Effect of friction stir welding parameters on the residual stress distribution of Al-2024-T6 alloy

Farhang, Majid; Sam-Daliri, Omid; Farahani, Mohammad Reza; Vatani, Azadeh

doi:10.15282/jmes.15.1.2021.06.0606

Cited by 15 publications

(6 citation statements)

References 34 publications

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“…Friction stir welding is a solid-state welding technology that uses a rotational tool to join two material pieces together along the welding path. The tool is plunged into the joining region between both the metallic and polymeric sheets, generating heat through friction and severe plastic strain that enables the joining process [3][4][5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

Correia

Santos

Braga

et al. 2023

JMMP

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An engineering grade polymer—glass fiber-reinforced polyphenylene ether blended with polystyrene—and an aluminum alloy—AA6082-T6—were joined by friction stir welding in an overlap configuration. A comprehensive analysis was conducted of the effects of the tool penetration by adjusting the pin length and the process control on the joints’ mechanical performance. To this end, a series of welds with a fixed 3° tilt angle, a travel speed of 120 mm/min, and 600 RPM of rotational speed was carried out. The analysis encompassed the mechanical strength of the fabricated joints and the mechanical energy input throughout the joining processes, the resulting cross-sectional interfaces, both on macro and micro scales, and the observed defects. The quasi-static shear tensile tests resulted in average tensile strengths varying between 5.5 and 26.1 MPa, representing joint efficiencies ranging from 10.1% to 47.4%, respectively. The joints that exhibited the lowest mechanical performance were fabricated with the highest level of tool penetration (higher pin length) with the process being position-controlled, while the best performance was recorded in joints welded with the lowest tool penetration and a force-controlled process. Nonetheless, the joint welded with a 2 mm long pin and position-controlled process exhibited a mechanical strength comparable with the highest one with a significantly lower standard deviation, a promising attribute for technological industrialization. In this way, it was found that the tool penetration, controlled by adjusting the pin length, played a significant role in the development of the joints’ morphology and, consequently, mechanical performance, whereas the process control exhibited a minor influence on the mechanical performance of the joints, but a considerable effect on process repeatability.

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Section: Introductionmentioning

confidence: 99%

Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

Correia

Santos

Braga

et al. 2023

JMMP

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“…For the UFG weld, the lower strength was caused by the dissolution of the precipitates but also grain coarsening, as an increase in grain size caused a decrease in mechanical strength [ 46 ]. Another factor could influence the strength of the welds, such as residual stress [ 48 , 49 ]. However, this factor was not investigated in the present study.…”

Section: Resultsmentioning

confidence: 99%

Microstructure and Mechanical Properties of the Joints from Coarse- and Ultrafine-Grained Al-Mg-Si Alloy Obtained via Friction Stir Welding

Lipińska

2023

Materials

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In the present study, the welding of coarse- (CG) and ultrafine-grained (UFG) Al-Mg-Si alloy using friction stir welding (FSW) was attempted. The purpose of welding the UFG material was to check the possibility of applying FSW to materials with a thermally unstable microstructure, which is achieved by severe plastic deformation. This group of materials has significant potential due to the enhanced mechanical properties as a result of the elevated number of structural defects. The CG sample was also examined in order to assess whether there is an influence of the base material microstructure on the weld microstructure and properties. To refine the microstructure, incremental equal channel angular pressing was used. Plastic deformation resulted in grain refinement from 23 µm to 1.5 µm. It caused an increase in the microhardness from 105 HV0.1 to 125 HV0.1 and the tensile strength from 320 MPa to 394 MPa. Similar welds obtained using an FSW method exhibited good quality and grain size in a stir zone of 5 µm. For both welds, a decrease in the microhardness occurred in the stir zone. However, for the weld of UFG Al-Mg-Si, the microhardness distribution was homogeneous, while for the weld of the CG, it was inhomogeneous, which was caused by different characteristics of the second-phase precipitates. The tensile strength of the welds was lowered and equaled 269 MPa and 220 MPa for the CG and UFG welds, respectively.

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“…Several studies have been conducted to investigate the influence of material location with respect to tool rotation on joint properties in FSW/P. The findings suggest that material position, rotational speed, and traverse speed significantly impact plastic flow behaviour, grain structure, and joint quality [33][34][35]. Research conducted by Guo et al [36] on AA 6061-AA 7075 showed that effective material mixing and the highest joint strength was achieved at the highest traverse speed when AA 6061 was positioned on the advancing side (AS) and AA 7075 on the retreating side (RS).…”

Section: Introductionmentioning

confidence: 99%

Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

et al. 2023

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Surface metal matrix composites offer an excellent solution for applications where surface properties play a crucial role in components’ performance and durability, such as greater corrosion resistance, better wear resistance, and high formability. Solid-state processing techniques, such as friction surfacing and friction stir welding/processing, offer several advantages over conventional liquid-phase processing methods. This research investigated the feasibility of producing surface composites of aluminium-based dissimilar alloys reinforced with functional microparticles through experimental validation, determined the process parameters that resulted in a more homogeneous distribution of the particles in the surface composites, and enhanced the understanding of Upward Friction Stir Processing (UFSP) technology. The production of aluminium-based dissimilar alloys (AA 7075-T651 and AA 6082-T651) surface composites reinforced with SiC particles was studied, and it was concluded that the macrography and micrography analyses, scanning electron microscopy (SEM) analysis, microhardness measurements, and eddy currents technique reveal an extensive and homogeneous incorporation of SiC particles. In the stirred zone, a decrease of approximately 20 HV 0.5 in hardness was observed compared to the base material. This reduction is attributed to the weakening effect caused by low-temperature annealing during UFSP, which reduces the strengthening effect of the T651 heat treatment. Additionally, the presence of particles did not affect the surface composite hardness in the stirred zone. Furthermore, despite the presence of significant internal defects, SEM analyses revealed evidence of the lower alloy merging with the upper zone, indicating that the lower plate had a role beyond being merely sacrificial. Therefore, the production of bimetallic composites through UFSP may offer advantages over composites produced from a monometallic matrix. The results of the eddy currents testing and microhardness measurements support this finding and are consistent with the SEM/EDS analyses.

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Effect of friction stir welding parameters on the residual stress distribution of Al-2024-T6 alloy

Cited by 15 publications

References 34 publications

Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

Microstructure and Mechanical Properties of the Joints from Coarse- and Ultrafine-Grained Al-Mg-Si Alloy Obtained via Friction Stir Welding

Aluminium-Based Dissimilar Alloys Surface Composites Reinforced with Functional Microparticles Produced by Upward Friction Stir Processing

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