Material flow in friction stir welding: A review

Ambrosio, Danilo; Morisada, Yoshiaki; Ushioda, Kohsaku; Fujii, Hidetoshi

doi:10.1016/j.jmatprotec.2023.118116

Cited by 38 publications

(4 citation statements)

References 108 publications

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“…When the rotational speed is constant, with an increase in the travel speed, the residence time of the shoulder at each place of the weld channel is decreased. The material is affected by the frictional heat for a shorter period of time; therefore, the plastic deformation ability of the material is gradually reduced, and the loss of material is reduced, so the rate of reduction decreases gradually [ 19 ].…”

Section: Resultsmentioning

confidence: 99%

Microstructure Evolution and Mechanical Properties of 7A52 Aluminum Alloy Thin Sheet Repaired with Friction Stir Surfacing

Li,

Shi,

Han

et al. 2024

Materials

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A solid-state repair technique based on surface friction welding is investigated in depth to achieve excellent mechanical properties of damaged 7A52 aluminum alloy. The results show that the yield strength and tensile strength along the repair direction are 436 MPa and 502 MPa, respectively, at a rotational speed of 1400 rpm and a travel speed of 300 mm/min, which are about 157.9% and 129.7% of those before the defects were repaired, respectively, while the elongation is 17.2% compared to the base material. Perpendicular to the repair direction, the yield strength and tensile strength are 254 MPa and 432 MPa, which are 111.4% and 129.7% of those before the defects were repaired, respectively, while the elongation is 11.8% compared to the base material. The mechanical properties of the repaired areas are still improved compared to those of the defect-free sheets. On the one hand, this is attributed to the dynamic recrystallization of the nugget zone due to the thermo-mechanical coupling, resulting in the formation of a fine, equiaxed grain structure; on the other hand, the precipitated Mg2Si phase, which is incoherent within the base material, transforms into the Al12(Fe, Mn)3Si phase, as well as the precipitation of the Al6Mn phase and η′ phase, resulting in the enhancement of the properties. The material fracture at the junction of the nugget zone and the heat-affected zone occurs after repair, which is attributed to the significant difference in the texture of the nugget zone and the heat-affected zone, as well as to the stress concentration at the junction.

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Section: Resultsmentioning

confidence: 99%

Microstructure Evolution and Mechanical Properties of 7A52 Aluminum Alloy Thin Sheet Repaired with Friction Stir Surfacing

Li,

Shi,

Han

et al. 2024

Materials

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“…The tool's rotation stirs and blends the material, forming a defect-free joint as it propagates along the weld line. FSW is particularly useful for joining materials such as aluminum and other non-ferrous alloys, providing superior strength and minimal distortion and making it valuable in the aerospace and automotive industries alongside many others [36][37][38][39]. Figure 1 shows a schematic diagram of the FSW process.…”

Section: Fundamentals Of Friction Stir Weldingmentioning

confidence: 99%

“…The alterations in microstructure within different zones have a substantial impact on the mechanical properties seen after welding. Consequently, numerous researchers have conducted investigations on the microstructural evolution that occurs during FSW [35,37,145,146]. Three unique zones, namely the stirred (nugget) zone, thermomechanically affected zone (TMAZ), and heataffected zone (HAZ) [147,148], have been discovered based on the microstructural characterization of grains and precipitates, as depicted in Figure 9 [147], Figure 10a [149] and Figure 10b [150].…”

Section: Microstructural Changes Occurring During Fswmentioning

confidence: 99%

A Review of Recent Developments in Friction Stir Welding for Various Industrial Applications

Bharti,

Kumar,

Singh

et al. 2023

JMSE

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Friction stir welding (FSW) has been recognized as a revolutionary welding process for marine applications, effectively tackling the distinctive problems posed by maritime settings. This review paper offers a comprehensive examination of the current advancements in FSW design, specifically within the marine industry. This paper provides an overview of the essential principles of FSW and its design, emphasizing its comparative advantages when compared with conventional welding techniques. The literature review reveals successful implementations in the field of shipbuilding and offshore constructions, highlighting design factors as notable enhancements in joint strength, resistance to corrosion, and fatigue performance. This study examines the progress made in the field of FSW equipment and procedures, with a specific focus on their application in naval construction. Additionally, it investigates the factors to be considered when selecting materials and ensuring their compatibility in this context. The analysis of microstructural and mechanical features of FSW joints is conducted, with a particular focus on examining the impact of welding settings. The study additionally explores techniques for mitigating corrosion and safeguarding surfaces in marine environments. The study also provides a forward-looking perspective by proposing potential areas of future research and highlighting the issues that may arise in the field of FSW for maritime engineering. The significance of incorporating environmental and economic considerations in the implementation of FSW for extensive marine projects is emphasized.

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“…Friction stir welding (FSW) has emerged as the preferred method for assembling aluminum alloys, owing to its manifold benefits, such as defect reduction and property enhancement [1][2][3]. FSW achieves joint formation through a combination of frictional heat and plastic deformation, resulting in distinct regions within the joint: the stir zone (SZ), advancing side (AS), retreating side (RS), and base metal (BM) [4][5][6]. The SZ represents the central region where the FSW tool interacts with the workpieces, undergoing significant plastic flow and grain refinement to form a metallurgical bond [7].…”

Section: Introductionmentioning

confidence: 99%

Quasi-In Situ Observation of the Microstructural Response during Fatigue Crack Growth of Friction Stir Welded AA2024-T4 Joint

Yang,

Chen,

Zhao

et al. 2024

Materials

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The reliability of friction stir welded joints is a critical concern, particularly given their potential applications in the aerospace manufacturing industry. This study offers a quasi-in situ observation of the microstructural response during fatigue crack growth (FCG) of a friction stir welded AA2024-T4 joint, aiming to correlate fatigue crack growth behavior with mechanical properties investigated using electron backscatter diffraction (EBSD). Notched compact tension (CT) specimens corresponding to the morphology of the stir zone (SZ), advancing side (AS), and retreating side (RS) were meticulously designed. The findings indicate that the welding process enhances the joint’s resistance to fatigue crack growth, with the base metal exhibiting a shorter fatigue life (i.e., ~105 cycles) compared to the welding zones (SZ ~ 3.5 × 105 cycles, AS ~ 2.5 × 105 cycles, and RS ~ 3.0 × 105 cycles). Crack propagation occurs within the stir zone, traversing refined grains, which primarily contribute to the highest fatigue life and lowest FCG rate. Additionally, cracks initiate in AS and RS, subsequently expanding into the base metal. Moreover, the study reveals a significant release of residual strain at the joint, particularly notable in the Structural-CT-RS (Str-CT-RS) sample compared to the Str-CT-AS sample during the FCG process. Consequently, the FCG rate of Str-CT-AS is higher than that of Str-CT-RS. These findings have significant implications for improving the reliability and performance of aerospace components.

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Material flow in friction stir welding: A review

Cited by 38 publications

References 108 publications

Microstructure Evolution and Mechanical Properties of 7A52 Aluminum Alloy Thin Sheet Repaired with Friction Stir Surfacing

Microstructure Evolution and Mechanical Properties of 7A52 Aluminum Alloy Thin Sheet Repaired with Friction Stir Surfacing

A Review of Recent Developments in Friction Stir Welding for Various Industrial Applications

Quasi-In Situ Observation of the Microstructural Response during Fatigue Crack Growth of Friction Stir Welded AA2024-T4 Joint

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