Influence of Friction Stir Welding Parameters on Mechanical Properties of dissimilar AA 7475 to AISI 304

Abstract

Joining of dissimilar materials is difficult and challenging. Trend towards replacement of high density material (HDM) by low density material (LDM) is gaining importance in automotive industries. In the present work, friction stir welding (FSW) of high strength dissimilar materials i.e. aluminium alloy AA7475-T761 and stainless steel AISI 304 was conducted. The mechanical properties and microstructure of butt joint were investigated on using Taguchi L8 orthogonal array (OA). Different combinations of FSW parameters were used to obtain the maximum value of UTS. It was observed that most dominating parameter affecting UTS is tool rotational speed, contributing 42.19%, followed by traverse speed with 38.96% and shoulder diameter with 12.60%. The maximum UTS was observed 75.22% of base material AA 7475 (452MPa) under the optimum combination of parameters; tool rotational speed at 450 rpm, traverse speed 63 mm/min and shoulder diameter 14 mm. The microstructure of the resulted efficient joint shows appreciable variation in grain sizes in different zones and the micro hardness was found maximum in SZ on the retreating side.

An Analytic Hierarchy Process for a General Ranking of Friction Stir Welding Parameters Optimized Through the Design of Experimental Arrays

“…Literature overviews of the optimization of FSW parameters for aluminum and its alloys , magnesium alloys [47][48][49][50][51][52] , steel and its alloys [53,54] , copper and its alloys (i.e., brass) [55,56] , dissimilar joints of aluminum to copper and their alloys [57][58][59][60][61][62][63][64][65] , aluminum alloys to steel alloys [66][67][68][69][70][71][72] , aluminum alloys to magnesium alloys [73] , and steel alloys to copper [74] are provided in Tables 1-8. It demonstrates the selected parameters in their optimization studies, percentage 3/20 https://www.doi.org/10.53964/jmim.2022005 of contributions % obtained, arrays used, alloys, thicknesses of materials, statistical DOE methods performed, and the efficiencies of responses (properties) acquired in these investigations.…”

“…Solid-state techniques such as FSW are available to overcome various flaws related to fusion processes, such as hot cracking, distortion, and porosity. FSW performs under the melting temperature, about 10-20%, of the materials [1] and has been vastly utilized for welding similar or dissimilar metals for aluminum and its alloys , titanium alloys [46] , magnesium alloys [47][48][49][50][51][52] , steel and its alloys [53,54] , copper and its alloys (i.e., brass) [55,56] , dissimilar joints of aluminum to copper or brass [57][58][59][60][61][62][63][64][65] , aluminum to steel [66][67][68][69][70][71][72] , aluminum to magnesium [73] , and steel to copper [74] . These metals are regarded as hard to weld by traditional fusion processes.…”

“…This study firstly ranked the parameters separately of each metal joining group based on the types of metals. Eight sets were selected, namely aluminum and its alloys , magnesium alloys [47][48][49][50][51][52] , steel and its alloys [53,54] , copper and its alloys (i.e., brass) [55,56] , dissimilar joints of aluminum to copper and their alloys [57][58][59][60][61][62][63][64][65] , aluminum alloys to steel alloys [66][67][68][69][70][71][72] , aluminum alloys to magnesium alloys [73] , and steel alloys to copper [74] . Each metal group had different combinations of optimized parameters.…”

Investigate the Process Parameter on the Friction Stir Welding of Dissimilar Aluminium Alloys

“…As a result, joining such alloys requires the use of a different welding technique. Welding different aluminium alloys with FSW is a suitable option [7].…”

Post-weld friction stir processing of AA5083-F TIG welds with scandium added fillers

“…FSW is a solid-state welding technology that welds the material below the solidus temperature, removing a number of defects and irregularities associated with fusion welding, and producing welds of exceptional strength and ductileness. FSW is referred to as green technology because it is significantly more environmentally friendly and energy efficient than modern FW procedures [15,16]. FSP is like friction stir welding but does not produce weld joints, it only alters the microstructure of the materials [10,17].…”