Refill friction stir spot welding of AlSi10Mg alloy produced by laser powder bed fusion to wrought AA7075-T6 alloy

Fritsche, S.; Draper, J.; Toumpis, A.; Galloway, A.; Amancio‐Filho, Sergio T.

doi:10.1016/j.mfglet.2022.09.010

Cited by 9 publications

(5 citation statements)

References 17 publications

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“…Figure 9 compares the results of this study with those of the published RFSSW literature for 2xxx series aluminium alloys, highlighting the positive influence of the chamfered shoulder and that a substantial reduction in welding time is achievable without a significant loss of ULSF. Post-tensile testing fractography revealed two modes of failure that have been reported extensively in the literature [5,9,34,38,51,52]: plug pull-out (PPO) (Fig. 10b-c) and 45° shear through the bottom sheet (TWS) (Fig.…”

Section: Tensile Shear Testing and Failure Modesmentioning

confidence: 99%

Exploring a novel chamfered tool design for short duration refill friction stir spot welds of high strength aluminium

Draper,

Fritsche,

de Traglia Amancio-Filho

et al. 2024

Int J Adv Manuf Technol

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This work investigates refill friction stir spot welded joints of AA2024-T3 aluminium alloy, produced with short welding times between 3 s and 0.75 s. A novel tool geometry that incorporates a chamfer on the inner edge of the shoulder tip is investigated as a means of improving joint quality at short welding times by easing material flow during the refill stage. The influence of shoulder design on weld microstructure, defect formation, material flow, and mechanical properties was assessed. When compared with a standard shoulder geometry, it was found that the introduction of a chamfer on the inner tip edge improved material flow during the refill stage and led to improved material mixing at the weld periphery. The formation of voids in the region of the weld periphery was eliminated and tensile lap-shear strength of the welded joints was increased by 19% to 7.2 kN, and 27% to 8.16 kN, for 0.75 s and 1.5 s duration welds, respectively.

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Section: Tensile Shear Testing and Failure Modesmentioning

confidence: 99%

Exploring a novel chamfered tool design for short duration refill friction stir spot welds of high strength aluminium

Draper,

Fritsche,

de Traglia Amancio-Filho

et al. 2024

Int J Adv Manuf Technol

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“…They suggested that the worn shoulder surface reduced the lap shear strength of the joints while all the tested welds surpassed the minimum standard lap shear strength requirements for aeronautical applications [80]. Numerous studies are available in the literature investigating the RF-SSW of various aluminum alloys such as AA7075 [95][96][97], AA7050 [98], AA2024 [99,100], AA2198 [80], AA2014 [101], AA6061 [102,103], AA2219 [93], dissimilar Al alloys [102,104], dissimilar Al/steel [105], Mg alloys [9,106,107], dissimilar Mg, and steel [7].…”

Section: Friction Stir Spot Weldingmentioning

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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“…To the best knowledge of the authors, there is only one study evaluating the use of the RFSSW process for welding AM Al parts. In this study, Fritsche et al [71] joined AlSi10Mg Al alloy produced by PBF-LB to wrought AA7075-T6. Although no joint defects were observed by metallographic examination (Figure 25), a significant softening effect was observed in the SZ and TMAZ zones.…”

Section: Solid State Welding Processesmentioning

confidence: 99%

A Review on the Weldability of Additively Manufactured Aluminium Parts by Fusion and Solid-State Welding Processes

Nunes,

Faes,

De Waele

et al. 2023

Metals

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Additive manufacturing (AM) processes are playing a significant role in several industrial sectors such as construction and machine building industries, involving a wide variety of metallic materials. Among these, the AM of aluminium alloys has developed significantly over the last decade, mainly through Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) processes. Despite the many advantages of AM technology, some large or complex products cannot be produced entirely without the use of conventional manufacturing and joining processes, generally for financial or operational reasons. In this way, the ability to join conventionally and additively manufactured components or parts represents a crucial step towards their future use and the consolidation of conventional and additive manufacturing technologies. Despite the growing interest in AM technologies, there is still a significant lack of information on the joining of conventionally and additively manufactured components. The present work proposes a first review of the literature evaluating the weldability of AM aluminium alloys. The focus is on the use of fusion and solid-state welding processes and analysing the achieved microstructural evolution and mechanical properties. A clear relationship is observed between the AM technology used to produce the part, and the physical principles of the joining process. In addition, the gaps in the literature are highlighted to enable focused future work.

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Refill friction stir spot welding of AlSi10Mg alloy produced by laser powder bed fusion to wrought AA7075-T6 alloy

Cited by 9 publications

References 17 publications

Exploring a novel chamfered tool design for short duration refill friction stir spot welds of high strength aluminium

Exploring a novel chamfered tool design for short duration refill friction stir spot welds of high strength aluminium

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

A Review on the Weldability of Additively Manufactured Aluminium Parts by Fusion and Solid-State Welding Processes

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