Friction stir welding of Aluminium matrix composites – A Review

Abstract

Friction stir welding (FSW) is established as one of the prominent welding techniques to join aluminium matrix composites (AMCs). It is a solid state welding process, takes place well below the melting temperature of the material, eliminates the detrimental effects of conventional fusion welding process. Although the process is capable to join AMCs, challenges are still open that need to be fulfill to widen its applications. This paper gives the outline of the friction stir welding technique used to join AMCs. Effect of process variables on the microstructure and mechanical properties of the joints, behavior of reinforcing materials during welding, effect of tool profiles on the joint strength are discussed in detail. Few improvements and direction for future research are also proposed.

A Review of Optimization and Measurement Techniques of the Friction Stir Welding (FSW) Process

“…FSW can be applied to nickel-titanium shape memory alloys (SMAs) without causing any impact to the transformation temperature [71]. The method of joining steel to aluminum have limitations such as limited weldability, formation of pores, intermetallic oxide inclusions, and hot cracks [72]. FSW has been proven to overcome these limitations [2].…”

Mechanical and Corrosion Studies of Friction Stir Welded Nano Al2O3 Reinforced Al-Mg Matrix Composites: RSM-ANN Modelling Approach

“…This non-homogeneous distribution of reinforcements in the crystal structure of the Base Metal can influence the isotropy of material characteristics. Friction stir welding (FSW) is a better process as it prevents clustered reinforcement because of the continuous stirring motion of the machine and brings uniform dispersion in the weldment owing to material blending and extreme plastic distortion [7][8][9][10]. It is a solid-state welding method that occurs far below the material's melting temperature and avoids the negative impacts of traditional fusion welding.…”

“…It is a solid-state welding method that occurs far below the material's melting temperature and avoids the negative impacts of traditional fusion welding. Additionally, it has developed itself as a popular method of joining AMCs [9]. It was introduced by the Welding Institute [11] which involves minimum heat intake and the bonding happens well below the alloys' melting temperature.…”

Evaluation of vehicle lightweighting to reduce greenhouse gas emissions with focus on magnesium substitution

“…An investigation conducted with 2010-2014 vehicle models in China concluded that 18 kg mass reduction improved fuel consumption by 0.07 L/100 km (Hao et al, 2016). Other research illustrated that magnesium: i) is 33% lighter than aluminium and 75% lighter than steel or cast-iron components (Wenlong et al, 2016); ii) (in the case of high-purity alloys) has a superior corrosion resistance when compared to conventional aluminium die cast alloys (Zhang et al, 2017); and iii) has better manufacturability when compared to aluminium because solidification is faster due to lower latent heat, thus producing approximately 25-50% more castings per unit time (Subramanya et al, 2018). Magnesium is the eighth most available element on earth and also composes about 2% of Earth's crust by weight.…”

“…In the case of high-purity alloys, magnesium has a superior corrosion resistance when compared to conventional aluminium die cast alloys (Zhang et al, 2017). Magnesium has better manufacturability when compared to aluminium because solidification is faster due to lower latent heat, thus producing approximately 25-50 per cent more castings per unit time (Subramanya et al, 2018). Magnesium is the eighth most available element on earth and also composes about 2 per cent of Earth's crust by weight.…”