Abstract:The heat-treated and artificially aged aluminium alloys of AA6061 and AA2017 are friction stir welded by employing five different tool pin profiles keeping the other process parameters constant. From this investigation, the mechanical properties of welded blanks were evaluated. The test results revealed that the straight square tool pin profile exhibited a higher ultimate tensile strength of 253 MPa with a tensile elongation of 6.7%. Higher Microhardness and joint efficiency were reported compared to other pin… Show more
“…An essential mechanical parameter to take into account when assessing the effectiveness of welded joints is tensile elongation (TE). A number of variables, such as the welding parameters, alloy composition, and the number of weld passes, might affect the TE of FSWed aluminum joints [14,15]. The TE in single and double pass welds (i.e., samples 1 and 2) was observed 7.92% and 8.45%, respectively, and the TE in both single and double pass welds (i.e., samples 3 and 4) was observed at 6.56% and 6.97%, respectively.…”
Section: Tensile Elongationmentioning
confidence: 99%
“…Additionally, it has been proven that the mechanical and microstructure behaviors are influenced by the TRS, WS, and TTA [14]. It was determined that the most appropriate pin profile for FSW joints in aluminum alloys was based on the beneficial improvements in the mechanical and micro-structural behavior of FSWed tailor blanks made of AA 6061-T6-AA and 2017-T6 [15]. Few researchers [16,17] used different process parameters to determine the formability of the TWBs.…”
Friction stir welding (FSW) is a method of joining solid materials, where the parent metal's melting temperature is below the point of amalgamation. FSW is a successful method for combining various ferrous and non-ferrous matrix materials. Many researchers' studies suggested that FSW is suitable for both soft and high melting-point materials by changing the conditional attributes. A defect-free dissimilar weld joint of the alloys AA2017 and AA6061 was fabricated for the current investigation, and the effect of multi-pass friction stir welding (MPFSW) on the development of mechanical and different microstructural behaviors has been investigated. Welding conditions were a constant 1600 rpm weld tool rotational speed, a transverse speed is 32 mm/min, and a tilt angle of 0°. As a consequence of the pinning effect, the results showed that increasing the number of welding passes in FSW from single to double improved the particle dispersion, which in turn improved the tensile strength, and micro-hardness of the FSWed joint. The primary objectives of this study investigate the strength that was improved because of the rise in the number of passes as well as the effective bonding of the materials' weld interface, which gives tailor-welded blanks (TWBs) a considerably stronger joint. The findings revealed that the TWB joints' metallurgical and mechanical properties are extremely varied from single-pass to double-pass, and the position of the base materials can significantly affect the joint properties that are produced.
“…An essential mechanical parameter to take into account when assessing the effectiveness of welded joints is tensile elongation (TE). A number of variables, such as the welding parameters, alloy composition, and the number of weld passes, might affect the TE of FSWed aluminum joints [14,15]. The TE in single and double pass welds (i.e., samples 1 and 2) was observed 7.92% and 8.45%, respectively, and the TE in both single and double pass welds (i.e., samples 3 and 4) was observed at 6.56% and 6.97%, respectively.…”
Section: Tensile Elongationmentioning
confidence: 99%
“…Additionally, it has been proven that the mechanical and microstructure behaviors are influenced by the TRS, WS, and TTA [14]. It was determined that the most appropriate pin profile for FSW joints in aluminum alloys was based on the beneficial improvements in the mechanical and micro-structural behavior of FSWed tailor blanks made of AA 6061-T6-AA and 2017-T6 [15]. Few researchers [16,17] used different process parameters to determine the formability of the TWBs.…”
Friction stir welding (FSW) is a method of joining solid materials, where the parent metal's melting temperature is below the point of amalgamation. FSW is a successful method for combining various ferrous and non-ferrous matrix materials. Many researchers' studies suggested that FSW is suitable for both soft and high melting-point materials by changing the conditional attributes. A defect-free dissimilar weld joint of the alloys AA2017 and AA6061 was fabricated for the current investigation, and the effect of multi-pass friction stir welding (MPFSW) on the development of mechanical and different microstructural behaviors has been investigated. Welding conditions were a constant 1600 rpm weld tool rotational speed, a transverse speed is 32 mm/min, and a tilt angle of 0°. As a consequence of the pinning effect, the results showed that increasing the number of welding passes in FSW from single to double improved the particle dispersion, which in turn improved the tensile strength, and micro-hardness of the FSWed joint. The primary objectives of this study investigate the strength that was improved because of the rise in the number of passes as well as the effective bonding of the materials' weld interface, which gives tailor-welded blanks (TWBs) a considerably stronger joint. The findings revealed that the TWB joints' metallurgical and mechanical properties are extremely varied from single-pass to double-pass, and the position of the base materials can significantly affect the joint properties that are produced.
“…The basic materials (BMs) were AA6061 and AA2017 aluminum alloys which are aged artificially. 15 The mechanical characteristics of the BM sheets and TWBs were tested with the uniaxial simple tension test and the sample was prepared as per ASTM E08 guidelines. Tension tests on the BMs and blanks were used to measure standard mechanical characteristics such as yield strength (YS), ultimate tensile strength (UTS), percentage of tensile elongation (%TE), strain hardening exponent (n), and strength coefficient (K).…”
Section: Fswmentioning
confidence: 99%
“…To process FSW on blanks, a straight square (SS) pin profiled tool was used. 15 The SS pin profile is signified schematically in Figure 1. Figure 1. Straight square pin profile (geometry).…”
The influence of the coefficient of friction between punch-blank interface on the formability of friction stir welded aluminum tailor welded blanks was studied. Experimental and finite element investigations were performed to evaluate the formability with four different lubricants like dry lubricant, graphite in water, graphite in machine oil, and Teflon sheet (TS). During simulation, the boundary condition of the punch-blank interface was assigned as a frictional contact and the assigned value is the coefficient of friction value of the respective lubricant. To carry out the simulation, the entire blank was divided into three zones. It has been found that the coefficient of friction between punch-blank interfaces has a significant influence on formability. In the four lubrication conditions, the dry lubrication applied blank exhibited the lowest formability properties, and the TS applied blank exhibited superior formability properties in all aspects such as punch load-carrying capacity, limiting dome height, forming limit diagrams, and strain distribution profiles (experimentation and simulation). The experimental and simulation have a good agreement in all strain conditions. The standard deviation between the experimental and simulation results is ±10%.
“…Battina et al studied the influence of five different tool pin profiles on mechanical and metallurgical behaviour of FSW AA6061-T6 and AA2017-T6 joint. The effect of five different tool pin profiles on the metallurgical and mechanical behaviour of FSW AA6061-T6 and AA2017-T6 joints were examined by Malleswararao Battina et al (2021). The straight square, taper square tool pin, straight pentagonal, straight cylindrical and straight hexagonal profiles were used in the FSW process.…”
Purpose
The purpose of this paper is to investigate the impact of ultrasonic vibration (UV) and tool pin profile on mechanical properties and microstructural behaviour of AA7075-T651 and AA6061-T6 joints was analysed.
Design/methodology/approach
The joints were fabricated using three different tool pin profiles such as cylindrical, square and triangle. For each tool pin profile, two different UV powers of 1.5 kW and 2 kW were used.
Findings
On both the advancing and retreating sides of the weld, the thermo-mechanically affected zone has the lowest microhardness. In all joints, the tensile fracture locations match to the minimum hardness values. Field emission scanning electron microscope fractography of tensile tested specimens reveals heterogeneous modes of brittle, shear and ductile fracture. Three-point bending analysis was performed to determine the ductility and soundness of the weld joint. The acoustic softening effect of UV, as well as the static and dynamic ratio of tool pin profile, plays an important role in determining the material flow and mechanical behaviour of the joint.
Practical implications
Dissimilar aluminium joining fascinates many applications like aircraft, aerospace, automobiles, ship building and electronics, where fusion welding is a very intricate process because of the deviation in its physical and chemical properties.
Originality/value
From this study investigation, it is found that the square pin profiled tool with 2 kW UV power produces metallurgical defect-free and mechanically sound weld with maximum tensile strength, hardness and bending load of 297 MPa, 151HV and 3.82 kN, respectively.
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