The Effect of Tool Rotation Speed on Mechanical Properties of Friction Stir Spot Welded (FSSW) AA7075-T6 Aluminium Alloy Sheets

Ugurlu, Mustafa; Cakan, Ahmet

doi:10.26701/ems.520139

Cited by 6 publications

(5 citation statements)

References 26 publications

(32 reference statements)

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“…In addition, high consumption of energy, high current use, and large joint distortion for resistance spot welding are also drawback [ 2 , 5 ]. Mazda Motor Corporation proposed fixed-friction stir-spot welding (FSSW) in 1993 [ 6 , 7 ] dependent on the principle of linear-friction stir welding (FSW), which TWI invented in 1991 [ 1 , 3 ]), and it was successfully used to manufacture the rear door and hood of the sport vehicle Mazda RX-8 [ 8 ]. FSSW is considered a green technology due to its high energy efficiency and eco-friendly nature, and because it is a versatile process [ 7 , 9 ].…”

Section: Introductionmentioning

confidence: 99%

“…Mazda Motor Corporation proposed fixed-friction stir-spot welding (FSSW) in 1993 [ 6 , 7 ] dependent on the principle of linear-friction stir welding (FSW), which TWI invented in 1991 [ 1 , 3 ]), and it was successfully used to manufacture the rear door and hood of the sport vehicle Mazda RX-8 [ 8 ]. FSSW is considered a green technology due to its high energy efficiency and eco-friendly nature, and because it is a versatile process [ 7 , 9 ]. Furthermore, FSSW is regarded as an excellent replacement for the existing spot-welding processes.…”

Section: Introductionmentioning

confidence: 99%

“…Their results indicated that joint strength is not considerably impacted by dwell time, although it does decrease with increasing rotational speed. In contrast, Uğurlu and Çakan [ 7 ] investigated FSSW of AA7075-T6 spot joints fabricated at a constant applied dwell time of 20 s and various tool rotation speeds of 1040, 1320, and 1500 rpm. Their results showed that joint properties improved by increasing the tool rotational rate, and maximum tensile strength was given by the defect-free joint processed at the highest tool rotation speed.…”

Section: Introductionmentioning

confidence: 99%

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Friction Stir-Spot Welding of AA5052-H32 Alloy Sheets: Effects of Dwell Time on Mechanical Properties and Microstructural Evolution

et al. 2023

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Friction stir-spot welding (FSSW) as a solid-state joining process for local welding offers a number of benefits for applications in the automotive, aerospace, and marine industries. In these industries, and from an economic point of view, producing spot welds at a low rotating speed and in a short time is critical for saving energy and enhancing productivity. This investigation helped fill a knowledge gap in the literature about FSSW of 4 mm similar lap joints of AA5052-H32 sheet materials, in which welding takes place over a short time period with a slow tool rotation speed. Consequently, the purpose of this work was to investigate the feasibility of FSSW 2 mm thick AA5052-H32 aluminum alloy sheets to produce 4 mm thick similar spot lap joints at various low dwell times of 1, 2, and 3 s and a constant relatively low tool rotation speed of 500 rpm. The introduced heat input for the friction stir-spot welded (FSSWed) lap joints was calculated based on the applied processing parameters. Joint appearance, cross-section macrostructures, and microstructure features of all the spot welds were evaluated. The mechanical properties (hardness contour maps and maximum tensile shear loads) were also examined. The results show that joining 2 mm sheet thickness AA5052-H32 at a low heat input in defect-free similar lap joints could be successfully achieved. The stir zone (SZ) region became wider as the dwell time increased from 1 to 3 s. The hardness value of the SZ was higher than that attained by the AA5052-H32 base material (BM) for all applied dwell times. Especially at 2 s, the hardness of the SZ was approximately 48% higher than that of the BM. This increase in hardness may be attributed to the high grain refinement of the new dynamically recrystallized grain (4 µm) in the SZ compared to the cold-rolled BM grain size (40 µm). Among the tried FSSW process variables, the dwell time of 2 s at a rotation rate of 500 rpm also produced the maximum tensile shear load of 4330 N. Finally, the locations and features of the fracture surfaces of the FSSWed joints were examined using a scanning electron microscope (SEM) and the obtained results were discussed.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Friction Stir-Spot Welding of AA5052-H32 Alloy Sheets: Effects of Dwell Time on Mechanical Properties and Microstructural Evolution

et al. 2023

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“…Aluminum and its alloys have been used widely, especially in the aerospace/aircraft and automotive industries [14][15][16]. During the design phase of a part, engineers demand high strength considering safety factors and design requirements.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of fracture toughness and Charpy V-notch test correlations for selected Al alloys

Yildiz

2022

European Mechanical Science

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This research experimentally compared the correlations between fracture toughness and Charpy V-notch tests.The fracture toughness tests are expensive, complex, and laborious. Therefore, researchers developed correlations to estimate fracture toughness using Charpy V-notch tests, thereby structural integrity assessment. For the current work, nine different fracture toughness correlations were selected using the existing literature, and most common Al alloys, including 2024-T4, 6061-T6, and 7075-T6, were chosen as testing materials. Tensile tests were utilized to determine the deformation behavior of the tested alloys. Also, Charpy V-notch tests were carried out to obtain absorbed energy during the low impact conditions. Rupture strain, yield, and ultimate tensile strengths of the alloys were determined by tensile testing. Charpy V-notch test results revealed that the energy absorption ability of the 6061-T6 Al alloy is roughly two times higher than the 2024-T4 and roughly four times higher than the 7075-T6 Al alloy. The fracture toughness estimations resulted in a broad range of values. The experimentally obtained fracture toughness values attained from the literature were used to define the error of each correlation. One of the tested correlation yielded the lowest average error with an error percentage of 15.6%. Lastly, the ductile fracture of the 6061-T6 Al alloy tensile test specimens executed at the quasi-static conditions was attributed to having a higher fracture toughness.

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“…In addition the fusion welded joints of dissimilar materials have welding defects like cavities, porosities, and cracks [4]. Therefore, solid-state welding methods are preferred in joining different types of Materials [5][6][7]. Friction stir welding (FSW), developed by The Welding Institute (TWI) in 1991, is a solid-state welding pin and shoulder design, tool rotational speed and dwell time are considered as basic FSSW parameters, the plunge depth of the tool is also considered as an important welding parameter.…”

Section: Introductionmentioning

confidence: 99%

Investigation of weld defects and mechanical properties of dissimilar friction stir spot welded dual phase (DP600) steel and aluminum alloy (AA 7075-T6) plates

Cakan

Ugurlu

2022

European Mechanical Science

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DP600 steel and AA7075-T6 aluminium alloy plates were joined using the friction stir spot welding process. The effects of different tool rotational speeds on the mechanical properties, intermetallic compound formation and interface microstructure of welded joints were investigated. The highest lap shear tensile load was obtained from the samples joined at a rotational speed of 1040 rpm (6.5 kN). It was determined that the tensile load of the welded joint decreased with increasing tool rotational speed. XRD analysis performed on broken surfaces, the intermetallic phase was determined to be Al13Fe4. As a result of Vickers microhardness tests, the samples joined at 1320 rpm and 1500 rpm, in the structure of which intermetallic compounds were determined by XRD analysis, displayed higher hardness values. In addition, when scanning electron microscope images were examined, it was determined that the cracks observed in the samples and the porosity both increased with increasing tool rotational speed.

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The Effect of Tool Rotation Speed on Mechanical Properties of Friction Stir Spot Welded (FSSW) AA7075-T6 Aluminium Alloy Sheets

Cited by 6 publications

References 26 publications

Friction Stir-Spot Welding of AA5052-H32 Alloy Sheets: Effects of Dwell Time on Mechanical Properties and Microstructural Evolution

Friction Stir-Spot Welding of AA5052-H32 Alloy Sheets: Effects of Dwell Time on Mechanical Properties and Microstructural Evolution

Evaluation of fracture toughness and Charpy V-notch test correlations for selected Al alloys

Investigation of weld defects and mechanical properties of dissimilar friction stir spot welded dual phase (DP600) steel and aluminum alloy (AA 7075-T6) plates

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