Effect of number of tool shoulders on the quality of steel to magnesium alloy dissimilar friction stir welds

Khalaf, Hassanein Ibraheem; Al-Sabur, Raheem; Derazkola, Hamed Aghajani

doi:10.1007/s43452-023-00673-z

Cited by 19 publications

(6 citation statements)

References 31 publications

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“…The surface roughness was measured via a Mitutoyo surface roughness tester to evaluate the roughness average (Ra) at different TTAs. Figure 5b,c show surface rough- Flow ring is a phenomenon that occurs via surface ripple in the welding area that is in contact with the tool shoulder [24]. The ripple spacing of this study is measured to indicate the visual surface quality of the welded joint as well as the mechanical action in the stir zone.…”

Section: Surface Flow Analysismentioning

confidence: 86%

“…In 1.5° TTA, the extrusion of AA1050 from the AS to the RS improved, but in 3° TTA, the big gap between tool and workpiece during forward moving increases the flash surface at both the AS and the RS. Flow ring is a phenomenon that occurs via surface ripple in the welding area that is in contact with the tool shoulder [24]. The ripple spacing of this study is measured to indicate the visual surface quality of the welded joint as well as the mechanical action in the stir zone.…”

Section: Surface Flow Analysismentioning

confidence: 99%

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Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

et al. 2023

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This study aims to investigate the impact of partial-contact tool tilt angle (TTA) on the mechanical and microstructure properties of the AA1050 alloy friction stir weld (FSW). Three levels of partial-contact TTA were tested, 0°, 1.5°, and 3°, compared to previous studies on total-contact TTA. The weldments were evaluated using surface roughness, tensile tests, microhardness, microstructure, and fracture analysis. The results show that in partial-contact conditions, increasing TTA decreases the generated heat in the joint line and increases the possibility of FSW tool wear. This trend was the opposite of joints that were friction stir welded via total-contact TTA. The microstructure of the FSW sample was finer at higher partial-contact TTA, while the possibility of defect formation at the root of the stir zone in higher TTA was more than in lower TTA. The robust sample prepared at 0° TTA had 45% of AA1050 alloy strength. The maximum recorded heat in 0° TTA was 336 °C and the ultimate tensile strength of this sample was 33 MPa. The elongation of the 0° TTA welded sample was 75% base metal, and the average hardness of the stir zone was 25 Hv. The fracture surface analysis of the 0° TTA welded sample consisted of a small dimple, indicating the brittle fracture mode.

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Section: Surface Flow Analysismentioning

confidence: 86%

Section: Surface Flow Analysismentioning

confidence: 99%

Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

et al. 2023

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“…Overall, the maximum UTS recorded in the study was 567 MPa in sample B2, while the minimum UTS was 471 MPa in sample A0, highlighting the significant influence of processing parameters on the mechanical strength of the FSP samples (Figure 9a). The analysis of elongation provided insights into the ductility of the FSP samples, elucidating the influence of process parameters, such as tool rotation and nanopowder addition, on material deformation properties [24]. Across the A-series samples, elongation values ranged from 17% for sample A3 to 31% for samples A0, A1, and A2.…”

Section: Tensile Strength Of Jointmentioning

confidence: 99%

“…In samples without nanopowder, elongation increased with higher tool rotational velocities, indicating enhanced ductility. The analysis of elongation provided insights into the ductility of the FSP samples, elucidating the influence of process parameters, such as tool rotation and nanopowder addition, on material deformation properties [24]. Across the A-series samples, elongation values ranged from 17% for sample A3 to 31% for samples A0, A1, and A2.…”

Section: Tensile Strength Of Jointmentioning

confidence: 99%

AA5754–Al2O3 Nanocomposite Prepared by Friction Stir Processing: Microstructural Evolution and Mechanical Performance

Mohammed,

Abdullah,

Rohim

et al. 2024

JMMP

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The utilization of Al2O3 nanopowder to reinforce AA5754 aluminum alloy through blind holes employing the friction stir processing (FSP) technique to produce an aluminum matrix nanocomposite is explored in this paper. Motivated by the necessity to enhance the strength and ductility of welded joints, the impacts of varying the tool rotational speed (rpm) and blind hole diameter on the microstructure and mechanical properties of the joints are investigated. Experimental characterization techniques including SEM, optical microscopy, microhardness, and tensile tests were employed to analyze the welded joints produced under different processing parameters (tool rotational speeds of 910, 1280, and 1700 rpm, and blind hole diameters of 0, 1, 1.5, and 2 mm). Comparative analyses were conducted against base metal properties and joints without reinforcement powder. It was found that the addition of nanopowder resulted in a decrease in the maximum generated heat during FSP, while also reducing the stir zone size compared to samples without nanopowder. Moreover, enhancements in both the strength and ductility of the joints were observed with the incorporation of Al2O3 nanoparticles. The optimal combination of welding conditions, observed at 1280 rpm rotational speed and 1.5 mm hole diameter, yielded a remarkable ultimate tensile strength of 567 MPa, accompanied by a hardness of 45 HV. These results underscore the potential of nano-Al2O3 reinforcement in significantly improving the mechanical properties of the produced nanocomposite, with implications for advancing the performance of welded structures in various engineering applications.

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“…For the AZ31B/SK7 joint, the interface layer at the keyhole exhibited a thickness of 0.9 µm, while for the AZ31B/DP980 and AZ31B/316L joints, it measured 1.5 µm and only 0.6 µm, respectively. Within a certain range, an increased compound thickness at the interface was more advantageous for joint performance [30]. In order to gain further insights into its composition and structure, quantitative point analysis using EPMA was performed at various positions within the keyholes of three joints, and the corresponding results are presented in Tables 6-8.…”

Section: Microstructurementioning

confidence: 99%

Effect of Alloying Elements in Steels on the Interfacial Structure and Mechanical Properties of Mg to Steel by Laser-GTAW Hybrid Direct Lap Welding

Liu,

Lang,

Wang

et al. 2024

Materials

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Mg alloy AZ31B was directly bonded to SK7 with a low alloy content, DP980 with a high Mn content, 316L with a high Cr and high Ni content by laser-gas tungsten arc welding (GTAW) and hybrid direct lap welding. The results showed that the tensile loads of AZ31B/SK7 and AZ31B/DP980 joints were 283 N/mm and 285 N/mm respectively, while the tensile load of AZ31B/316L joint was only 115 N/mm. The fracture and interface microstructures were observed using scanning electron microscopy (SEM), electron probe microanalysis (EPMA), and identified through X-ray diffractometry (XRD). For AZ31B/SK7 and AZ31B/DP980, the interface of the front reaction area and the keyhole reaction area was mainly composed of an Fe-Al phase and an Al-Mn phase. However, for AZ31B/316L, the interface of the keyhole reaction area was mainly composed of an Fe-Al phase and an Al-Mn phase, but a multi-layer composite structure consisting of the Mg17Al12 compound layer and eutectic layer was formed in the front reaction area, which led to a deterioration in the joint property. The influencing mechanism of Mn, Cr and Ni elements in steel on the properties and interface structure of the laser-GTAW lap joint between the Mg alloy and the steel was systematically analyzed.

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Effect of number of tool shoulders on the quality of steel to magnesium alloy dissimilar friction stir welds

Cited by 19 publications

References 31 publications

Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

AA5754–Al2O3 Nanocomposite Prepared by Friction Stir Processing: Microstructural Evolution and Mechanical Performance

Effect of Alloying Elements in Steels on the Interfacial Structure and Mechanical Properties of Mg to Steel by Laser-GTAW Hybrid Direct Lap Welding

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