Three-dimensional material flow during friction stir welding of AA5083

Kumar, Rahul; Pancholi, V.

doi:10.1016/j.jmapro.2021.06.051

Cited by 11 publications

(5 citation statements)

References 48 publications

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“…8 The locally plasticized material is subsequently transported from the front to the back of the tool by a combined rotary and linear movement. 9 Due to the acting tool pressure, temperature and intermixing, diffusion processes finally take place, leading to a material bond between the joining partners. 10 However, FSW is subjected to process-specific challenges including comparatively high process forces 11 and FSW tool wear, resulting from specific tool-workpiece interactions.…”

Section: Introductionmentioning

confidence: 99%

Effect of friction stir welding tool hardness on wear behaviour in friction stir welding of AA-6060 T66

Hasieber

Kranz

Löhn

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Friction stir welding is a solid-state joining process with a wide range of industrial applications in the e-mobility, automotive, aerospace and energy industries. However, friction stir welding is subjected to process-specific challenges, including comparatively high process forces and friction stir welding tool wear resulting from tribological interaction between the tool and workpiece. The geometric-related friction stir welding tool wear can cause varying material flow conditions, lateral path deviations and premature tool failure, with detrimental economic and technological consequences. This study systematically analyses the wear behaviour of friction stir welding tools as a function of tool hardness. To compare and differentiate the geometric-related tool wear as a function of tool hardness, experiments were carried out with a hardness of 240 HV, 410 HV and 580 HV. Whereas 240 HV is non-hardened, 410 HV is 50% of the secondary hardness maximum and 580 HV is the secondary hardness maximum of the tools made of H13 tool steel (hot-working steel, X40CrMoV5-1). During the experimental tests, the shoulder and probe exhibited varying wear and geometrical deviations. The investigations were carried out with a force-controlled robotized welding setup in which AA-6060 T66 sheets with a thickness of 8 mm were joined by weld seams up to a total length of 80 m.

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Section: Introductionmentioning

confidence: 99%

Effect of friction stir welding tool hardness on wear behaviour in friction stir welding of AA-6060 T66

Hasieber

Kranz

Löhn

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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show abstract

“…This dissimilarity in softening temperatures can have a significant impact on the material flow dynamics during the rotational action induced by the pin during the friction stir welding process. Consequently, this discrepancy in softening behaviour can lead to the formation of tunnel defects and other microstructural irregularities [26][27][28]. The presence of tunnel defects, as observed in figures 2 and 3, can be attributed to this particular phenomenon of improper softening of the materials during the welding process.…”

Section: Macrography Resultsmentioning

confidence: 96%

Traverse and longitudinal analysis of AA5083/AA6082 dissimilar joint

2023

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This study investigates the mechanical and microscopic characteristics of the friction stir welded AA5083/AA6082 dissimilar joint. The welding process was performed at a rotational speed of 900 rpm, traverse speed of 60 mm/min, and a tool tilt angle of 1º. Samples were extracted from the joint's start, middle, and end positions in both the traverse and longitudinal directions. The analysis of these samples involved various tests, including microstructural analysis, bending, and tensile tests. The microstructural analysis revealed non-linear behaviour in both the longitudinal and traverse sampling directions along the joint. Specifically, there were notable differences in the microstructure between the different locations within the joint. In terms of mechanical properties, the ultimate tensile strength results of the traverse specimens were found to be higher compared to the specimens sampled longitudinally. This suggests that the joint's strength may vary depending on the sampling direction. On the other hand, the flexural strength results showed a contrasting pattern, with the traverse specimens exhibiting lower strength values compared to the longitudinally sampled specimens. This indicates that the joint's resistance to bending forces may differ based on the sampling direction.

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“…The material in the area of its contact with the tool moves in accordance with both the adhesive and extrusion nature of the flow process. Its transfer along the tool contour occurs with a clear dependence on the mechanics of the process, associated with the presence of advancing and retreating sides and the difference in the flow of metal in the vertical direction [100][101][102]177,[190][191][192][193][194]. Even in early works on friction stir welding, the material around the tool was separated into an extrusion zone (material transfer zone, superplastic flow zone), a plastic deformation initiation zone (thermomechanically affected zone), a preheating zone, and a cooling zone [2,177].…”

Section: Adhesion Friction and Materials Flow In Friction Stir Weldin...mentioning

confidence: 99%

“…Even in early works on friction stir welding, the material around the tool was separated into an extrusion zone (material transfer zone, superplastic flow zone), a plastic deformation initiation zone (thermomechanically affected zone), a preheating zone, and a cooling zone [2,177]. Later works using mathematical modeling [192] and experimental studies [190] show the peculiarities of material flow both on the advancing and retreating sides and in local areas of the tool action zone. It should be noted that the works show an identical character of metal flow during the welding of both titanium [192] and aluminum [190] alloys.…”

Section: Adhesion Friction and Materials Flow In Friction Stir Weldin...mentioning

confidence: 99%

“…Later works using mathematical modeling [192] and experimental studies [190] show the peculiarities of material flow both on the advancing and retreating sides and in local areas of the tool action zone. It should be noted that the works show an identical character of metal flow during the welding of both titanium [192] and aluminum [190] alloys.…”

Section: Adhesion Friction and Materials Flow In Friction Stir Weldin...mentioning

confidence: 99%

See 1 more Smart Citation

Friction Stir Welding/Processing of Various Metals with Working Tools of Different Materials and Its Peculiarities for Titanium Alloys: A Review

Чумаевский

Amirov

Иванов

et al. 2023

Metals

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A review of the state of research in the field of friction stir welding and processing has been carried out. The features of plastic flow in friction stir welding and their connection with the processes of adhesion friction are shown. The main direction of research is related to the features of friction stir welding of titanium alloys. Special attention is paid to the selection of working tool materials from various alloys for friction stir welding and the processing of titanium alloys. The main advantages and disadvantages of applying different types of tools for friction stir welding of titanium alloys are shown. Different mechanisms of tool wear in friction stir welding associated with the interaction of processed material and tools are demonstrated. Information on the influence of tool and material interaction at welding on the mechanical properties and operational characteristics of obtained joints is given.

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Three-dimensional material flow during friction stir welding of AA5083

Cited by 11 publications

References 48 publications

Effect of friction stir welding tool hardness on wear behaviour in friction stir welding of AA-6060 T66

Effect of friction stir welding tool hardness on wear behaviour in friction stir welding of AA-6060 T66

Traverse and longitudinal analysis of AA5083/AA6082 dissimilar joint

Friction Stir Welding/Processing of Various Metals with Working Tools of Different Materials and Its Peculiarities for Titanium Alloys: A Review

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