Effect of tool geometry and process parameters on mechanical properties of friction stir spot welded dissimilar aluminum alloys

Kim, Ju-Ri; Ahn, Eun-Yeong; Das, Hrishikesh; Jeong, Yong-Ha; Hong, Sung-Tae; Miles, Michael; Lee, Kwang-Jin

doi:10.1007/s12541-017-0053-0

Cited by 26 publications

(14 citation statements)

References 18 publications

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“…The 5A06 is a corrosion-resistant non-heat treatable aluminium alloy (Al-Mg alloy), while 6061 is a high-strength heat-treatable aluminium alloy (Al-Mg-Si alloy) [24]. In the present work, a forced air cooling system that is cheap and easy to use was added to the commercial friction stir welding machine.…”

Section: Introductionmentioning

confidence: 99%

Effect of Forced Air Cooling on the Microstructures, Tensile Strength, and Hardness Distribution of Dissimilar Friction Stir Welded AA5A06-AA6061 Joints

Peng

Yan

et al. 2019

Metals

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Friction stir welding (FSW) is a promising welding method for welding dissimilar materials without using welding flux. In the present work, 5A06-H112 and 6061-T651 aluminium alloys were successfully welded by friction stir welding with forced air cooling (FAC) and natural cooling (NC). Nanoindentation tests and microstructure characterisations revealed that forced air cooling, which can accelerate the cooling process and suppress the coarsening of grains and the dissolution of precipitate phases, contributes to strengthening and narrowing the weakest area of the joint. The tensile strength of joints with FAC were commonly improved by 10% compared to those with NC. Scanning electron microscopy (SEM) images of the fracture surface elucidated that FSW with FAC tended to increase the number and reduce the size of the dimples. These results demonstrated the advantages of FSW with FAC in welding heat-sensitive materials and provide fresh insight into welding industries.

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Section: Introductionmentioning

confidence: 99%

Effect of Forced Air Cooling on the Microstructures, Tensile Strength, and Hardness Distribution of Dissimilar Friction Stir Welded AA5A06-AA6061 Joints

Peng

Yan

et al. 2019

Metals

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“…Therefore, the welded material during process moves from the front side to the back side of the tool and after, string and softening of the material, the material moves from the front side (leading edge) to the back side (trailing edge) of the tool [23,24]. To develop welding conditions, the welding parameters at different welding stages (as illustrated in Figure 1) should be investigated in studying the process thermal behavior more in detail, the modelling techniques could be as a cost-efficient approach.…”

Section: Introductionmentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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“…7 Researchers also investigated the effects of the tool geometry on dissimilar friction-stir welding of polyethylene-polypropylene. 18 Four different pin profiles, including threaded cylindrical, squared, triangular and straight cylindrical ones were considered. The interaction effects of welding variables, including the rotational speed and traverse speed were also studied.…”

Section: Introductionmentioning

confidence: 99%

Effect of pin profiles on the mechanical properties of friction-stir-welded AA5383 and AA7075

Kumar¹,

Anbumalar²

2020

Mater. Tehnol.

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Friction-stir welding (FSW) is an unyielding-state welding process developed by The Welding Institute, United Kingdom. FSW is mainly based on the tool geometry, process parameters and welding material. The tool geometry plays the principle role in obtaining desirable microstructures of the welds, improving the strength and fatigue resistance of the joints. Currently, friction-stir-welding tools are designed using the trial-and-error method. In this study, three different types of FSW tools are considered for the fabrication of butt joints from AA5383 and AA7075. Various tool profiles such as the cylindrical taper projection, cylindrical thread-pin projection and triangle-pin projection are considered in the present study. The pin profiles are assessed based on the weld quality during tensile tests and hardness tests conducted on welded samples. With the analysis, it is found that the triangular pin produces sound welds at an 800-min-1 speed, 20-mm/min feed and 4-kN load.

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Effect of tool geometry and process parameters on mechanical properties of friction stir spot welded dissimilar aluminum alloys

Cited by 26 publications

References 18 publications

Effect of Forced Air Cooling on the Microstructures, Tensile Strength, and Hardness Distribution of Dissimilar Friction Stir Welded AA5A06-AA6061 Joints

Effect of Forced Air Cooling on the Microstructures, Tensile Strength, and Hardness Distribution of Dissimilar Friction Stir Welded AA5A06-AA6061 Joints

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Effect of pin profiles on the mechanical properties of friction-stir-welded AA5383 and AA7075

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