Evaluation of dissimilar joints properties of 5083-H12 and 6061-T6 aluminum alloys produced by tungsten inert gas and friction stir welding

Abstract

In the present study, friction stir welding (FSW) and tungsten inert gas (TIG) techniques were used to join the dissimilar aluminum alloys of 5083-H12 and 6061-T6. The laboratory tests were designed using design of experiment (DOE) method. Variables for the FSW process were the rotational speed, traverse speed, shoulder diameter, and pin diameter. They changed in ranges of 700-2500 r/min, 25-400 mm/min, 10-14 mm, and 2-4 mm, respectively. In the case of TIG process, the variables were current intensity, traverse speed, and tilt angle. These parameters varied from 80 to 90 A, 200 to 400 mm/min, and 3 to 12 , respectively. The optimum amounts of parameters were obtained using response surface methodology (RSM). The RSM-based model was developed to predict ultimate tensile strength (UTS) of the welds produced. In FSW, the difference between predicted and measured UTS was about 1.28% and in TIG it was 1.78%. The good agreement between experimental and predicted results indicates the high accuracy of the developed model. Mechanical properties and also the microstructure of the welds were compared after optimizing both welding processes using RSM. The results showed that the welds produced by FSW indicated a considerably higher quality and also improved mechanical properties compared to TIG. Properties of the joints obtained by FSW in single-sided joints were more desirable. In the double-sided welds obtained by FSW these differences were of an even higher significance.

Friction Stir Welding of Dissimilar Aluminum Alloy Combinations: State-of-the-Art

“…It is therefore necessary to select the appropriate combination of tool rotation and welding speed for a defect free joint with a good metallurgical bond and mechanical properties. As it can be seen in Table 1, quite a lot of papers have focused on the optimization of these parameters for different combinations of Al alloys [23,29,32,33,35,36,41,42,50,54,55,58,64,80]. welding speed for a defect free joint with a good metallurgical bond and mechanical properties.…”

Effect of Pulse Duration on Corrosion and Impression Creep Properties of AA5083‐H111 Al–Mg Alloy Weldments Processed by P‐GTAW

“…A substantial amount of Mg‐rich β ‐phase precipitates (Al 3 Mg 2 ) and the existence of Mn, Fe rich particles were seen on the grain boundaries. Commonly, the β ‐phase is stimulated by cold working . The β ‐phase particles are strongly anodic with the Al–Mg sloid‐solution matrix and dissolve in saline environments rapidly.…”

“…Since work‐hardening attains the strength of AA5083 Al–Mg alloy, heat input during welding causes loss of strain hardening effects. It leads to recrystallization and softening in heat affected zone (HAZ), and thus affects joint characteristics . These issues can be minimized by controlling the heat input using newly developed joining processes.…”

Friction Stir Welding of EN 10130 Low Carbon Steel

“…This is usually due to the incorrect selection of welding parameters such as imprecise tool rotation speed, advancing speed, pin and shoulder diameters, tilt angle, preheat temperature, tool rotation direction (clockwise or counter clockwise), fixture and clamping system, tool geometry, etc. [1][2][3][4] . A flawless joint can only be obtained by selecting welding parameters in a limited range; otherwise, mechanical properties will suffer significantly 5,6) .…”

“…Moreover, tungsten carbide (WC) particles were observed in the cross-section of the specimen welded by a higher rotation speed resulting in a lower joint ductility. Ghafarpour et al 2) joined 5083-H12 and 6061-T6 aluminum alloy sheets by FSW and optimized welding parameters including tool rotation speed, advancing speed, pin diameter, and shoulder diameter using design of experiment (DOE). They also determined a safe range for every parameter by performing limiting dome height (LDH) tests on the welded specimens and could maximize the formability of welded joints by optimizing the welding parameters.…”