Review on friction stir welding of dissimilar magnesium and aluminum alloys: Scientometric analysis and strategies for achieving high-quality joints

Ahmed, Mohamed M.Z.; El-Sayed Seleman, Mohamed M.; Fydrych, Dariusz; ÇAM, Gürel

doi:10.1016/j.jma.2023.09.039

Cited by 59 publications

(8 citation statements)

References 135 publications

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“…From the statics of the robot, the relationship between the joint torque of the robot and the forces at the end-effector can be derived as Equation (5).…”

Section: Stiffness Model Of Robotmentioning

confidence: 99%

“…As a solid-state joining process, FSW possesses a low welding temperature and minimal residual stress, and it has been widely used in fields such as aviation, automotive, railway, maritime, and more [3,4]. Especially in the field of dissimilar metal welding, such as aluminum-magnesium, aluminum-copper, carbon steel-stainless steel, etc., FSW technology demonstrates irreplaceable advantages [5,6]. The development of FSW technology has progressed rapidly with significant contributions from many scholars.…”

Section: Introductionmentioning

confidence: 99%

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Digital Twin Virtual Welding Approach of Robotic Friction Stir Welding Based on Co-Simulation of FEA Model and Robotic Model

Chen,

Zong,

Kang

et al. 2024

Sensors

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Robotic friction stir welding has become an important research direction in friction stir welding technology. However, the low stiffness of serial industrial robots leads to substantial, difficult-to-measure end-effector deviations under the welding forces during the friction stir welding process, impacting the welding quality. To more effectively measure the deviations in the end-effector, this study introduces a digital twin model based on the five-dimensional digital twin theory. The model obtains the current data of the robot and six-axis force sensor and calculates the real-time end deviations using the robot model. Based on this, a virtual welding model was realized by integrating the FEA model with the digital twin model using a co-simulation approach. This model achieves pre-process simulation by iteratively cycling through the simulated force from the FEA model and the end displacement from the robot model. The virtual welding model effectively predicts the welding outcomes with a mere 6.9% error in lateral deviation compared to actual welding, demonstrating its potential in optimizing welding parameters and enhancing accuracy and quality. Employing digital twin models to monitor, simulate, and optimize the welding process can reduce risks, save costs, and improve efficiency, providing new perspectives for optimizing robotic friction stir welding processes.

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“…From the statics of the robot, the relationship between the joint torque of the robot and the forces at the end-effector can be derived as Equation (5).…”

Section: Stiffness Model Of Robotmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Digital Twin Virtual Welding Approach of Robotic Friction Stir Welding Based on Co-Simulation of FEA Model and Robotic Model

Chen,

Zong,

Kang

et al. 2024

Sensors

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“…So, this con ned plasticity leads to low ductility values. Similarly, low ductility values are also usually exhibited by inhomogeneous welded joints, such as by strength overmatching steel joints [15,16,45], bi-metallic joints involving materials with different strength [46][47][48][49][50], and particularly by Alalloys joints with a very high strength undermatching weld region [51][52][53][54][55][56][57][58], which all have con ned plasticity. Furthermore, all the weld specimens fractured within the transition region between AISI 430 ferritic BM and FGHAZ, far away from the weld nugget, as illustrated in Fig.…”

Section: Mechanical Propertiesmentioning

confidence: 99%

MIG Welded Dissimilar AISI 430/304L Butt Joint: Microstructure and Joint Performance

SERİNDAĞ,

Cam

2024

Preprint

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In recent years, dissimilar welds are increasingly demanded in numerous industrial applications due to the economic advantages and superior joint performance. Thus, joining of dissimilar steels is highly demanded in various industries and production of defect-free dissimilar joints by conventional fusion welding processes is rather important. In this study, 5 mm thick AISI 430 ferritic and AISI 304L austenitic plates were joined by the gas metal arc welding in butt configuration. A detailed microstructural investigation was conducted across the weld region of the joint by optical microscopy and SEM. Micro-hardness and mechanical tests were employed to determine the mechanical properties of the joints fabricated. The welded joint exhibited a tensile strength value of about 100% of the lower strength base metal, i.e. AISI 430 BM. In contrast, the confined plasticity in the lower strength AISI 430 base metal side resulted in low ductility performance, i.e. about 57%.

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“…Friction stir welding (FSW) tools have witnessed a significant research efforts and development for industrial applications since inventing the process in 1991 [1][2][3]. The time needed to prepare specimens for the welding process, the welding time, and the number of welding passes [4] are all advantages of the FSW over TIG and MIG welding processes.…”

Section: Introductionmentioning

confidence: 99%

Impact of the tool shoulder diameter to pin diameter ratio and welding speed on the performance of friction sir-welded AA7075-T651 Al alloy butt joints

Hammad,

Lu,

Seleman

et al. 2024

Mater. Res. Express

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This study investigates the friction stir welding (FSW) of aluminum alloy 7075-T651, mainly focusing on managing heat generation during the process. The critical parameters influencing heat amount and the material flow including FSW tool shoulder diameter (SD) and travel speed (TS) were investigated. Two far different SD of 10 mm and 20 mm with constant pin diameter (PD) of 5.70 mm that resulted in PD: SD ratios of 1:1.75 and 1: 3.50, respectively, were employed. Furthermore, three different travel speeds of 25, 50, and 75 mm/min at a constant rotation rate of 600 rpm were used in combination with the two PD: SD ratios. The macrographic and radiographic results indicated that the smallest PD: SD ratio has successfully achieved sound friction stir welded (FSWed) joints for the same travel speeds. Results also indicated that a significant amount of material deformed under a high PD: SD ratioat a high TS of 75 mm/min, while flash increased with reducing PD: SD ratio.Mechanical properties were compared, revealing that hardness in the nugget zone (NZ) decreased with a lower TS of 25 mm/min. A small PD: SD ratioallowed for more symmetrical heat distribution, supported by the hardness map. The ultimate tensile strength decreased with increasing TS, and the highest ultimate strength, reaching 319 MPa, was observed with a 1:1.75 ratio and TS of 25 mm/min. X-ray diffraction analysis (XRD) found an increase in peaks with increasing shoulder diameter and the number of peaks increased with decreasing travel speeds.

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Review on friction stir welding of dissimilar magnesium and aluminum alloys: Scientometric analysis and strategies for achieving high-quality joints

Cited by 59 publications

References 135 publications

Digital Twin Virtual Welding Approach of Robotic Friction Stir Welding Based on Co-Simulation of FEA Model and Robotic Model

Digital Twin Virtual Welding Approach of Robotic Friction Stir Welding Based on Co-Simulation of FEA Model and Robotic Model

MIG Welded Dissimilar AISI 430/304L Butt Joint: Microstructure and Joint Performance

Impact of the tool shoulder diameter to pin diameter ratio and welding speed on the performance of friction sir-welded AA7075-T651 Al alloy butt joints

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