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

Abstract

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.

Local binary pattern for the evaluation of surface quality of dissimilar Friction Stir Welded Ultrafine Grained 1050 and 6061-T6 Aluminium Alloys

“…The welded joint is formed by deforming the material at temperatures below the melting point of parent material [6]. At a very cold welding conditions defects such as void formation and non-bonding can occur while at very hot welding condition issues such as degradation of the strength of the joint can occur as well as there is a formation of collapsible nugget within the stir zone occurs [7].…”

Impact of Bonding Temperature on Microstructure, Mechanical, and Fracture Behaviors of TLP Bonded Joints of Al2219 with a Cu Interlayer

“…However, joining aluminum alloys to other metal alloys using conventional fusion welding is not recommended due to the formation of weld flaws and brittle intermetallics at the interface. Advanced welding techniques such as TIG and MIG generate welding defects such as porosity, cracks, and incomplete penetration, and friction stir welding is a complex process where identification of the defects produced at the interface is not simple. − …”

Numerical Studies on Temperature and Material Flow During Friction Stir Welding using Different Tool Pin Profiles

“…The absence of melting and solidification in FSW reduces the chances of defect formation. The acceptability of FSW for joining the precipitation hared enable alloys which are commonly referred to as non-weldable alloys is gaining momentum these days [1,2].…”