Investigations on the effects of friction stir welding parameters on intermetallic and defect formation in joining aluminum alloy to mild steel

Dehghani, Marzieh; Amadeh, A.; Mousavi, S.A.A. Akbari

doi:10.1016/j.matdes.2013.01.013

Cited by 212 publications

(118 citation statements)

References 27 publications

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“…10b for WD 800/10, shows that the voids propagate longitudinally along the weld. Dehghani et al 29 showed that increasing downward forging force by using threaded pin or increasing the plunge depth, can reduce or even eliminate the tunnel defect.…”

Section: Microstructurementioning

confidence: 99%

Effect of Heat Input on the Mechanical Behaviour of Al-Cu FSW Lap Joints

et al. 2018

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Dissimilar Al-Cu joints are desirable due to the combination of the good electrical and thermal properties of copper with the economic advantages of aluminium. However, different chemical, mechanical and thermal properties turn dissimilar welding into a challenge with traditional fusion welding techniques. Friction stir welding appears to be a good alternative to welding dissimilar materials. Most of the works in Al-Cu FSW have been performed with Al on top. This work investigates the influence of heat input on the shear strength of aluminium-copper lap joints produced by FSW with a copper over aluminium lap configuration. Welds produced with the ω/ν rate of 200 rev.mm -1 or 500 rev.mm -1 resulted in the melting of the base materials and material leaking. Joints with shear tensile strength varying from 76 to 85% of the original resistance of AA6060 T5 were produced when the ω/ν rate was varied from 80 to 110 rev.mm -1 . The fracture was governed by tension overload on the aluminium sheet, resulting in little influence of welding defects, such as tunnelling, on the joint strength.

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Section: Microstructurementioning

confidence: 99%

Effect of Heat Input on the Mechanical Behaviour of Al-Cu FSW Lap Joints

et al. 2018

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“…The left-handed (LH) orientation of the threads was used with a clockwise rotation direction to generate a vertical flow of the AA towards the steel. Both the shoulder and the probe were made from H13 steel, as in previous studies from other authors [5,15]. The main welding parameters for the single-pass welding of the innovative overlap joint (step 1) are shown in Table 4.…”

Section: Experimental Conditionsmentioning

confidence: 99%

“…Fusion welding methods, such as laser welding and gas tungsten arc welding (GTAW), operate above the melting point of the base materials. Dehghani et al [5] mentioned that the high heat input can create a large amount of brittle intermetallic compounds (IMCs) in the weld zone, which is detrimental to the mechanical resistance of the welds. To reduce the formation of IMCs, solid-state welding methods such as ultrasonic welding and friction stir welding (FSW) can be employed because of their low heat input [6].…”

Section: Introductionmentioning

confidence: 99%

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FSW of aluminum AA5754 to steel DX54 with innovative overlap joint

et al. 2017

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An innovative overlap joint concept was tested to evaluate the quality improvement of welds between aluminum alloy AA5754-H22 (2 mm) and steel DX54 (1.5 mm). The innovation is a wave-shaped interface produced on the steel being directly processed by the tip of the probe, generating localized heat, extensive chemically active surfaces, and additional mechanical interlocking. Welds with different parameters were evaluated by metallographic analysis and mechanical tests. The best set of parameters was then implemented in a conventional overlap joint, plus in two-and three-passes welding, with the innovative overlap joint concept, to evaluate the effect on microstructure and mechanical efficiency. With a single-pass weld, the new concept presented lower strength in tensile shear tests, but higher strength in peeling tests. The main mechanism governing this behavior was the reduction of effective thickness in the aluminum alloy sheet, due to the flow of steel into the aluminum alloy. The characterization and distribution of the intermetallic compounds were evaluated via SEM-EDX. The two-passes weld resulted in the best strength values in tensile shear tests, reaching about 50% of the ultimate tensile strength of the aluminum alloy base material.

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“…Joint exhibits high tensile strength and IMC depreciation on the increase of welding speed. Dehghani et al [19] report suggests that ultimate tensile strength was found decreased from 246 to 187 MPa, when the plunge depth was decreased from 0.4 mm to 0.3 mm. Laser-assisted friction stir welding of 3 mm thick 6061-T6 aluminum alloy and Q235 steel was carried out.…”

Section: Introductionmentioning

confidence: 96%

Friction Stir Welding of Dissimilar Butt Joints with Novel Joint Geometry

Jayabalakrishnan¹,

Balasubramanian²

2018

Acta Phys. Pol. A

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In this study, 1 mm thin sheets of AA 6061 and steel were welded by friction stir, with new joint geometry. Conventional friction stir welding develops high distortion to the specimen, particularly when the thickness is very small. In this process, friction stir welding is carried out by a tool without probe and with new joint geometry. Contrary to the conventional friction stir welding, where various tool profiles are used to obtain successful joints, the present study of investigation focused on developing a profile in the sheet metal edges to be joined. The aluminium sheet was positioned on the contoured steel sheet. Rotating tool with tilt angle was made to progress into the top sheet. Frictional heat plasticized the upper blank and the edges of the aluminium sheet were forged and extruded into the steel contour. The welding between steel and aluminium was due to a coalescence of the two materials and clamping effect was provided by the contour in the steel sheet. Tensile test was conducted to evaluate the quality of the welding along with macro and micro metallographic investigations. Further to this, scanning electron microscopy with energy dispersive X-ray and X-ray diffraction analysis have been done to understand the presence of intermetallics at the weld nugget. Tensile strength of 122.22 MPa was achieved. Intermetallics of Mg2Si, MnAl6 and FeAl6, Al5Fe2 was found as dominant compound at the interface. Welding of thin sheets is enhanced by form clamping and chemical diffusion bonding.

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Investigations on the effects of friction stir welding parameters on intermetallic and defect formation in joining aluminum alloy to mild steel

Cited by 212 publications

References 27 publications

Effect of Heat Input on the Mechanical Behaviour of Al-Cu FSW Lap Joints

Effect of Heat Input on the Mechanical Behaviour of Al-Cu FSW Lap Joints

FSW of aluminum AA5754 to steel DX54 with innovative overlap joint

Friction Stir Welding of Dissimilar Butt Joints with Novel Joint Geometry

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