Abstract
Friction stir welding (FSW) is the most widely used solid-state joining technique for light-weight plate and sheet products. This new joining technique is considered an energy-saving, environment friendly, and relatively versatile technology. FSW has been found to be a reliable joining technique in high-demand technology fields, such as high-strength aerospace aluminum and titanium alloys, and for other metallic alloys that are hard to weld by conventional fusion welding. Several studies accounted for the microstructural modifications induced by solid-state FSW, based on the resulting mechanical properties obtained at the FSW joints, such as tensile, bending, torsion, ductility and fatigue responses. In the last few years with the need and emerging urgency to widen the FSW application fields, broadening the possible alloy systems, and to optimize the resulting mechanical properties, this joining technique was further developed. In this respect, the present contribution focuses on two modified-FSW techniques and approaches applied to aluminum alloys plates. In a first case, an age-hardening AA6082 sheets were double side friction stir welded (DS-FSW). In a second case a non-age-hardening AA5754 sheet was FSW by an innovative approach in which welding pin was forced to slightly deviate away from the joining centreline (defined by authors as RT). In both the cases different pin heights were used, the sheets were subjected to heat treatments (peak hardening T6 for the AA6082, and annealing for the AA5754) and compared to the non-heat treated FSW conditions. Microstructural modifications were characterized by optical microscopy (OM). The mechanical properties were characterized both locally, by nanoindentation techniques, and globally, by tensile (yield, YT; ultimate, UT; and elongation, El) or forming limit curve (FLC) tests. Both the new approaches were directly compared to the conventional FSW techniques in terms of resulting microstructures and mechanical responses.
Highlights
IntroductionThe friction stir welding (FSW) technique was developed by The Welding Institute (UK) in 1991 under the solid state welding techniques
Irrespective of the welding methodology used, limiting dome height (LDH) values of joints are lower than those measured for the base material, due to the presence of the welding line that leads to a reduction in formability [60,61,74,75,76,77,78]
By focusing on the DS-friction stir welding (FSW), it can be observed that the joints are characterized by LDH values higher than those measured on conventional FSW joints, leading to a reduction of LDH, as compared to the base metal, of 10.9%; compare that to 27.7% between the conventional joint FSW and the BM [17]
Summary
The friction stir welding (FSW) technique was developed by The Welding Institute (UK) in 1991 under the solid state welding techniques. In FSW (Figure 1) a non-consumable rotating is inserted in between the interfaces of the sheets to create inter-diffusion between the parts that constitute the joining volume of the material. The rotating pin tool produces a stirring action until the tool shoulder contacts the top surface of the sheets with a given plunge depth, generating a large amount of heat. As the toolsevere movesplastic along the welding line, the blanks joinedthe through process process owing to the strain and the metal mixingare across weld. AAsolid-state large number of owing to the severe plastic strain and the metal mixing across the weld. As the toolsevere movesplastic along the welding line, the blanks joinedthe through process process owing to the strain and the metal mixingare across weld. aAsolid-state large number of owing to the severe plastic strain and the metal mixing across the weld.
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