Effect of tool size on AA6061‐T6 double‐sided friction stir welds

Abstract

The present work investigates the effects of tool size on microstructural evolution, tensile strength, and microhardness on double‐sided friction stir welding of 12.7‐mm‐thick AA6061‐T6 plates. Three different tools were designed having pin diameters equal to pin lengths of 6.25, 7.5, and 8.5 mm and corresponding shoulder diameters of 18.75, 22.5, and 24.5 mm, respectively. The welds obtained with these three tools were designated as Welds A, B, and C, respectively. Results showed the highest tensile and yield strength for Weld B. The tensile fracture appearance of Welds A and B indicated reasonable necking with crack initiation and propagation through heat affected zone on the advancing side of the weld. However, in the Weld C, fracture appeared in the stir zone near the confluence of thermo‐mechanically affected zone. Electron back scatter diffraction indicates dominance of high angle grain boundaries and major shear textures C and B/trueB¯ components which corresponds to {001}<110>, {}1true1¯2<110>, and {}true1¯1true2¯< true1¯true1¯0> textures in the weld nugget.

Correlation of microstructure, texture, and mechanical properties of friction stir welded Joints of AA7075-T6 plates using a flat tool pin profile

“…Further, the tool profile in FSW can also have an effect on the microhardness enhancement of aluminium welds. The tool profile can influence the heat generation, material flow, and mechanical forces during the FSW process, which can affect the resulting microstructure and mechanical properties of the weld, including microhardness [ [74] , [75] , [76] ]. The design of the FSW pin, including its diameter, and shape can impact the material stirring and deformation during FSW.…”

Effect of exfoliation corrosion on the efficient hybrid joint of AA2024-T3 and AA2198-T8 formed by friction stir welding

“…In the past few decades, the application of aluminum alloys in the industrial sector has increased by 90% [ [1] , [2] , [3] , [4] , [5] , [6] ]. Despite the thickness reduction, flashes and keyholes are formed in FSW joints [ 7 ].…”

Influence of Friction Stir Welding Process on the Mechanical Characteristics of the Hybrid Joints AA2198-T8 to AA2024-T3

“…Meanwhile, microstructural characterization and mechanical test results should be conducted to advise the applicable weld parameters [13].…”