Mixed mode I/II crack growth investigation for bi-metal FSW aluminum alloy AA7075-T6/pure copper joints

“…However, at the authors' best knowledge, there are no test results and data for investigating the fracture toughness and crack growth resistance of aluminium cylinders manufactured by the orbital FSW method probably due to lack of a suitable testing specimen and procedure for conducting the fracture experiments on curved and cylindrical geometries. The only investigations reported in the literature for crack growth and fracture toughness study of FSW parts are limited to flat plate FSW joints using different test specimens 34–40 …”

Section: Introductionmentioning

confidence: 99%

Mechanical and fracture properties of aluminium cylinders manufactured by orbital friction stir welding

Aliha

Ghoreishi

Imani

et al. 2020

Fatigue Fract Eng Mat Struct

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Butt welding of AA6063 aluminium cylindrical shells was performed using the orbital friction stir welding (FSW) method. Tool rotation speed and orbital speed (i.e., traverse speed of rotating cylinder during welding) were considered as variable, and the strength and the mechanical properties including tensile strength, microhardness, mode I fracture energy and mode I crack growth behaviour of manufactured cylinders were investigated experimentally. A novel and subsized test specimen was designed and manufactured for fracture testing of specimens extracted from both base metal and weld zone region of cylinders. The initial precrack was introduced along (i) the tool penetration through the pipe thickness (i.e., T-direction) and (ii) along the tool travelling direction (i.e., L-direction). It was found that the crack growth resistance and fracture energy values of FSW samples are greater than the corresponding values of base aluminium material along both "L"and "T"-directions. Also, the fracture resistance value in T-direction was higher than the L-direction for the whole tested FSW samples with different welding speeds. K E Y W O R D Scylinder butt joining, mechanical and microstructure properties, novel mode I fracture test specimen, orbital FSW, welding speeds

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“…This process was primarily used for joining aluminium and aluminium alloys (Thomas and Nicholas, 1997). Over the past decade, researchers have also successfully welded dissimilar metals such as aluminium alloys (Devaiah, Kishore and Laxminarayana, 2018;Elnabi et al, 2018;Muthu Krishnan et al, 2018;Abd Elnabi et al, 2019;Eskandari et al, 2019), aluminium alloys and copper (Zhang et al, 2014;Aliha et al, 2019;Muhammad and Wu, 2019;Rzaev et al, 2019;Shankar et al, 2019), aluminium and brass (Esmaeili et al, 2011b(Esmaeili et al, , 2011b(Esmaeili et al, , 2012Shojaeefard et al, 2013;Elfar et al, 2016), aluminium and magnesium (Jayaraj et al, 2017;Paradiso et al, 2017;Abdollahzadeh et al, 2019;Md and Birru, 2019), aluminium and nickel (Zheng et al, 2017), aluminium and steel (Kasai et al, 2015;Pourali et al, 2017;Hatano et al, 2018;Helal et al, 2019) and aluminium and titanium (Wu et al, 2015;Choi et al, 2018;Yu et al, 2019). The FSW process produces a weld with minimum defects as compared to fusion welding.…”

Section: Introductionmentioning

confidence: 99%

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

Panaskar

Terkar

2020

WJE

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Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

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Mixed mode I/II crack growth investigation for bi-metal FSW aluminum alloy AA7075-T6/pure copper joints

Cited by 30 publications

References 54 publications

Heat treatment effects on fracture resistance of additively manufactured PLA specimens under mode I loading

Heat treatment effects on fracture resistance of additively manufactured PLA specimens under mode I loading

Mechanical and fracture properties of aluminium cylinders manufactured by orbital friction stir welding

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

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