Friction stir welding of aluminium alloys: An overview of experimental findings – Process, variables, development and applications

Shah, Pratik H.; Badheka, Vishvesh J.

doi:10.1177/1464420716689588

Cited by 55 publications

(35 citation statements)

References 201 publications

(311 reference statements)

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“…There are review papers available on FSW of same Al alloy joints, which discuss various aspects of the process such as tool design, process parameters, heat generation, microstructure and mechanical properties [4][5][6][7][8][9][10][11]. The number of research papers on FSW of dissimilar Al alloy joints published to date is shown in Figure 2 (search on December 15, 2017 found 68 papers from Web of Science).…”

Section: General Progress In Fsw Of Dissimilar Al-al Combinationsmentioning

confidence: 99%

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

Patel

Wang

et al. 2019

Metals

112

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Friction stir welding (FSW) has enjoyed great success in joining aluminum alloys. As lightweight structures are designed in higher numbers, it is only natural that FSW is being explored to join dissimilar aluminum alloys. The use of different aluminum alloy combinations in applications offers the combined benefit of cost and performance in the same component. This review focuses on the application of FSW in dissimilar aluminum alloy combinations in order to disseminate research this topic. The review details published works on FSWed dissimilar aluminum alloys. The detailed summary of literature lists welding parameters for the different aluminum alloy combinations. Furthermore, auxiliary welding parameters such as positioning of the alloy, tool rotation speed, welding speed and tool geometry are discussed. Microstructural features together with joint mechanical properties, like hardness and tensile strength measurements, are presented. At the end, new directions for the joining of dissimilar aluminum alloy combinations should guide further research to extend as well as to improve the process, which is expected to raise further interest on the topic.

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Section: General Progress In Fsw Of Dissimilar Al-al Combinationsmentioning

confidence: 99%

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

Patel

Wang

et al. 2019

Metals

112

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“…Moreover, some researchers [45][46][47] were focused on the thermography method which has been defined as a modern method for investigating the thermal field through online monitoring of the process, inspection and research. It should be mentioned that, this method is mainly used to determine the thermal field variations, when the measurements are difficult or impossible to record (i.e., inside the weld).…”

Section: Thermal Analysis Of Fsw (Friction Stir Welding)mentioning

confidence: 99%

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Meyghani

Awang

Emamian

et al. 2017

Metals

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Friction Stir Welding (FSW) is a novel kind of welding for joining metals that are impossible or difficult to weld by conventional methods. Three-dimensional nature of FSW makes the experimental investigation more complex. Moreover, experimental observations are often costly and time consuming, and usually there is an inaccuracy in measuring the data during experimental tests. Thus, Finite Element Methods (FEMs) has been employed to overcome the complexity, to increase the accuracy and also to reduce costs. It should be noted that, due to the presence of large deformations of the material during FSW, strong distortions of mesh might be happened in the numerical simulation. Therefore, one of the most significant considerations during the process simulation is the selection of the best numerical approach. It must be mentioned that; the numerical approach selection determines the relationship between the finite grid (mesh) and deforming continuum of computing zones. Also, numerical approach determines the ability of the model to overcome large distortions of mesh and provides an accurate resolution of boundaries and interfaces. There are different descriptions for the algorithms of continuum mechanics include Lagrangian and Eulerian. Moreover, by combining the above-mentioned methods, an Arbitrary Lagrangian-Eulerian (ALE) approach is proposed. In this paper, a comparison between different numerical approaches for thermal analysis of FSW at both local and global scales is reviewed and the applications of each method in the FSW process is discussed in detail. Observations showed that, Lagrangian method is usually used for modelling thermal behavior in the whole structure area, while Eulerian approach is seldom employed for modelling of the thermal behavior, and it is usually employed for modelling the material flow. Additionally, for modelling of the heat affected zone, ALE approach is found to be as an appropriate approach. Finally, several significant challenges and subjects remain to be addressed about FSW thermal analysis and opportunities for the future work are proposed.

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“…When this tool rotates on a workpiece, friction occurred which generates the heat needed to plasticized the material at the joint interface, permitting the stirring of the material by the rotating tool pin. The pressure from the tool shoulder and the mixing of materials by the tool bonded the workpiece interface together [1][2][3][4][5][6][7][8]. The heat generated during FSW alters the mechanical properties of the weld through microstructural modifications.…”

Section: Introductionmentioning

confidence: 99%

Effects of processing parameters on mechanical, material flow and wear behaviour of friction stir welded 6101-T6 and 7075-T651 aluminium alloys

Abolusoro

Akinlabi

2020

Manufacturing Rev.

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Dissimilar friction stir welding (FSW) between 6101-T6 and 7075-T651 aluminium alloys was conducted. Three different parameters each were investigated for rotational speed and travel speed, and the effects of these parameters on the tensile behaviour, hardness and wear were evaluated. The results indicate that the ultimate tensile strength increases with an increase in the feed rate. However, the increase in rotational speed decreases the ultimate tensile values. The fractured analysis of the tensile samples shows similarities in the fractured pattern as all the samples failed at heat affected zone close to the 6101-T6 alloy. The hardness varies across the heat affected zones and nugget zone both at constant rotational speed and welding speeds. The highest resistance to wear occurred at 65 mm min À1 and 1850 rpm welding speed and rotational speed respectively while better material mixing was achieved at the nugget zone of the welds at 1250 rpm and 110 mm/min. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.2 O.P. Abolusoro and E.T. Akinlabi: Manufacturing Rev. 7, 1 (2020)

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Friction stir welding of aluminium alloys: An overview of experimental findings – Process, variables, development and applications

Cited by 55 publications

References 201 publications

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

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

A Comparison of Different Finite Element Methods in the Thermal Analysis of Friction Stir Welding (FSW)

Effects of processing parameters on mechanical, material flow and wear behaviour of friction stir welded 6101-T6 and 7075-T651 aluminium alloys

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