Effects of tool rotation direction on microstructure and mechanical properties of 6061 aluminum alloy joints by the synergistically double-sided friction stir welding

Tang, Yishuang; Li, Wenya; Zou, Yangfan; Wang, Weibing; Xu, Yaxin; Vairis, Achilles; Çam, Gürel

doi:10.1016/j.jmapro.2024.07.067

Journal of Manufacturing Processes

2024

DOI: 10.1016/j.jmapro.2024.07.067

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Effects of tool rotation direction on microstructure and mechanical properties of 6061 aluminum alloy joints by the synergistically double-sided friction stir welding

Yishuang Tang,

Wenya Li,

Yangfan Zou

et al.

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2024

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Cited by 7 publications

References 35 publications

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Process Parameters and Tool Design in Friction Stir Extrusion: A Sustainable Recycling Technique

Akbari,

Asadi,

Behnagh

et al. 2024

Engineering Reports

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Friction stir extrusion (FSE) is a versatile technique that plays a dual role in sustainable recycling and shaping of materials. This method involves a rotating mandrel and a fixed matrix within a mold, where compressed waste metal chips or primary bulk materials are introduced. The rotating mandrel exerts continuous axial pressure, generating frictional heat that softens and bonds the materials together. As the mandrel advances, the materials are reshaped and extruded through the cavity inside the mandrel or the space between the mandrel and the matrix, resulting in the desired product, such as wires or pipes. FSE finds applications in recycling machining wastes, improving powder metallurgy products, producing wire raw materials, creating structures with fine microstructures, and developing new alloys and composites. The resulting materials exhibit refined grains, leading to enhanced mechanical and metallurgical properties. This review article compiles experimental studies exploring the mechanical and microstructural characteristics of samples manufactured using FSE for recycling, reshaping, alloying, or bilayer production. Additionally, it discusses various tool, mold, and machine designs proposed by researchers. Beyond its unique properties, FSE is highlighted as an energy‐efficient, sustainable, and eco‐friendly process.

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Process Parameters and Tool Design in Friction Stir Extrusion: A Sustainable Recycling Technique

Akbari,

Asadi,

Behnagh

et al. 2024

Engineering Reports

View full text Add to dashboard Cite

show abstract

Characteristics of Dissimilar AA5083 and AA7050 Aluminium Alloys Friction Stir Butt Welded with Different Tool Axis Offsets

Subrahmanian,

Rajeev,

Renjith

et al. 2024

J Inorg Organomet Polym

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Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding

Mishra,

Patel,

Hussain

et al. 2024

Discov Mater

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This study focuses into strategizing the usage of self-reacting bobbin tool friction stir welding (SRBT-FSW) to obtain consistent microstructural homogeneity along the thickness of AA6061 aluminium alloy (AA) thick plates during welding. The SRBT-FSW technology, distinguished by its dual-shoulder design, represents a significant step forward in FSW by eliminating the requirement for a backing anvil and promoting balanced heat distribution. This study seeks to address the issues of maintaining uniform microstructural characteristics throughout the weld zone, which is crucial for the mechanical performance and durability of welded joints in structural applications. The experimental study entails the systematic welding of AA6061 plates of 6 mm thickness using a self-reacting bobbin tool under a fixed processing condition. Electron backscatter diffraction (EBSD) was used to characterize the grain structure and phase distribution over the weld. Mechanical parameters like as tensile strength and hardness were determined to establish correlations between microstructure and mechanical performance. The results demonstrated that SRBT-FSW significantly enhances microstructural homogeneity across the weld zone, leading to improved mechanical properties. In the Bottom Zone (BZ), a refined grain structure with an average grain size (AGS) of 3.53 µm and a random or weak texture was observed, contributing to enhanced hardness and mechanical performance, with an ultimate tensile strength (UTS) of 220 MPa. In contrast, the Top Zone (TZ) exhibited a coarser AGS of 4.33 µm with a pronounced {111} crystallographic texture, resulting in a slightly lower UTS of 205 MPa. The Middle Zone (MZ), influenced by the greater heat input from both the TZ and BZ, showed an intermediate AGS of 3.99 µm, predominantly oriented along the {101} plane, and achieved a UTS of 194 MPa, with a slight reduction in ductility. This study highlights the potential of self-reacting bobbin tool friction stir welding as a reliable method for making high-quality, homogeneous welds in thick aluminium plates and paving way for their wider application in the aerospace, automotive, and shipbuilding industries, where homogeneous microstructural qualities are of significant importance.

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Effects of tool rotation direction on microstructure and mechanical properties of 6061 aluminum alloy joints by the synergistically double-sided friction stir welding

Cited by 7 publications

References 35 publications

Process Parameters and Tool Design in Friction Stir Extrusion: A Sustainable Recycling Technique

Process Parameters and Tool Design in Friction Stir Extrusion: A Sustainable Recycling Technique

Characteristics of Dissimilar AA5083 and AA7050 Aluminium Alloys Friction Stir Butt Welded with Different Tool Axis Offsets

Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding

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