Microstructure, static and fatigue properties of refill friction stir spot welded 7075-T6 aluminium alloy using a modified tool

Shen, Zhikang; Ding, Yifan; Chen, J.; Fu, Li; Liu, Xiaochao; Chen, H.; Guo, Wei; Gerlich, A.P.

doi:10.1080/13621718.2019.1572300

Cited by 37 publications

(12 citation statements)

References 60 publications

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“…The tool used in the re-filling process consists of three components: an outer clamping ring, a sleeve, and a central pin. Both the sleeve and pin components rotate at the same rotational speed and direction [ 30 ]. In the FSSW process, in the first step, both the central rotating pin and outer rotating clamping ring move down and impose compressive pressure on the contact surface (Step 1 in Figure 2 ).…”

Section: Methodsmentioning

confidence: 99%

Fatigue Modeling and Numerical Analysis of Re-Filling Probe Hole of Friction Stir Spot Welded Joints in Aluminum Alloys

et al. 2021

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In the present study, the fatigue behavior and tensile strength of A6061-T4 aluminum alloy, joined by friction stir spot welding (FSSW), are numerically investigated. The 3D finite element model (FEM) is used to analyze the FSSW joint by means of Abaqus software. The tensile strength is determined for FSSW joints with both a probe hole and a refilled probe hole. In order to calculate the fatigue life of FSSW joints, the hysteresis loop is first determined, and then the plastic strain amplitude is calculated. Finally, by using the Coffin-Manson equation, fatigue life is predicted. The results were verified against available experimental data from other literature, and a good agreement was observed between the FEM results and experimental data. The results showed that the joint’s tensile strength without a probe hole (refilled hole) is higher than the joint with a probe hole. Therefore, re-filling the probe hole is an effective method for structures jointed by FSSW subjected to a static load. The fatigue strength of the joint with a re-filled probe hole was nearly the same as the structure with a probe hole at low applied loads. Additionally, at a high applied load, the fatigue strength of joints with a refilled probe hole was slightly lower than the joint with a probe hole.

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Section: Methodsmentioning

confidence: 99%

Fatigue Modeling and Numerical Analysis of Re-Filling Probe Hole of Friction Stir Spot Welded Joints in Aluminum Alloys

et al. 2021

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“…The cracking response highly depends on applied load levels. At high cyclic load levels and in the presence of tensile loads, nuggets experience pull-out or even lap-shear fracture modes [29,30]. The local alloying process of the FSW joints by inserting thin copper foils altered the microstructures of the weld regions, affecting the static and fatigue response of aluminum joints.…”

Section: Microstructural Features Of Joint Samplesmentioning

confidence: 99%

Section: Microstructural Features Of Joint Samplesmentioning

confidence: 99%

A Comparative Study on Fatigue Response of Aluminum Alloy Friction Stir Welded Joints at Various Post-Processing and Treatments

Hassanifard

Varvani‐Farahani

2021

JMMP

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The present study examines the fatigue of friction stir welded (FSW) aluminum 6061, 7075, 1060 joints followed by (i) in situ and sequential rolling (SR) processes, (ii) plastic burnishing (iii) solution-treatment artificial aging (STA), (iv) local alloying through depositing thin copper foils, and (v) inserting alumina powder in the weld nugget zone (NZ). The microstructural features and fatigue life of post-processed joints were compared with those of as-welded joints. The in situ rolling technique offered simultaneous rolling and welding operations of aluminum joints, while through the sequential rolling process, the top surface of FSW joints was rolled after the welding process. The fatigue life of in situ rolled samples was increased as the ball diameter of welding tool increased. The fatigue life of friction stir welded joints after a low-plasticity burnishing process was noticeably promoted. The addition of 1 wt.% alumina in the NZ of joints resulted in a significant elevation on fatigue life of friction stir spot welded joints, while an increase in alumina powder to 2.5 wt.% adversely affected fatigue strength. Weld NZ was alloyed through the insertion of copper foils between the faying surfaces of joints. This localized alloy slightly improved the fatigue life of joints; however, its effects on fatigue life were not as influential as STA heat-treated or in situ rolled joints. The microstructure of weld joints was highly affected through post-processing and treatments, resulting in a substantial influence on the fatigue response of FSW aluminum joints.

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“…Silva et al [37] had been studied the temperature distribution around a FSW tool on bead-on-plate welds in 20 mm thickness aluminum alloy, AA6082-T6. Shen [38] had been evaluated the weld performance in terms of microstructure, interfacial bonding, hardness, static and fatigue strength of 7075-T6 Al alloy welded joint in refill friction stir spot welding using a modified tool based on the experimental analysis.…”

Section: Literature Reviewmentioning

confidence: 99%

Recent Advances in Joining of Aluminum Alloys by Using Friction Stir Welding

Rudrapati¹

2020

Mass Production Processes

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Aluminum and its alloys have gained much interest in advanced industrial applications due to its excellent mechanical properties. Welding is one of prominent fabrication technique which has to be performed to make assembling of different parts to create one complete product. Welding of aluminum alloys (al) using traditional welding methods is difficult task due to un-weldability of aluminum alloys, more defects in weldment, presence of aluminum oxide film, etc. Friction stir welding (FSW) is a novel welding technique which was developed specially to join the aluminum alloys without melting of materials to be joined. Achieving the good qualities of welded joint with enhanced efficiency of the FSW process needs, proper understanding of principles of FSW. In the present chapter, various aspects of FSW of aluminum alloys related to effects of process welding parameters and temperature distribution during welding on mechanical and metallurgical properties of weldment has been presented. Extending applications of FSW in joining of dissimilar aluminum alloys and welding of al alloys with other materials has also been discussed. Concluding remarks are drawn from the study. From the study, it is stated that FSW is suitable for mass production welding method for joining of similar/dissimilar aluminum alloy materials in large quantity of similar products.

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Microstructure, static and fatigue properties of refill friction stir spot welded 7075-T6 aluminium alloy using a modified tool

Cited by 37 publications

References 60 publications

Fatigue Modeling and Numerical Analysis of Re-Filling Probe Hole of Friction Stir Spot Welded Joints in Aluminum Alloys

Fatigue Modeling and Numerical Analysis of Re-Filling Probe Hole of Friction Stir Spot Welded Joints in Aluminum Alloys

A Comparative Study on Fatigue Response of Aluminum Alloy Friction Stir Welded Joints at Various Post-Processing and Treatments

Recent Advances in Joining of Aluminum Alloys by Using Friction Stir Welding

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