Investigation of Single-Pass/Double-Pass Techniques on Friction Stir Welding of Aluminium

Sathari, N. A. A.; Shah, L. H.; Razali, Akhtar Razul

doi:10.15282/jmes.7.2014.4.0102

Cited by 25 publications

(16 citation statements)

References 17 publications

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“…These alloys have excellent corrosion resistance, formability, and weldability [1][2][3][4][5]. Additionally, these alloys are desirable for making components of internal combustion engines such as the cylinder block and head and piston, which are usually subjected to relatively high temperatures during service [6].…”

Section: Introductionmentioning

confidence: 99%

Effects of temperature on the surface and subsurface of Al-Mg-Si welded joints

Hussin¹,

Lah²

2017

J. MECH. ENG. SCI.

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Al-Mg-Si (6061) Al alloy represents a widely used light material which is highly dependent on the distribution of its alloying element. Yet, when it involved a welded structure, the performance was absolutely dissimilar due to the influence of alloying element from filler metal addition, especially when it is subjected to high temperature environment. Thus, the study focuses on the surface and subsurface oxide growth patterns, its morphologies, and phases that formed after oxidation exposure. The plates were joined by GMAW using Al-5%Mg (ER5356) filler metal, and then subjected to an oxidation process in air environment at 400 °C, 500 °C and 600 °C for 40 h; their mass gains were then measured. The oxidised parent and fused metal parts were subsequently analysed using the scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction technique (XRD). It was observed that with the increasing temperature, the fused metal parts exhibited different oxide morphologies on both surface and subsurface compared to the parent metal parts. Additionally, the less oxidation attack was found after exposure at 400 °C and poor oxidation behaviour showed at 500 and 600 °C. The -Al2O3 phase was detected in both parent and fused metal samples after exposure at 400, 500, and 600 °C. Meanwhile, contradicted observation showed that the MgO phase was detected in fused metal part responsible for the poor oxidation behaviour. Thus, this would lead to a formation of non-protective oxide on the fused metal surfaces. This study suggested that the 6061 welded structure can withstand at 400 °C for long periods in air without serious deterioration but could not withstand exposure to 500 and 600 °C conditions in air.

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Section: Introductionmentioning

confidence: 99%

Effects of temperature on the surface and subsurface of Al-Mg-Si welded joints

Hussin¹,

Lah²

2017

J. MECH. ENG. SCI.

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“…It is a very challenging process due to the significant difference in the material properties. A lot of research has been done and reported on dissimilar welding [10][11][12]. Arguably the most famous research is on welding between aluminium and steel [2,[13][14][15][16][17][18].…”

Section: Introductionmentioning

confidence: 99%

Lap joint dissimilar welding of aluminium AA6061 and galvanized iron using TIG welding

Shah¹,

Mohamad²,

Yaakob³

et al. 2016

J. Mech, Eng, Sci.

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In this paper, aluminium AA6061-O and galvanized iron were lap-joined using tungsten inert gas (TIG) welding. The experiments were conducted using Si-rich filler metals ER4043 (Si 5 wt.%) and ER4047 (Si 12 wt.%). The mechanical properties and the microstructure of the samples were analysed using dye penetrant non-destructive tests (NDT), optical microscope observation and shear tests. All samples showed good quality joints, with Al-GI specimens showing better quality. Through optical microscope observation, the intermetallic compounds (IMC) of specimens using ER4043 fillers show a thin IMC layer ranging from 4 µm to 7 µm, compared to ER4047 samples which ranged between 20 µm and 40 µm. The shear tests show that the GI-Al group fractured at the IMC layer, while the Al-GI group fractured at the FZ-HAZ aluminium matrix. The highest shear strength value obtained was 89.82 MPa and 76.59 MPa for the Al-GI and GI-Al positions, respectively. It can be concluded that the GI-Al (galvanized iron on top and aluminium at the bottom) configuration with filler type ER4043 (Si 5 wt.%) has the optimum mechanical properties with a thin IMC layer and tensile strength of 76.59 MPa.

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“…The method of clamping and its effects on machine processes are well understood. Besides that, clamping claws is an easy and less costly system, however, it leads to varying temperature distributions which could be improved through the use of pressure bars [5][6][7]. Advanced research have indicated that continuous clamping approaches could lead to a more consistent FSW quality along the joint's length [8].…”

Section: Introductionmentioning

confidence: 99%

A simplified design of clamping system and fixtures for friction stir welding of aluminium alloys

Hasan¹,

Ishak²,

Rejab³

2015

J. Mech. Eng. Sci.

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Sound friction stir welds could be attained by using an active design of backing/clamping system with a proper selection of the welding parameters. This work presented a simplified design of fixtures and backing plates to be used for friction stir welding of aluminum alloys. The test-rig was constructed to prevent dispersal or lifting of the specimens throughout the joining process and to ensure uniform distribution of temperature along the plates. The workpieces were subjected to uniform lateral and vertical pressures by means of bolts and nuts. Compound backing plates and pressure bars with additional side plates were included to increase the heat sink. Several coupons of dissimilar aluminum alloys AA7075 and AA6061 were joined to inspect the validity of this design. The tests showed promising results with defects-free welds, good strength and smooth surface finish without geometric imperfection and gap creation between the welded specimens. Efficiency of the joint reached its maximum value of about 82% with respect to the ultimate strength of the AA6061 alloy at 1100 rpm rotation speed and 300 mm/min feed. These results encourage using and improving the present design for future studies of friction stir welding.

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Investigation of Single-Pass/Double-Pass Techniques on Friction Stir Welding of Aluminium

Cited by 25 publications

References 17 publications

Effects of temperature on the surface and subsurface of Al-Mg-Si welded joints

Effects of temperature on the surface and subsurface of Al-Mg-Si welded joints

Lap joint dissimilar welding of aluminium AA6061 and galvanized iron using TIG welding

A simplified design of clamping system and fixtures for friction stir welding of aluminium alloys

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