Effects of Underwater Friction Stir Welding Heat Generation on Residual Stress of AA6068-T6 Aluminum Alloy

Khalaf, Hassanein Ibraheem; Al-Sabur, Raheem; Abdullah, Mahmoud E.; Kubit, Andrzej; Derazkola, Hamed Aghajani

doi:10.3390/ma15062223

Cited by 47 publications

(23 citation statements)

References 40 publications

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“…In general, in the FSW of dissimilar materials, the portion of participation of materials determines the joint properties [ 42 , 43 ]. Imbalance in the volume ratio of plastic flow leads to inappropriate material mixing at weld nugget and finally increment in defects density [ 44 , 45 , 46 ]. The tool offset in the dissimilar joint is an essential issue because it increases FSW tool life and base metal mixing.…”

Section: Resultsmentioning

confidence: 99%

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

et al. 2022

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Friction Stir Welding (FSW) is a solid-state bonding technique. There are many direct and indirect factors affecting the mechanical and microstructural properties of the FSW joints. Tool offset, tilt angle, and plunge depth are determinative tool positioning in the FSW process. Investigating the effect of these factors simultaneously with other parameters such as process speeds (rotational speed and translational speed) and tool geometry leads to a poor understanding of the impact of these factors on the FSW process. Because the three mentioned parameters have the same origin, they should be studied separately from other process parameters. This paper investigates the effects of tilt angle, plunge depth, and tool offset on Ultimate Tensile Stress (UTS) of joints between AA6061-T6 and AA7075-T6. To design the experiments, optimization, and statistical analysis, Response Surface Methodology (RSM) has been used. Experimental tests were carried out to find the maximum achievable UTS of the joint. The optimum values were determined based on the optimization procedure as 0.7 mm of tool offset, 2.7 degrees of tilt angle, and 0.1 mm of plunge depth. These values resulted in a UTS of 281 MPa. Compared to the UTS of base metals, the joint efficiency of the optimized welded sample was nearly 90 percent.

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Section: Resultsmentioning

confidence: 99%

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

et al. 2022

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“…The increasing of using FSW and FSSW in many new fields, such as joining polymers and composites [26], underwater welding [27], and battery trays [28], must result in the simplification and expansion of FSSW equipment manufacturing. This article tries to apply domestic drilling machines to be part of the FSSW apparatus.…”

Section: Fig 1 Stages Of the Fssw Processmentioning

confidence: 99%

Portable Drilling Machine Applied as a Friction Stir Tool to Join Light Metals

Jassim¹,

Al-Subar²,

Ali³

2022

Applied Engineering Letters

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Sustainable manufacturing technology is one of the requirements of the current industrial fields to reduce the weight and energy used. Friction stir welding (FSW) can be considered a quantum leap in the development of welding technology. A solid-state process utilizes a non-consumable tool and less electrical energy. Friction stir spot welding (FSSW) is a particular case of FSW that began to spread rapidly, especially for similar and dissimilar metals, which has extended to weld the polymers. The increase of FSSW use in different fields needs to simplify the equipment. This study used a portable drilling machine to construct an FSSW apparatus with a rotational speed between 1500 and 3000 rpm with a pin diameter of 2, 3 and 4 mm. The results indicated that the joints welded by the developed apparatus have good strength and hardness. Furthermore, many specimens succeeded in the bending test, especially when the rotational speed was set at 2250 rpm and the pin diameter was 3 mm. In addition, it was found that the mechanical properties increased with the rotational speed and pin diameter, then gradually decreased. Finally, the Response Surface Methodology (RSM), besides the analysis of variation (ANOVA), was utilized to maximize the lap-shear fracture load. The results indicated that the maximum lap-shear fracture load can be achieved at a tool speed N of {2300>N>1600} rpm with a pin diameter (d) of {2.75>N>3.75 mm}.

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“…Friction stir joining (FSJ) is an advanced joining process compared to other welding methods with many advantages, including low cost, high flexibility, no need for a skilled operator, and no contamination [1,2]. It is commonly used to join various metals in the production of similar and dissimilar joints [3].…”

Section: Introductionmentioning

confidence: 99%

Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6)

et al. 2022

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In this study, the effects of the traverse and rotational velocities of the noncontact shoulder tool on the heat generation and heated flux during the friction stir joining of high-density polyamide 6 (PA6) polymer were investigated. The computational fluid dynamics (CFD) method was employed to simulate the thermomechanical phenomena during the friction stir joining (FSJ) process of PA6. A developed model was used to consider the void formation and thermochemical properties of PA6. The surface and internal heat flow, material flow, and geometry of the joint were simulated, and an experimental study evaluated the simulation results. The simulation results indicated that the stir zone formed was smaller than regular joints with a noncontact shoulder tool. Despite the polymer’s traditional FSJ, heat generation and material flow do not differ significantly between advancing and retreating sides. On the other hand, the surface flow is not formed, and the surface temperature gradient is in a narrow line behind the tool. The material velocity increased at higher rotational speed and lower transverse velocity and in the stir zone with more giant geometry forms. The maximum generated heat was 204 °C, and the maximum material velocity was predicted at 0.44 m/s in the stir zone, achieved at 440 rpm and 40 mm/min tool velocities.

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Effects of Underwater Friction Stir Welding Heat Generation on Residual Stress of AA6068-T6 Aluminum Alloy

Cited by 47 publications

References 40 publications

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

Effect of Tool Positioning Factors on the Strength of Dissimilar Friction Stir Welded Joints of AA7075-T6 and AA6061-T6

Portable Drilling Machine Applied as a Friction Stir Tool to Join Light Metals

Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6)

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