Abstract
Solid state joining of 1 mm thick AA 5052 aluminium alloys is carried out in the current study using both traditional friction stir welding (FSW) and underwater friction stir welding procedures. In the underwater FSW process, the tool and the welding plates are totally submerged underwater while the welding is being done. The underwater welding procedure contributes to improving the mechanical characteristics and formability of aluminium alloys by lowering heat dissipation. The current study compares the mechanical characteristics, formability, microstructure, and fractography of the joints made of the AA5052 aluminium alloy using the two different welding procedures. When performing FSW or underwater FSW, a process parameter called welding speed is changed from 30 mm/min to 60 mm/min at intervals of 15 mm/min while keeping a constant speed of 1200 rpm. Both FSWed and underwater FSWed samples are subjected to the Erichsen cupping test, where the dome height is taken into account as a metric of formability and the strains created during the deformation is also measured. Optical microscopes and scanning electron microscopes were utilized to analyse microstructure and fracture. At various speeds, the mechanical characteristics, formability behaviour, and microstructure of the two weldings were examined. Due to underwater welding's lower heat dissipation than conventional friction stir welding, it has been discovered that underwater welding has better mechanical, formability, and microstructure behaviour, making them more appropriate for automotive applications.
Published Version
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