Author(s):  
Hao Wu ◽  
Ying Chun Chen ◽  
David Strong ◽  
Philip Prangnell
Keyword(s):  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Aluminium Alloy ◽  
Surface Quality ◽  
Heat Affected Zone ◽  
Heat Input ◽  
High Strength ◽  
Temperature Gradients ◽  
Systematic Evaluation ◽  
Friction Stir

Static Shoulder Friction Stir Welding (SS-FSW) is a modification to conventional FSW that was originally developed to improve the weldability of titanium alloys by reducing through thickness temperature gradients. Surprisingly, to date, there have been no published systematic studies comparing SS-FSW to FSW for aluminium welding. This may be because the high conductivity of aluminium means the heat input produced by the shoulder is thought to be beneficial. In the work presented when welding a high strength 7050 aluminium alloy, even in a relatively thin 6 mm plate, it is shown that SS-FSW has several advantages; including a reduction in the heat input, a massive improvement in surface quality, and a more uniform through thickness temperature distribution, which leads to narrower welds with a reduced heat affected zone width and more homogeneous through thickness properties. The reasons for these benefits are discussed.

scholarly journals Effect of Shoulder–Workpiece Interference Depth on the Quality of Friction Stir Welding of AA7075-T6 Aluminium Alloy

2019 ◽  
Vol 26 (1) ◽  
pp. 150-159
Author(s):  
Abbas Akram Abbas ◽  
Hazim H. Abdulkadhum
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Welding Process ◽  
High Strength ◽  
Filling Defect ◽  
Welding Quality ◽  
Left Hand ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Welding Surface

The joining of high strength aluminium alloy AA7075-T6 sheets of 3 mm thickness was an attempt utilizing friction stir welding process. The effect of interference depth between tool shoulder and surface workpiece on the welding quality and its effect on the mechanical and metallography properties of welded joints were studied. This process is carried out using a composite tool consists of a concave shoulder made of H13 tool steel and cylindrical left-hand thread with 1mm pitch pin (probe) made of cobalt-based alloy MP159. The dimensions of tools were 14mm shoulder diameter and the pin has 5mm diameter and 2.7mm length. The tool rotation speed and welding speed were 981 rpm 169 mm/min respectively, and the tilt angle was 2°. The range of interference depth between the shoulder and workpiece was selected (0.05, 0.1, 0.15, 0.2, 0.25, and 0.3) mm. various tests were executed to evaluate the welding quality. The results show that lack of filling defect appeared on the welding surface at the interference depth 0.05 mm. An invisible tunnel and lack of penetration in the bottom of the stir zone appeared when the interference depths were 0.1 mm and 0.15 mm. Defect-free welds obtained when interference depths were (0.2, 0.25, and 0.3) mm. The welding efficiency of the defect-free welds was in the range (85.3-92.3%) depending on the ultimate tensile strength of the parent alloy.

Effect of Friction Stir Welding Parameters on Microstructure and Properties of Welded 5083 Aluminium Alloy

2020 ◽  
Vol 20 (8) ◽  
pp. 5055-5063
Author(s):  
Lixin Hao ◽  
Ruiling Jia ◽  
Xiwei Zhai ◽  
Huixia Zhang ◽  
Jian Hou
Keyword(s):  
Mechanical Properties ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Heat Affected Zone ◽  
Intermetallic Phase ◽  
Welding Parameters ◽  
Kelvin Probe ◽  
Friction Stir ◽  
The Difference ◽  
Fsw Parameters

The friction stir welding (FSW) parameters were designed in this study by orthogonal experimental method. The microstructure, mechanical properties and corrosion behavior of corresponding FSW joints of 5083 aluminium alloy (AA5083) were also investigated. Scanning Kelvin probe force microscopy (SKPFM) was employed to study local potential differences on the FSW joint. Results showed that the welding parameters greatly influenced the FSW joint properties of the AA5083. The ratio of rotation speed to welding speed (n/v) mainly affected the mechanical properties of the joint. The tensile strength for the joint was reduced when welded with too large or too small n/v. The hardness of all FSW joints was characterized with similar ‘W-shaped,’ and minimum hardness value appeared on advancing side of the heat affected zone. Different heat input and agitation intensity caused heterogeneous microstructure for the AA5083 FSW joint, which led to differences in passivation properties of weld nugget zone, thermo-mechanically affected zone and heat-affected zone. Susceptibility of the AA5083 FSW joint to pitting corrosion was attributed to the difference of relative potential between the intermetallic phase and Al matrix.

Microstructural Characterization and Mechanical Properties in Friction Stir Welding of Aa7075 Aluminium Alloy

2012 ◽  
Vol 622-623 ◽  
pp. 330-334 ◽  
Author(s):  
G. Elatharasan ◽  
V.S. Senthil Kumar
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Welding Speed ◽  
Mechanical Response ◽  
Weight Ratio ◽  
High Strength ◽  
Microstructural Characterization ◽  
Optical Microscope ◽  
Heterogeneous Distribution ◽  
Friction Stir

The heat treatable aluminium alloy AA7075 is used extensively in the aircraft industry because of its high strength to weight ratio and good ductility. In this present study the effect of process parameters on the mechanical and micro-structural properties of AA 7075 joints produced by friction stir welding was analyzed. The two sheets, aligned with perpendicular rolling directions, have been welded successively. The welded sheets have been tested under tension at room temperature in order to analyze the mechanical response with respect to the parent materials. Effects of welding speed and fixed location of base metals on microstructures, hardness distributions, and tensile properties of the welded joints were investigated. Optical microscope and SEM analysis revealed that the stir zone contains a mixed structure and onion ring pattern with a periodic change of grain size as well as a heterogeneous distribution of alloying elements. The maximum tensile strength was achieved for the joint produced at rotation speed of 800rpm and a welding speed of 20 mm/s.

scholarly journals Optimization of process parameters on friction stir welding of 2014 aluminum alloy plates

2017 ◽  
Vol 7 (1.1) ◽  
pp. 9 ◽  
Author(s):  
V. Jaiganesh ◽  
D. Srinivasan ◽  
P. Sevvel
Keyword(s):  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
High Strength ◽  
Frictional Heat ◽  
Weld Strength ◽  
Electron Interaction ◽  
Welding Parameters ◽  
Work Piece ◽  
Friction Stir

Aluminum Alloy 2014 is a light weight high strength alloy used widely in the aerospace and also in other industries. 2014 is the second most popular of the 2000-series aluminium alloys, after 2024 aluminium alloy. However, it is difficult to weld, as it is subject to cracking. Joining of 2014 aluminium alloy in friction stir welding which is based on frictional heat generated through contact between a rotating tool and the work piece. Determination of the welding parameters such as spindle speed, transverse feed , tilt angle plays an important role in weld strength. The whole optimization process is carried out using Taguchi technique. The SEM analysis is done to check the micro structure of the material after welding by electron interaction with the atoms in the sample. Tensile test have been conducted and the s-n ratio curve is generated. The test is conducted and analysed on the basis of ASTM standards.

scholarly journals Friction Stir Welding of 5754 Aluminum Alloy with Cover Sheet

Materials ◽  
2019 ◽  
Vol 12 (11) ◽  
pp. 1765 ◽  
Author(s):  
Daxin Ren ◽  
Fanyu Zeng ◽  
Yi Liu ◽  
Liming Liu ◽  
Zhubin He
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Heat Affected Zone ◽  
High Strength ◽  
Welding Seam ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Fracture Position ◽  
Cover Sheet

Friction stir welding can realize high-strength aluminum alloy joints. In this study, friction stir welding with cover sheet (CFSW) is proposed to solve the thinning caused by the tool shoulder and reduce the heat-affected zone. The microstructures and mechanical properties of CFWS were also studied. After the cover sheet was added, a reinforcement was formed on the weld surface, which compensated the thinning caused by the friction of the tool shoulder. As the cover absorbed heat from the shoulder, the width of the heat-affected zone of the welded sheet became smaller than the diameter of the shoulder. Without milling the cover sheet, the tensile strength of the 5754 aluminum alloy joint reached 94% of that of the base metal. The fracture position was the heat-affected zone of the forward-side weld joint. After the cover sheet was added, the stress concentration shifted from the thinning area of traditional friction stir welding to the outside of the welding seam.

Investigation of the friction stir welding conditions of V95T2 high-strength aluminium alloy

2011 ◽  
Vol 25 (11) ◽  
pp. 880-882
Author(s):  
P. V. Bakhmatov ◽  
V. I. Murav'ev ◽  
K. A. Melkostupov
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
High Strength ◽  
Friction Stir

scholarly journals Heat input effect of friction stir welding on aluminium alloy AA 6061-T6 welded joint

2016 ◽  
Vol 20 (2) ◽  
pp. 637-641 ◽  
Author(s):  
Aleksandar Sedmak ◽  
Ratnesh Kumar ◽  
Somnath Chattopadhyaya ◽  
Sergej Hloch ◽  
Srdjan Tadic ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Aluminium Alloy ◽  
Heat Input ◽  
Welded Joint ◽  
Friction Stir

scholarly journals Assessment of the Advantages of Static Shoulder FSW for Joining Aluminium Aerospace Alloys

2014 ◽  
Vol 783-786 ◽  
pp. 1770-1775
Author(s):  
Hao Wu ◽  
Ying Chun Chen ◽  
David Strong ◽  
Philip Prangnell
Keyword(s):  
Friction Stir Welding ◽  
Temperature Distribution ◽  
Temperature Gradient ◽  
Systematic Study ◽  
Aluminium Alloys ◽  
High Strength ◽  
Heating Effect ◽  
Friction Stir ◽  
Aerospace Alloys ◽  
Symmetric Temperature

Stationary (or Static) Shoulder Friction Stir Welding (SS-FSW) is a variant of FSW that was developed primarily to improve the weldability of titanium alloys by reducing the through thickness temperature gradient. Surprisingly, SS-FSW has been largely ignored by the Al welding community because it is widely supposed a rotating shoulder is an essential aspect of the process and that the higher conductivity means the surface heating effect of the shoulder is generally beneficial. In the work presented it is shown that SS-FSW has major advantages when welding high strength aluminium alloys; including a reduction in the heat input, a massive improvement in surface quality, and a narrower and more symmetric temperature distribution, which leads to narrower welds with a reduced heat affected zone width and lower distortion. The reasons for these benefits are discussed based on a systematic study aimed at directly comparing both processes.

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