Influence of friction stir welding parameters on properties of 2024 T3 aluminium alloy joints

Abstract

The aim of this work is to analyse the process of friction stir welding (FSW) of 3 mm thick aluminium plates made of high strength aluminium alloy -2024 T3, as well as to assess the mechanical properties of the produced joints. Friction StirWelding is a modern procedure which enables joining of similar and dissimilar materials in the solid state, by the combined action of heat and mechanical work. This paper presents an analysis of the experimental results obtained by testing the butt welded joints. Tensile strength of the produced joints is assessed, as well as the distribution of hardness, micro-and macrostructure through the joints (in the base material, nugget, heat affected zone and thermo-mechanically affected zone). Different combinations of the tool rotation speed and the welding speed are used, and the dependence of the properties of the joints on these parameters of welding technology is determined.

Optimization of AA5083 Friction Stir Welding Parameters Using Taguchi Method

“…The friction stir welding operation has several phases. It starts with facing the work pieces and clamping them; then the pin plunges and penetrates into the plates until the tool shoulder has penetrated into the material at prescribed depth (a few tenths of a millimeter) enabling sufficient pressure and producing enough heat by friction and plastic deformation for establishing the appropriate welding conditions [4,5]. Then, the fast rotating tool starts moving along the facing contact of the plates (joint line), generating heat by friction between the head probe and the plate.…”

“…Majority of heat generated (about 95%) in the welding operation is transferred to the work piece and the remaining (about 5%) flows back into the tool. The material around the pin becomes soft and moves it from the front of the pin to the back by the rotation of the pin [4,5]. The process takes place in the solid phase, below the melting point of the materials to be joined and this gives the possibility of producing high quality joints, [7,8].…”

Melting behind the front of the shock wave

“…The constants are calculated according to the shock-wave experiments, determined from isentropic curves of unloading of porous samples, or are found from the experimental data in a wide area of the phase diagram from thermodynamic relations. It is worth mentioning the modern models with fewer constants as the initial data, but still there are too many of them to solve real engineering problems [4][5][6][7][8][9][10]. With this approach, the search for constants for the equation of state becomes a separate, time-consuming research task.…”

Analysis of the tool plunge in friction stir welding - comparison of aluminium alloys 2024 T3 and 2024 T351

“…It is mostly in plastic state and it is difficult to determine its temperature, due to the large plastic strain values. The FSW process has been considered in [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16], from the point of view of manufacturing, modelling, as well as testing of the specimens cut from the welded joints. Zhang and Zhang [1] carried out semi-coupled thermomechanical finite element (FE) analyses of the FSW process and the associated microstructural changes.…”

“…Zhang and Zhang [1] carried out semi-coupled thermomechanical finite element (FE) analyses of the FSW process and the associated microstructural changes. In some references, the main objective was to examine the effect of various FSW process parameters (including tool design) on the heat/mass transport processes, e. g. [1][2][3][4]. Song and Kovačević [5] and Chen and Kovačević [6] presented numerical thermomechanical modeling of FSW for both similar and dissimilar joints; dissimilar joints -------------- were also analysed in [7].…”