“…A wave-like morphology in the wormhole region, also marked by a white arrow, obtained in Specimen 1 was most likely the result of the stirring effect of the probe, where the waves represent the incremental material addition by the probe sides. This type of fracture surface morphology was also found by other researchers, including Oluwaseun in an AA5083 alloy [34], Gratecap et al in an AA2017 alloy [35], and Chen et al in an AA5456 alloy [36].…”
Section: Tensile Testing Resultssupporting
confidence: 85%
“…This occurred on the AS, when consolidation did not take place due to the loss of fluidity and poor forging pressure of the low-interference tool. These features were also found by Oluwaseun in an AA5083 alloy [34], Gratecap et al in an AA2017 alloy [35], and Chen et al in an AA5456 alloy [36]. Additionally, a quasi-cleavage fracture mode was present, exhibiting both cleavage and plastic deformation with clearly visible shear dimples, present on both sides of the wormhole, Figure 17b,c.…”
Bobbin tool friction stir welding (BTFSW) is a variant of the FSW process which uses the special two-shoulder tool that forms the top and bottom of a weld surface. As such, a significant simplification of the welding setup is achieved. One of the dominant parameters of the BTFSW process is the interference between the tool shoulder pinch gap and the weld metal thickness. In this research, the influence of interference of the square pin tool with convex shoulders on process temperature, microstructure, tensile, impact, and bend performance were studied, and appropriate correlations were devised. The base metal was an aluminum–magnesium alloy in which the interference varied in the range of 0.1 to 0.5 mm. Wormhole defects and irregularities were found in all specimens except in the specimen welded with 0.4 mm interference. An optimal interference of 0.4 mm resulted in the best mechanical properties, which, in terms of tensile strength and reduction of area, were similar to the base metal. Furthermore, the impact strength was significantly higher, which was attributed to the grain refinement effect in the nugget zone.
“…A wave-like morphology in the wormhole region, also marked by a white arrow, obtained in Specimen 1 was most likely the result of the stirring effect of the probe, where the waves represent the incremental material addition by the probe sides. This type of fracture surface morphology was also found by other researchers, including Oluwaseun in an AA5083 alloy [34], Gratecap et al in an AA2017 alloy [35], and Chen et al in an AA5456 alloy [36].…”
Section: Tensile Testing Resultssupporting
confidence: 85%
“…This occurred on the AS, when consolidation did not take place due to the loss of fluidity and poor forging pressure of the low-interference tool. These features were also found by Oluwaseun in an AA5083 alloy [34], Gratecap et al in an AA2017 alloy [35], and Chen et al in an AA5456 alloy [36]. Additionally, a quasi-cleavage fracture mode was present, exhibiting both cleavage and plastic deformation with clearly visible shear dimples, present on both sides of the wormhole, Figure 17b,c.…”
Bobbin tool friction stir welding (BTFSW) is a variant of the FSW process which uses the special two-shoulder tool that forms the top and bottom of a weld surface. As such, a significant simplification of the welding setup is achieved. One of the dominant parameters of the BTFSW process is the interference between the tool shoulder pinch gap and the weld metal thickness. In this research, the influence of interference of the square pin tool with convex shoulders on process temperature, microstructure, tensile, impact, and bend performance were studied, and appropriate correlations were devised. The base metal was an aluminum–magnesium alloy in which the interference varied in the range of 0.1 to 0.5 mm. Wormhole defects and irregularities were found in all specimens except in the specimen welded with 0.4 mm interference. An optimal interference of 0.4 mm resulted in the best mechanical properties, which, in terms of tensile strength and reduction of area, were similar to the base metal. Furthermore, the impact strength was significantly higher, which was attributed to the grain refinement effect in the nugget zone.
“…It can also be seen that the dimples had different sizes (diameter and depth). The larger size indicated larger grains, larger precipitates and higher shear ductility [21]. Figure 11 SEM image of the tensile specimen of FSW test # 5.…”
Welding of copper and aluminium has been problematic with tradition fusion method. The friction stir welding (FSW) was employed to butt weld the T2 copper and 1061 aluminum alloy plates. The welding parameters were planned by the orthogonal experiment design method. The samples obtained in experiments were investigated in the aspects of microstructure, tensile strength, fatigue performance and micro-hardness.Sound weld with the best tensile strength and fatigue life was produced under the welding parameters of rotation speed, 1100rpm and welding speed 50mm/min. The tensile strength was 193.16MPa, 85% of the base aluminium material. Three intermetallic compounds (IMC) of CuAl, Cu3Al and Cu9Al4 were detected at the copper-aluminium interface in XRD analysis.
“…A cleavage fracture was observed, and the fractured surface resembles a collection of rocks. This is due to the rapid fracture due to stress concentration at the angle zone of the defect [34]. Furthermore, the fracture surface is perpendicular to stress in the tensile test.…”
Aluminum alloys are used in the modern automotive industry because they are lightweight. However, it is establised that conventional fusion welding processes affect weld performance. In this study, friction stir welding (FSW), also known as solid-state welding, was used to weld dissimilar aluminum alloys, AA6061-T6 and AA5083plates. Response surface methodology based on Box-Behnken design (BBD) was used to investigate the appropriate process parameters. In this study, the effects of rotation speed (S), welding feed rate (f), and work angle (θ) were investigated. These three factors were examined at three levels over 17 experimental runs. The design was used to conduct experiments and develop mathematical regression models. Variance analysis was performed to examine the adequacy of the developed models. Finally, the effects of the process parameters on the mechanical properties of welded alloyes were investigated using mathematical models based on the macrostructure, microstructure, chemical composition, and fracture characteristics of the joints using SEM. The investigation found that the optimum welding parameters are a rotational speed of 777 rpm, welding speed of 44 mm/min, and a work angle of 0.75o. Furthermore, the results confirm that the mathematical models and experiments are consistent.
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