Exploring the application domain of friction stir welding in aluminum and other alloys

Verma, Sanjeev; Kumar, Vinod; Kumar, Raman; Sidhu, R. S.

doi:10.1016/j.matpr.2021.07.449

Cited by 17 publications

(9 citation statements)

References 83 publications

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Section: Resultsmentioning

confidence: 99%

“…Compared with Q235, the grains of AA7075 become much coarser, which may be related to the heating of the solution treatment (Figure 2b). The grains easily grow under the high temperature of the solution treatment [25], and meanwhile, the strengthening precipitates (i.e., Guinier-Preston zones, η/η'-MgZn2 phases [26,27]) dissolve into the aluminum matrix, and only some Fe-Mn-Cr particles with high dissolution points remained (Figure 2c). The overviews of a dissimilar Al/steel butt-lap joint fabricated by FSW and UaFSW joints are shown in Figure 3, which exhibit three features: (I) the initially straight Al/steel interface becomes a curve due to the stirring of the tool; (II) the broken steel particles distribute in the NZ of the aluminum matrix; and (III) an upward steel hook inserts into the AA7075 plate.…”

Section: Resultsmentioning

confidence: 99%

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Improving the Quality of Dissimilar Al/Steel Butt-Lap Joint via Ultrasonic-Assisted Friction Stir Welding

Zhang

2022

Materials

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A dissimilar AA7075/Q235 butt-lap joint was fabricated via ultrasonic-assisted friction stir welding (UaFSW), and the characteristics of the UaFSW joint were investigated systematically. The acoustoplastic effect of the ultrasonic vibration led to the softening of the materials and enhanced the material flow during welding, decreasing the volume of welding defects in the nugget zone of the UaFSW joint. With the help of ultrasonic vibration, a smooth and thin intermetallic compounds (IMCs) layer could generate along the Al/steel interface at the top of nugget zone, which possibly consisted of Al5Fe2 and Al13Fe4 phases. However, the positive effects of the ultrasonic vibration were weakened at low temperatures; consequently, the IMCs layer became discontinuous at the bottom of the nugget zone and the welding defects also formed. The ultrasonic vibration accelerated the dynamic recrystallization and refined the microstructures in the nugget zone due to the increased strain rate and stored energy. As a result, the UaFSW joint exhibited a better mechanical performance in comparison to the FSW joint, and the increment in the peak tensile load/elongation was more than twice. In addition, the UaFSW joint failed in the nugget zone along with the Al/steel interface, and the fracture mode was a mixture of ductile and brittle.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Improving the Quality of Dissimilar Al/Steel Butt-Lap Joint via Ultrasonic-Assisted Friction Stir Welding

Zhang

2022

Materials

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“…This variation was perhaps due to the grain-size evolution along the transverse direction in the joint. Vickers hardness values are strongly dependent on grain size [ 35 ]. Nevertheless, a linear relation was found and agreed with the Hall–Petch relationship.…”

Section: Resultsmentioning

confidence: 99%

Joining of Dissimilar Al and Mg Metal Alloys by Friction Stir Welding

Sidhu

Kumar

Goel³

et al. 2022

Materials

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In engineering applications, such as automobile, marine, aerospace, and railway, lightweight alloys of aluminum (Al) and magnesium (Mg) ensure design fitness for fuel economy, better efficiency, and overall cost reduction. Friction stir welding (FSW) for joining dissimilar materials has been considered better than the conventional fusion welding process because of metallurgical concerns. In this study, dissimilar joints were made between the AA6061 (A), AZ31B (B), and AZ91D (C) combinations based on the varying advancing side (AS) and retreating side (RS). The dissimilar joints prepared by the FSW process were further characterized by tensile testing, impact testing, corrosion testing, fracture, and statistical and cost analysis. The results revealed a maximum tensile strength of 192.39 MPa in AZ91 and AZ31B, maximum yield strength of 134.38 MPa in a combination of AA6061 and AZ91, maximum hardness of 114 Hv in AA6061 and AZ31B, and lowest corrosion rate of 7.03 mV/A in AA6061 and AZ31B. The results of the properties were supported by photomicrographic fracture analysis by scanning electron microscopy (SEM) observations. Further, the performance of dissimilar joints was statistically analyzed and prioritized for preference by similarity to the ideal solution (TOPSIS) method.

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“…The FSW method can be applied for the similar or dissimilar materials, materials which have different melting points and non-ferrous materials [7].…”

Section: Introductionmentioning

confidence: 99%

A review of friction stir welding parameters, process and application fields

Kaygusuz

2023

Turkish Journal of Engineering

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Lightweight and durable materials such as aluminum alloys are widely used in sectors such as defense industry, aerospace industry, automotive industry, and high-speed train manufacturing. Some of these materials cannot be welded by conventional methods due to their high thermal conductivity and low melting point. In welding processes, the material properties are expected to be as close as possible to base material. Friction stir welding (FSW) is a joining method that provides welding below the melting point of materials that cannot be welded by conventional methods or where the welding process causes the mechanical structure of the material to deteriorate. In this study, FSW application, advantages and disadvantages and usage areas of friction stir welding were examined.

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Exploring the application domain of friction stir welding in aluminum and other alloys

Cited by 17 publications

References 83 publications

Improving the Quality of Dissimilar Al/Steel Butt-Lap Joint via Ultrasonic-Assisted Friction Stir Welding

Improving the Quality of Dissimilar Al/Steel Butt-Lap Joint via Ultrasonic-Assisted Friction Stir Welding

Joining of Dissimilar Al and Mg Metal Alloys by Friction Stir Welding

A review of friction stir welding parameters, process and application fields

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