A semi-empirical model for peak temperature estimation in friction stir welding of aluminium alloys

Ambrosio, Danilo; Aldanondo, Egoitz; Wagner, Vincent; Dessein, Gilles; Girard, Christian; Vivas, Javier; Cahuc, Olivier

doi:10.1080/13621718.2022.2065106

Cited by 7 publications

(4 citation statements)

References 24 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…• τ y depends on the stirred material (AA6061) temperature, which has been approximated to 400 • C (based on measurement at similar welding conditions 27 ), and the flow stress at 400 • C is taken from 28 ; • tool tip completely in contact with aluminum, only rubbing the steel upper surface, with a plunge depth of 2.1 mm.…”

Section: Discussionmentioning

confidence: 99%

Extremely thin intermetallic layer in dissimilar AA6061-T6 and mild steel friction stir lap welding using a hemispherical tool

Ambrosio,

Morisada,

Ushioda

et al. 2024

Sci Rep

Self Cite

View full text Add to dashboard Cite

The dissimilar friction stir lap welding of AA6061-T6 and mild steel using the hemispherical tool tilted towards the retreating side is investigated. Critical defects such as hook features and internal voids are avoided by limiting the plunge depth in the lower plate to a tenth of a millimeter. The low heat generation guaranteed by the hemispherical tool produces a nanoscale intermetallic compound layer alternatively composed of an Al-rich and a ternary Al–Fe–Mg phases. The complex and extremely thin interlayers strengthen the Al–Fe mechanical bonding, guaranteeing high mechanical properties and rupture within the Al-stirred zone. Thermomechanical phenomena governing friction stir lap welding with the hemispherical tool drastically limit the growth of intermetallics, leading to the high mechanical strength of the lap joint.

show abstract

Section: Discussionmentioning

confidence: 99%

Extremely thin intermetallic layer in dissimilar AA6061-T6 and mild steel friction stir lap welding using a hemispherical tool

Ambrosio,

Morisada,

Ushioda

et al. 2024

Sci Rep

Self Cite

View full text Add to dashboard Cite

show abstract

“…One such application is monitoring the temperature of a substrate from the back surface such as any conventional thermocouple sensor [60,61]. In the latter case, numerical models were applied to calculate the interfacial temperature taking into account the thermal properties of materials [62].…”

Section: Monitoring Of the Interfacial Temperaturementioning

confidence: 99%

Assembling of Carbon Fibre/PEEK Composites: Comparison of Ultrasonic, Induction, and Transmission Laser Welding

et al. 2022

Self Cite

View full text Add to dashboard Cite

In the present work, an ultrasonic, an induction, and a through transmission laser welding were compared to join carbon fibre reinforced polyetheretherketone (CF/PEEK) composites. The advantages and drawbacks of each process are discussed, as well as the material properties required to fit each process. CF/PEEK plates were consolidated at 395 °C with an unidirectional sequence and cross-stacking ply orientation. In some configurations, a polyetherimide (PEI) layer or substrate was used. The thermal, mechanical, and optical properties of the materials were measured to highlight the specific properties required for each process. The drying conditions were defined as 150 °C during at least 8 h for PEI and 24 h for CF/PEEK to avoid defects due to water. The optical transmission factor of PEI is above 40% which makes it suitable for through transmission laser welding. The thermal conductivity of CF/PEEK is at most 55 W·(m·K)−1, which allows it to weld by induction without a metallic susceptor. Ultrasonic welding is the most versatile process as it does not necessitate any specific properties. Then, the mechanical resistance of the welds was measured by single lap shear. For CF/PEEK on CF/PEEK, the maximum lap shear strength (LSS) of 28.6 MPa was reached for a joint obtained by ultrasonic welding, while an induction one brought 17.6 MPa. The maximum LSS of 15.2 MPa was obtained for PEI on CF/PEEK assemblies by laser welding. Finally, interfacial resistances were correlated to the fracture modes through observations of the fractured surfaces. CF/PEEK on CF/PEEK joints resulted in mixed cohesive/adhesive failure at the interface and within the inner layers of both substrates. This study presents a guideline to select the suitable welding process when assembling composites for the aerospace industry.

show abstract

“…However, the difficulties in welding these alloys by conventional fusion welding processes has limited the possibilities for an efficient manufacturing, opening a new research field for the use of alternative joining technologies based on solid-state processes. One of the most recognized solid-state joining processes for high-strength aluminium alloys is friction stir welding (FSW) [2][3][4][5]. FSW has been successfully used as an alternative to riveting in aircraft structural components for joining precipitation-hardening aluminium alloys such as 2024-T3 [6], 7075-T6 [7] and even dissimilar joining 2024-T3 to 7075-T6 alloys [8].…”

Section: Introductionmentioning

confidence: 99%

Fretting Fatigue as a Limiting Factor on the Durability of Friction Stir Welded Lap Joints Using AA2099-T83 and AA2060-T8E30 Aluminium Alloys

Aldanondo

Zubiri

Vivas

et al. 2022

JMMP

Self Cite

View full text Add to dashboard Cite

Friction stir welding (FSW) has been proposed as an alternative modern joining technology and demonstrated important benefits for the manufacturing of efficient and lightweight aircraft structures using high-strength aluminium alloys. These structures are required to be corrosion- resistant and thus, it is necessary to use technologies such as surface treatments and sealants in their manufacturing and assembly. In this work, the feasibility of combining innovative Cr-free surface treatments, sealants and FSW technology was investigated with the focus on the durability of the joints in fatigue. FSW lap joints were produced using AA2099-T83 extrusions and AA2060-T8E30 sheets in the as-received or surface-treated condition. A sealant was also applied in some cases at the overlapping interface before the FSW process. Static tensile tests and fatigue tests were carried out applying hoop-stress loading conditions. Different fracture modes were identified depending on the stress levels applied in the fatigue tests: High stress levels resulted in fractures in the HAZ of the FSW joints, while the specimens tested at low stress levels showed fractures out of the FSW joint. In general, FSW joints produced using surface-treated aluminium components and sealant presented improved fatigue life and extended durability in comparison with non-treated aluminium joints. The surface treatments and sealant at the interface of AA2099-T83 extrusions and AA2060-T8E30 sheets reduced the friction and local damage produced due to the sliding movement during the fatigue tests, minimizing the fretting fatigue effect, which was found to be the main limiting factor on the durability and fatigue life of the FSW joints.

show abstract

A semi-empirical model for peak temperature estimation in friction stir welding of aluminium alloys

Cited by 7 publications

References 24 publications

Extremely thin intermetallic layer in dissimilar AA6061-T6 and mild steel friction stir lap welding using a hemispherical tool

Extremely thin intermetallic layer in dissimilar AA6061-T6 and mild steel friction stir lap welding using a hemispherical tool

Assembling of Carbon Fibre/PEEK Composites: Comparison of Ultrasonic, Induction, and Transmission Laser Welding

Fretting Fatigue as a Limiting Factor on the Durability of Friction Stir Welded Lap Joints Using AA2099-T83 and AA2060-T8E30 Aluminium Alloys

Contact Info

Product

Resources

About