A novel seal-flow multi-vortex friction stir lap welding of metal to polymer matrix composites

NIAN, Shuaiqiang; LI, Mingshen; Ji, Shude; Hu, Wei; Zhang, Zhiqing; Sun, Zelin

doi:10.1016/j.cja.2023.04.009

Cited by 26 publications

(3 citation statements)

References 30 publications

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“…For the FSLW joint, the failure load is mainly determined by the fracture location and the length and complexity of the fracture path [30,56]. Nian et al [57] reported that the micro-and macro-mechanical interlockings in dissimilar materials' FSLW joints enhanced the joint loading capacity due to the lengthened fracture path and the enhanced path complexity. In this study, the traditional FSLW joint rather than the UAFSLW joint has micropores (Figure 3b,c), and the pores decrease the length of the fracture path under the shear fracture mode and go against the loading capacity of the welded lap joint.…”

Section: Mechanical Propertiesmentioning

confidence: 99%

Improved Interface Morphology and Failure Load of Ultrasonic-Assisted Friction Stir Lap Welding Joint of 2024 Aluminum Alloy to 304 Stainless Steel

Han,

Yu,

Yan

et al. 2024

Metals

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Achieving high-strength welding joint of aluminum to steel is a highly pressing and challenging task in the manufacturing industries, and friction stir lap welding (FSLW) has advantages for joining these two metals. To further heighten the strength of dissimilar aluminum and steel metals (Al/steel) FSLW joint, the ultrasonic-assisted FSLW (UAFSLW) process was used, and the upper 2024-T4 aluminum alloy and the lower 304 stainless steel were chosen as research object. The results show that the addition of ultrasound eliminates the micro pores, changes the aluminum-rich intermetallic compounds (IMCs) into the iron-rich IMCs and enhances the micro and macro mechanical interlocking structures along the Al/steel lap interface. Under the rational IMCs layer thickness lower than 1.5 μm, the UAFSLW joint has the failure load higher than the traditional FSLW joint. The maximum failure load of UAFSLW joint reaches 7.06 kN, and the loading capacity of this joint is higher than that of reported Al/steel traditional FSLW joint. The UAFSLW process is an effective way to fabricate the high-strength Al/steel lap joint.

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Section: Mechanical Propertiesmentioning

confidence: 99%

Improved Interface Morphology and Failure Load of Ultrasonic-Assisted Friction Stir Lap Welding Joint of 2024 Aluminum Alloy to 304 Stainless Steel

Han,

Yu,

Yan

et al. 2024

Metals

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“…Refill friction stir spot welding (RFSSW) is a green, energy-saving, environmentally friendly, and efficient spot-welding technology developed based on friction stir welding [3][4][5]. The technology is similar to friction stir welding, in which a solid joint is formed while the workpiece is kept below the melting temperature under the action of frictional heat and mechanical forces [6,7].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Refill Friction Stir Spot-Welded Joints of 2A12Al and 7B04Al: Effects of Tool Size and Welding Parameters

Wang,

Li,

Jiang

et al. 2024

Materials

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To solve problems in dissimilarly light metal joints, refilled friction stir spot welding (RFSSW) is proposed instead of resistance spot welding. However, rotation speed, dwell time, plunge depth, and the diameter of welding tools all have a great influence on joints, which brings great challenges in optimizing welding parameters to ensure their mechanical properties. In this study, the 1.5 mm thick 2A12Al and 2 mm thick 7B04Al lap joints were prepared by Taguchi orthogonal experiment design and RFSSW. The welding tool (shoulder) diameters were 5 mm and 7 mm, respectively. The macro/microstructures of the cross-section, the geometrical characteristics of the effective welding depth (EWD), the stir zone area (SZA), and the stir zone volume (SZV) were characterized. The shear strength and failure mode of the lap joint were analyzed using an optical microscope. It was found that EWD, SZA, and SZV had a good correlation with tensile–shear force. The optimal welding parameters of 5 mm diameter joints are 1500 rpm of rotation speed, 2.5 mm of plunge depth, and 0 s of dwell time, which for 7 mm joints are 1200 rpm, 1.5 mm, and 2 s. The tensile–shear force of 5 mm and 7 mm joints welded with these optical parameters was 4965 N and 5920 N, respectively. At the same time, the 5 mm diameter joints had better strength and strength stability.

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“…Solid-state welding methods such as explosive welding can avoid the shortages of fusion welding when it comes to dissimilar materials [4,5], but many of them are only suitable for the welding of plates with a large size. Friction stir welding (FSW) has been widely used in the welding of dissimilar metals because of the characteristics such as low welding temperature and large plastic deformation [6][7][8]. Many methods were proposed to improve the mechanical properties of the joints.…”

Section: Introductionmentioning

confidence: 99%

Extrinsic-Riveting Friction Stir Lap Welding of Al/Steel Dissimilar Materials

Meng,

Gao,

Xie

et al. 2024

Materials

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To obtain high-quality joints of Al/steel dissimilar materials, a new extrinsic-riveting friction stir lap welding (ERFSLW) method was proposed combining the synthesis advantages of mechanical riveting and metallurgical bonding. SiC-reinforced Al matrix composite bars were placed in the prefabricated holes in Al sheets and steel sheets, arranged in a zigzag array. The bars were stirred and mixed with Al sheets under severe plastic deformation (SPD), forming composite rivets to strengthen the mechanical joining. SiC particles were uniformly dispersed in the lower part of the welding nugget zone (WNZ). The smooth transition between the SiC mixed zone and extrinsic-riveting zone (ERZ) ensured the metallurgical bonding. The maximum tensile shear load of the joints reached 7.8 kN and the maximum load of the weld per unit length was 497 N/mm. The fracture occurred at the interface between the rivets and steel sheets rather than the conventional Al/steel joining interface. Moreover, ERFSLW can prolong the service life of joints due to three fracture stages. This method can be further extended to the welding of other dissimilar materials that conform to the model of “soft/hard”.

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A novel seal-flow multi-vortex friction stir lap welding of metal to polymer matrix composites

Cited by 26 publications

References 30 publications

Improved Interface Morphology and Failure Load of Ultrasonic-Assisted Friction Stir Lap Welding Joint of 2024 Aluminum Alloy to 304 Stainless Steel

Improved Interface Morphology and Failure Load of Ultrasonic-Assisted Friction Stir Lap Welding Joint of 2024 Aluminum Alloy to 304 Stainless Steel

Microstructure and Mechanical Properties of Refill Friction Stir Spot-Welded Joints of 2A12Al and 7B04Al: Effects of Tool Size and Welding Parameters

Extrinsic-Riveting Friction Stir Lap Welding of Al/Steel Dissimilar Materials

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