Microstructure and Mechanical Properties of Friction Stir Welded 2205 Duplex Stainless Steel Butt Joints

Ahmed, Mohamed M. Z.; Hajlaoui, K.; Seleman, Mohamed M. El-Sayed; Elkady, Mahmoud F.; Ataya, Sabbah; Latief, Fahamsyah H.; Habba, Mohamed I. A.

doi:10.3390/ma14216640

Cited by 17 publications

(10 citation statements)

References 49 publications

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“…Furthermore, it was reported [ 36 ] that the flash formed on the advanced side (AS) is higher than the retreating side (RS) due to the stirring mechanism during the FSW process, in which the material in the stir zone flows the plasticized material from AS to RS [ 41 ]. Thus, FSW welding variables should be considered to control the formation of an excessive welding flash, including tool design, plunge depth, tilt angle, and introduced heat input [ 42 , 43 ]. Hence, the FSW machine parameters (400 rpm rotation speed, 100 and 400 mm/min travel speeds, 4.8 mm tool plunge depth, and 3° tilt angle) and the FSW tool design should be chosen carefully to reduce flash forming during the welding process of AA5083-H1111.…”

Section: Resultsmentioning

confidence: 99%

“…Since the amounts of temperature and deformation experienced are insufficient to cause dynamic recrystallization, these grains are generated mainly by dynamic recovery [ 53 , 54 ]. Finally, a refined equiaxed grain structure can be seen in the SZ [ 43 , 53 ]. Since the heat generated and plastic deformation are sufficiently high, in contrast to the TMAZ, to induce this phenomenon, the new grain structure is formed by continuous dynamic recrystallization [ 53 , 55 , 56 , 57 ].…”

Section: Resultsmentioning

confidence: 99%

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Comparative Study of FSW, MIG, and TIG Welding of AA5083-H111 Based on the Evaluation of Welded Joints and Economic Aspect

Habba,

Alsaleh,

Badran

et al. 2023

Materials

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Selecting an economically suitable welding technique and optimizing welding parameters to obtain high joint quality is considered a challenge for expanding the 5xxx aluminum alloy series in various industrial applications. This work aims to investigate the effect of applying different welding techniques, tungsten inert gas (TIG) and metal inert gas (MIG), as fusion welding processes compared to friction stir welding (FSW), a solid-state joining process, on the joint performance of the produced 5 mm thick similar AA5083-H111 butt weldments at different welding conditions. Different methods were used to evaluate the quality of the produced joints, including visual inspection, radiographic testing (RT), and macrostructure evaluation, in addition to hardness and tensile tests. The fracture surface of the tensile-failed specimens was also investigated using a scanning electron microscope (SEM). Furthermore, the current study ended with an economic analysis of the welding techniques used. The results showed that, for the friction stir-welded joints, the radiographic films revealed defect-free joints at the two applied travel speeds of 100 mm/min and 400 mm/min and a constant tool rotating speed of 400 rpm. In addition, only one joint was welded by MIG at a welding current of 130 Amp, with a 19 L/min flow rate of pure argon. In contrast, the radiographic films showed internal defects such as lack of fusion (LOF), lack of penetration (LOP), and porosity (P) for the two joints welded by TIG and one joint welded by MIG. The hardness of the welded joints was enhanced over the AA5083-H111 base material (BM) by 24–29, 31–35, and 46–50% for the MIG, TIG, and FSW joints, respectively. The maximum ultimate tensile strength was obtained for the FSW joint welded at a 400 mm/min travel speed. Adopting FSW in shipbuilding applications can further produce the AA5083-H11 joints with higher quality and efficiency than fusion welding techniques such as MIG and TIG processes. In addition, time and cost comparisons between TIG, MIG, and FSW were performed for five-millimeter-thick and one-meter-long AA5083-H111.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Comparative Study of FSW, MIG, and TIG Welding of AA5083-H111 Based on the Evaluation of Welded Joints and Economic Aspect

Habba,

Alsaleh,

Badran

et al. 2023

Materials

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“…As a result, the aerospace sector increasingly relies on recycled aluminum Al to meet its growing demand. In addition, there is a push for development in the materials used, the joining techniques, and the design structure of aircraft [41,141].…”

Section: Future Perspective Of Al In Aerospace Applicationsmentioning

confidence: 99%

Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review

et al. 2023

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The use of the friction stir welding (FSW) process as a relatively new solid-state welding technology in the aerospace industry has pushed forward several developments in different related aspects of this strategic industry. In terms of the FSW process itself, due to the geometric limitations involved in the conventional FSW process, many variants have been required over time to suit the different types of geometries and structures, which has resulted in the development of numerous variants such as refill friction stir spot welding (RFSSW), stationary shoulder friction stir welding (SSFSW), and bobbin tool friction stir welding (BTFSW). In terms of FSW machines, significant development has occurred in the new design and adaptation of the existing machining equipment through the use of their structures or the new and specially designed FSW heads. In terms of the most used materials in the aerospace industry, there has been development of new high strength-to-weight ratios such as the 3rd generation aluminum–lithium alloys that have become successfully weldable by FSW with fewer welding defects and a significant improvement in the weld quality and geometric accuracy. The purpose of this article is to summarize the state of knowledge regarding the application of the FSW process to join materials used in the aerospace industry and to identify gaps in the state of the art. This work describes the fundamental techniques and tools necessary to make soundly welded joints. Typical applications of FSW processes are surveyed, including friction stir spot welding, RFSSW, SSFSW, BTFSW, and underwater FSW. Conclusions and suggestions for future development are proposed.

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“…values. Another recent work on stainless steel based on implementing a high pin to shoulder ratio (65%) tungsten carbide (W.C.) by Ahmed et al [39] concluded that a highly defect-free weld can be generated by optimising rotational rate, travel speed, and downward force parameters.…”

Section: Fsw Of Steelmentioning

confidence: 99%

Experimental and numerical analysis of friction stir welding: a review

Sen

Jayaprakash

2022

Eng. Res. Express

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Friction stir welding (FSW) is a topic of immense interest to researchers worldwide. The solid-state welding process has gained considerable popularity in the joining industry, replacing the orthodox welding techniques. To understand the necessity of friction stir welding, in this study, literature on experimental studies of friction stir welding on Steel, Aluminium, Magnesium and Titanium alloys have been summarised. Due to the interaction of multiple process parameters and complex geometry in FSW, the experimental study of this type of welding faces a challenge that can be overcome using numerical analysis like the finite element method. However, before initiating the design of the finite element model, a correct set of parameters and modelling methods needs to be made by the user to obtain results of high precision. This paper summarised the results obtained by various numerical modelling methods based on the review of over 100 research articles and suggested a suitable way for particular applications. Results show that ANSYS and ABAQUS are mainly preferred for friction simulation, thermomechanical behaviour, stress and strain analysis, while FLUENT finds its application mainly in material flow simulations. This review paper summarises both the experimental studies and the numerical approach to FSW modelling by distinctly mentioning the merits and demerits in each case. The results summarised would be beneficial for future researchers in the areas of FSW of advanced materials. Also the summarized results would be useful to choose the appropriate experimental parameter and numerical analysis techniques for FSW of various materials.

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Microstructure and Mechanical Properties of Friction Stir Welded 2205 Duplex Stainless Steel Butt Joints

Cited by 17 publications

References 49 publications

Comparative Study of FSW, MIG, and TIG Welding of AA5083-H111 Based on the Evaluation of Welded Joints and Economic Aspect

Comparative Study of FSW, MIG, and TIG Welding of AA5083-H111 Based on the Evaluation of Welded Joints and Economic Aspect

Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review

Experimental and numerical analysis of friction stir welding: a review

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