Tensile and Fracture Properties of Aluminium Alloy AA2219-T87 Friction Stir Weld Joints for Aerospace Applications

Manikandan, P.; Prabhu, T. Antony; Manwatkar, Sushant K.; Rao, G. Sudarshan; Murty, S. V. S. Narayana; Sivakumar, D.; Pant, Bhanu; Mohan, M.

doi:10.1007/s11661-021-06337-y

Cited by 25 publications

(5 citation statements)

References 43 publications

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“…When examined at higher magnifications, it becomes apparent that the weld nugget displays fine grains that are equiaxed, while TMAZ exhibits larger and elongated grains. Similar observations have been stated by Aydin et al and Manikandan et al [30,32]. They elucidated that the microstructure of the nugget zone (NZ) primarily arises from elevated temperatures and plastic deformation, resulting in dynamic recrystallization.…”

Section: Microstructuresupporting

confidence: 83%

Assessment of the Thermomechanical Behavior and Microstructure of AA 7075-T6 Aluminum Alloy Lap Joints at Optimal Predicted FSW Process Parameters

Toumi,

Khalifa,

Silvestri

et al. 2024

Preprint

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Lap joints were friction stir welded in AA 7075-T6 at 1320 rpm and using two welding speeds: 70 mm/min and 120 mm/min. The temperature profiles of the weld zone were registered during the process; furthermore, the microhardness, tensile strength, and microstructure of the joints produced were examined. This study brings new insights into the thermomechanical behavior of the material during the process. The peak temperature obtained with the lower welding speed (70 mm/min) is 10% higher than that obtained with the higher speed (120 mm/min). Moreover, a 5% increase in microhardness and a 6% increase in tensile strength were were observed increasing the welding speed. Addition-ally, the microstructure examination demonstrated that, by decreasing the welding speed, the larger interaction between the tool and the material results in a deeper stir zone due to the increased heat diffusion downwards to the material. This heat flow affects the thermal profile and influences the resulting mechanical properties of the welded joints.

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Section: Microstructuresupporting

confidence: 83%

Assessment of the Thermomechanical Behavior and Microstructure of AA 7075-T6 Aluminum Alloy Lap Joints at Optimal Predicted FSW Process Parameters

Toumi,

Khalifa,

Silvestri

et al. 2024

Preprint

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Section: Validation Of Coupled Eulerian Modelsupporting

confidence: 66%

“…Thermomechanically-affected Zone -TMAZ, 570 K < T  603 K; Heat-affected Zone -HAZ, 457 K < T  570 K) with the measured zones by Manikaandan et al [48]. It must be noted that the above temperature ranges for different zones of AA2219-T87 material are inferred from the literature on precipitation kinetics study by Kang et al [49] as well as the measured temperatures in different zones by Manikaandan et al [48]. In this validation exercise, a friction stir butt welding of AA2219-T87 plates (300 mm  200 mm  6 mm) by a conical tool-pin (H13 tool steel) with a shoulder diameter of 23.8 mm, pin top diameter of 9 mm, pin bottom diameter of 6.8 mm and pin height of 5.8 mm are considered [48].…”

Section: Validation Of Coupled Eulerian Modelmentioning

confidence: 60%

“…Figure(4) depicts the comparison between predicted and measured weldment zones[48]. It can be clearly observed that the size and shape of different zones at top and bottom of the plates are in close agreement, which indicates the precise modelling of plasticized workpiece material flow around the tool-pin profile by the present coupled thermal-material flow model.…”

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confidence: 64%

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Tool-pin profile effects on thermal and material flow in friction stir butt welding of AA2219-T87 plates: computational fluid dynamics model development and study

Bagadi,

Jaidi,

Rao

et al. 2024

Int J Adv Manuf Technol

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A three-dimensional coupled model in a Eulerian framework has been developed in COMSOL Multiphysics software and used to study the complex phenomena of thermal and material flow during the Friction Stir Welding (FSW) process. The moving heat source (tool) effect is modeled using a coordinate transformation. The frictional heat as a function of temperature dependent yield strength of AA2219-T87 material, and the deformation energy of plasticized material flow are considered. Further, the plasticized material is modeled as non-Newtonian fluid and a no-slip boundary condition at the workpiece-tool material interfaces is used. The coupled Eulerian model prediction accuracy has been validated against the experimental weldment zones, and found a good agreement in terms of the shape and size. Subsequently, studied the effects of tool-pin profiles (cylindrical and conical) on thermal distribution, material flow, shear strain rates, thermal histories and weldment zones. It is found that the maximum temperatures, material flow velocities and shear strain rates are low with the conical tool-pin in contrast to the cylindrical one, and it is partly attributed to increased mixing of shoulder and pin driven material flow around the rotating tool, which in turn decreased the size of weldment zones. Also, the maximum temperatures, material flow velocities and shear strain rates on advancing side are higher than that of retreating side. Therefore, it is suggested to use the coupled Eulerian model to design the FSW process and tool parameters in a cost effective way in contrast to the tedious experimental route.

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“…The highest reduction in microhardness occurred at the boundary between the HAZ and TMAZ, which can be identified as the low-hardness zone (LHZ). Depending on the parameters of the FSW process, it can be located at the HAZ/TMAZ interface, in the TMAZ or in the SZ [ 36 , 37 ]. The LHZ is often the location where the tensile failure of FSW joints occurs [ 38 ].…”

Section: Resultsmentioning

confidence: 99%

Effect of Welding Parameters on Mechanical Properties and Microstructure of Friction Stir Welded AA7075-T651 Aluminum Alloy Butt Joints

et al. 2022

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The aim of this study was to examine the mechanical properties of 5-mm-thick AA7075-T651 alloy using three different welding velocities, 50, 75 and 100 mm/min, and four various sets of tool rotation speeds: 400, 600, 800 and 1000 rpm. All obtained joints were defect-free. In all cases, the values of UTS exceeded 400 MPa, corresponding to 68.5% minimum joint efficiency. The highest value of 447.7 MPa (76.7% joint efficiency) was reported for the joint produced via 400 rpm tool rotation speed and 100 mm/min welding velocity. The SZ microstructure of the strongest joint was characterized by a 5.2 ± 1.7 μm grain size and microhardness of approximately 145 HV0.1. The TMAZ/HAZ interface was identified as the low-hardness zone (105–115 HV0.1, depending on parameters), where the failure of the tensile samples takes place. The fracture mechanism is dominated by a transgranular ductile rupture with microvoid coalescence.

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Tensile and Fracture Properties of Aluminium Alloy AA2219-T87 Friction Stir Weld Joints for Aerospace Applications

Cited by 25 publications

References 43 publications

Assessment of the Thermomechanical Behavior and Microstructure of AA 7075-T6 Aluminum Alloy Lap Joints at Optimal Predicted FSW Process Parameters

Assessment of the Thermomechanical Behavior and Microstructure of AA 7075-T6 Aluminum Alloy Lap Joints at Optimal Predicted FSW Process Parameters

Tool-pin profile effects on thermal and material flow in friction stir butt welding of AA2219-T87 plates: computational fluid dynamics model development and study

Effect of Welding Parameters on Mechanical Properties and Microstructure of Friction Stir Welded AA7075-T651 Aluminum Alloy Butt Joints

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