An overview on joining of aluminium and magnesium alloys using friction stir welding (FSW) for automotive lightweight applications

Kayode, Oyindamola; Akinlabi, Esther Titilayo

doi:10.1088/2053-1591/ab3262

Cited by 54 publications

(28 citation statements)

References 56 publications

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“…The tool was fabricated using high carbon, high chromium material for this investigation. It has been already proven by several researchers that, tool rotational speed in the range of 800 rpm to 1200 rpm and welding speed of 20 mm/min to 40 mm/min were effective in fabricating superior quality FSW joints 12,17,25 . Based on these literature reviews, we have employed a constant tool rotational speed of 900 rpm and welding speed of 30 mm/min using the taper cylindrical shape tool as seen in Figure 2(a).…”

Section: Materials Preparation and Methodologymentioning

confidence: 99%

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Microstructural Analysis and Mechanical Behaviour of Copper CDA 101/AISI-SAE 1010 Dissimilar Metal Welds Processed by Friction Stir Welding

Giridharan¹,

Sevvel²,

Stalin

et al. 2022

Mat. Res.

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In this work, low-carbon steel AISI-SAE grade 1010 with copper grade CDA 101 was joined by friction stir welding (FSW) using a tapered pin profiled tool. The rotational speed of the tool is 900 rpm, a traverse rate of 30 mm/min, and an axial force of 5 kN were used to produce the joints. The microstructural analysis and mechanical properties of the weld joints have been successfully examined. The optical microscopy, scanning electron microscopy, and X-ray diffraction (XRD) techniques were performed to examine the macropatterns and micropatterns of the welded joints. The tensile and hardness test was performed to evaluate the mechanical behaviours of the FSW joints. The fine ferrite grain features with uniform size were obtained in the microstructure of the nugget zone (stir zone). It is purely influenced by the alternating dynamic rearrangement (recrystallization) mechanism. High hardness was identified in the stir zone, even as the slightest stability was established in the heat-affected zone. The tensile investigation proposed that all the joints explored just lesser unbending nature than the parent material. The tensile strength of 181.5 MPa, the hardness of 144 VHN, and elongation of 14.03% were observed for the welded samples. The better properties for the weld joints were attained at 900 rpm spindle speed and tool traverse speed of 30 mm/min. The FSW is an attractive material joining process for both similar and dissimilar materials compared to other conventional types of joining processes, such as aerospace, marine engineering, shipbuilding, and industrial sector applications.

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Section: Materials Preparation and Methodologymentioning

confidence: 99%

“…FSW process parameters and applications were discussed. The welded joints properties and their effects were analysed [16][17] .…”

Section: Introductionmentioning

confidence: 99%

Microstructural Analysis and Mechanical Behaviour of Copper CDA 101/AISI-SAE 1010 Dissimilar Metal Welds Processed by Friction Stir Welding

Giridharan¹,

Sevvel²,

Stalin

et al. 2022

Mat. Res.

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“…Different stiffener shapes were simulated on panels. A FSW joint provides some perspective concerning the structure's overall stability based on the impact of the heat generation [15]. Heat generation (Q) at the infinitesimal surface of the weld bits can be described by:…”

Section: Heat Generation Modelsmentioning

confidence: 99%

Modeling of Heat Energies and Forces in Friction Stir Welding

Hadi¹

2021

International Journal of Mechanical Engineering and Technology (Ijmet)

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Since its inception, friction stir welding, FSW has been promising easy operation and environmental stewardship through contact friction between the tool and the weld part. The Aluminum alloy 2024-T351 was used in both working pieces. Six processes in FSW may include sticking, plunging into the welding pieces, half and full sliding, full welding along the joint line for the weld to be created, and spacing when picking away the welding tool from the weld. In determining the weld quality, their values should be within a safe range during the welding process, to derive heat from friction, modifying the parameters of the process causes variation in force in the traverse and axial directions. The ability to measure forces and understand their relationship with welding parameters is essential to a successful FSW energy strategy. The analytical models presented in this study depict each welding phase as it occurs and can be applied to predict welding forces and the heat energies.

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“…Due to the development of lightweight materials and forming techniques, various lightweight materials are widely used in body structures to reduce weight, fuel consumption, and CO 2 emissions, such as ultrahigh strength steels, aluminum alloys, titanium alloy, and so on [1,2]. Significant weight reduction through the extensive use of lightweight aluminum alloys and advanced high-strength steel materials has become the most important means of body-weight reduction [3].…”

Section: Introductionmentioning

confidence: 99%

Effect of low-velocity impact on mechanical property and fatigue life of DP590/AA6061 self-piercing riveted joints

Zhao

Huang

Jiang

2022

Mater. Res. Express

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The low-velocity impact behaviors of DP590/AA6061 self-piercing riveting (SPR) joints are studied at the impact energies of 5 J, 10 J, 20 J, 30 J, and room temperature (25℃). The lap shear and fatigue tests, and the cross-sectional microscopies of joints are used to assess the mechanical property evolutions of the joints after low-velocity impact. The results show that the absorbed impact energies of SPR joints reach the critical value at an impact energy of 30 J, the exceeded impact energy causes crack failures in the sheets and decreases the interlocking performance of the joints. The static property and the absorbed energy of the SPR joints are reduced by 16% and 36% when the joints are impacted at 30 J, respectively. The low-velocity impacts do not change the failure forms of the joints, but significantly reduce the mechanical interlocking properties of the joints. The fatigue lives of the SPR joints are reduced due to low-velocity impact, and the impacted joints are more sensitive to cyclic loadings.

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An overview on joining of aluminium and magnesium alloys using friction stir welding (FSW) for automotive lightweight applications

Cited by 54 publications

References 56 publications

Microstructural Analysis and Mechanical Behaviour of Copper CDA 101/AISI-SAE 1010 Dissimilar Metal Welds Processed by Friction Stir Welding

Microstructural Analysis and Mechanical Behaviour of Copper CDA 101/AISI-SAE 1010 Dissimilar Metal Welds Processed by Friction Stir Welding

Modeling of Heat Energies and Forces in Friction Stir Welding

Effect of low-velocity impact on mechanical property and fatigue life of DP590/AA6061 self-piercing riveted joints

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