Conventional Stir Research Articles

Welding speed effects in underwater and conventional friction stir welding of dissimilar aluminum alloy 6061-T6 and 5083-H12 joints

This study investigates the influence of welding speed on the mechanical and microstructural properties of dissimilar aluminum alloy joints (AA6061-T6 and AA5083-H12) joined using Underwater Friction Stir Welding (UFSW) and Conventional Friction Stir Welding (CFSW). The experiments were conducted at a constant tool rotation speed of 1120 rpm and varying welding speeds (20 to 80 mm/min). Results showed that UFSW achieved peak temperatures 13% lower than CFSW. Moreover, the generated peak welding temperature was inversely proportional to welding speed in UFSW and CFSW. Optimal performance was observed at 63 mm/min, where UFSW produced an 89% reduction in intermetallic compound (IMC) thickness and a 21% finer grain size compared to CFSW. Additionally, UFSW joints exhibited a 10.20% increase in tensile strength and a 7% increase in hardness over CFSW. The enhanced cooling effect in UFSW contributed to these improvements, yielding more uniform material flow, refined microstructure, and reduced IMC formation. These findings suggest UFSW as a superior technique for achieving high-quality dissimilar aluminum alloy joints, with significant enhancements in mechanical properties and microstructural refinement.

Effect of Process Parameters on the Mechanical Properties of Simultaneous Double-Sided Friction Stir Welding Joints

Currently, conventional single-sided friction stir welding is primarily suitable for joining thin plate aluminum alloys, and its application to thick plates is still challenging in terms of welding efficiency and joint mechanical properties. Simultaneous double-sided friction stir welding (SDS-FSW) is a high-efficiency joining technique specifically developed for welding thick plates. However, there is little research on the influence of SDS-FSW process parameters on the joint mechanical properties. In this study, a 12 mm thick AA6061-T6 aluminum alloy and dual robot welding equipment are used to conduct SDS-FSW experiments exploring the influence of rotational speed ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} and welding speed v on the mechanical properties and microstructure. The results show that when the welding parameters are ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} = 800 r/min and v = 60–80 mm/min, smooth and defect-free thick plate aluminum alloy SDS-FSW joints can be obtained, and the macroscopic morphology of the joints is distributed in a “dumbbell” shape. The grain size in the weld nugget zone increases with increasing welding heat input. The microhardness distribution in the joint displays a “W” shape, and the hardness value of the weld nugget zone can reach 67% to 86% of that of the base metal (BM). The junction between the thermo-mechanically affected zone and the heat affected zone is the weakest region of the joint, with the lowest hardness being approximately 51% of that of the BM. When the welding parameters are ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} = 800 r/min and v = 140 mm/min, the SDS-FSW joint has the highest tensile strength, reaching 78.43% of the BM strength and exhibiting ductile fracture characteristics. This research indicates that acceptable weld strength in thick aluminum alloys can be achieved via the SDS-FSW joining mechanism, highlighting its significant potential for industrial applications.

Role of submerged friction stir welding in reducing intermetallic growth and enhancing microstructure in dissimilar Al-Ti joints

The integrity of dissimilar Al-Ti welds during conventional friction stir welding (CFSW) is compromised by excessive material mixing, leading to thick intermetallic layers. Underwater friction stir welding (UWFSW) mitigates these effects by inhibiting material mixing due to lower thermal conditions. Scanning electron microscopy revealed substantial Ti particles, appearing as blocks and strips, within the stir zone during CFSW. Static recrystallization, driven by exothermic reactions between Ti blocks and the Al matrix, resulted in over 93% recrystallized grains along stir zone, 10.7% higher than in UWFSW. In contrast, UWFSW resulted in a finer dispersion of Ti particles with reduced density due to lower frictional heat. The average grain size at the Ti interface of CFSW was 1.0 μm, compared to 2.6 μm in UWFSW. The inhomogeneous distribution of Ti particles in CFSW led to uneven dislocation distribution and increased stress concentrations, while finer Ti particles in UWFSW promoted a uniform grain structure, enhancing joint strength to 267 MPa, 13.4% higher than CFSW. Additionally, the γ-fibre and basal fibre texture in UWFSW increased joint ductility. The study highlights UWFSW’s effectiveness in joining dissimilar metals, offering significant advantages for industries such as aerospace and automotive.

Stepwise double-sided friction stir welding: an alternative for root defect mitigation in aluminium plates with lower gauge numbers

Penetration-induced fractional unbonded defects and flow-induced root flaws are part of the discontinuities of the conventional friction stir welded (FSW’ed) aluminium alloys with limited impact assessment/clarification in literature. The novelty of this study lies in the attempt to eliminate penetration-aided root defect via a stepwise double-sided welding process as well as identify its impact on loadbearing. As a result, the stepwise double-sided FSW welding of a thick aluminium plate (6 mm) was carried out while the microstructure, strength, and fracture modes of the ensuing welds were compared with the conventional (single-sided) friction stir welded counterparts. The stepwise double-sided FSW-welded joint demonstrated better tensile strength relative to the single-sided FSW-welded counterparts owing to its material flow consolidation (two-side deformation) and elimination of penetration-induced fractional unbonded region/root defect. The welding processes do not have a noteworthy influence on the fracture location of the welds as failure ensued via the stir zones of the respective welds. Transient breaking/brittle appearance, and ductile fracture modes were noticed in the single-sided and stepwise double-sided FSW-welded samples respectively. The stepwise double-sided FSW process is recommended as a better choice for thick workpieces relative to conventional FSW to improve the weld’s loadbearing resistance.

Ultrasound-Enhanced Friction Stir Welding of Aluminum Alloy 6082: Advancements in Mechanical Properties and Microstructural Refinement

This study examines the effects of ultrasound-enhanced friction stir welding (USE-FSW) on the mechanical properties and microstructural characteristics of aluminum alloy AA6082-T6, commonly used in automotive, aerospace, and construction industries. The investigation included tensile and bending tests, as well as detailed microstructural evaluations using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and energy-dispersive X-ray spectroscopy (EDS). The results indicate that USE-FSW led to an approximately 26% increase in tensile strength compared to similar samples produced by conventional friction stir welding (CFSW). Additionally, the elongation at break improved by around 52%, indicating better ductility. Flexural strength also showed a notable improvement of over 70%. Microstructural analysis revealed a finer grain structure in the stir zone, contributing to these mechanical enhancements. However, the changes in texture and grain orientation were relatively modest, as shown by EBSD and Kernel Average Misorientation (KAM) analyses. Overall, USE-FSW offers incremental improvements in weld quality and mechanical performance, making it a promising technique for producing joints with slightly enhanced strength and ductility.

Ultrasonication-Boosted Resorcinol-Formaldehyde Resin Nanoparticle Bromine Fixation and Corresponding Upgraded Aquatic Applications.

Bromine (Br2) and related species removal from water systems are rather complicated due to the complicated chemistry instability, and materials with high Br2 removal rate and efficiency, along with stimuli/apparatus suitable for highly corrosive environments, are necessary. Ultrasonication as a non-destructive process is especially suitable in scenarios where conventional stir apparatus is not applicable, such as highly corrosive environments. Considering the validity nature of Br2 and combining the advantages of ultrasonic with a highly stable Br2 fixation method through aromatic polymer nanoparticles, we demonstrate highly efficient acoustic-aided Br2 removal in aqueous solutions with two times capacity compared to the non-treated sample. Related aquatic applications are also proposed for the materials to be cost-effective, including silver (Ag) recovery, recyclable MnO2-mediated Br2 deep removal, and aqueous zinc anode modification. The coupled novel-material-based processes motivate the strategic design of water purification with high-safety and sustainable industrial procedures and post-value-added utilizations.

Low cycle fatigue behavior of AZ31 magnesium alloy joined by friction stir welding

AbstractThis study, aims to weld the 5.2 mm thick AZ31 magnesium alloy with conventional friction stir welding at the highest joining efficiency. As a result of the experiments, 88% joining efficiency in tensile strength has been obtained at 1250 rpm, 400 mm.min−1 welding parameter. As a result of micro–macrostructure photographic examinations of the samples joined with these parameters, it is seen that the joining is fully realized. Samples joined with these parameters have been used in fatigue tests. According to the strain‐controlled low cycle fatigue test results performed on welded and base metal samples, the base metal samples have exceeded the 50,000‐cycle limit without failure, with an elongation rate of 0.3%, and the welded samples with an elongation rate of 0.2%. Low cycle fatigue parameters of welded and base metal samples have been obtained according to the Coffin‐Manson‐Basquin equation.

Welding load, temperature, and material flow in ultrasonic vibration enhanced friction stir lap welding of aluminum alloy to steel

To elucidate the effect of ultrasonic vibration on the welding process (welding load, thermal cycle, and material flow) of aluminum/steel dissimilar metals in friction stir lap welding, conventional friction stir lap welding (FSLW) and ultrasonic vibration enhanced friction stir lap welding (U-FSLW) were used to weld aluminum/steel dissimilar metals. The results indicate that applying ultrasonic vibration to the FSLW of aluminum/steel dissimilar metals can effectively decrease welding loads (tool torque, axial force, and spindle power), and it was found that the reduction in welding load was inversely proportional to the welding speed. The effect of additional ultrasonic vibration on axial force was the largest. Ultrasonic vibration had a significant preheating effect, and its thermal effect in the width and depth directions of the workpiece gradually weakened. Additional ultrasound can reduce the peak temperature during the welding process. The instantaneous state of the weld was obtained using the "emergency stop+emergency cooling" technology, and the three-dimensional visualization characterization of material flow near the keyhole was achieved using X-ray based computer tomography (CT). It was found that ultrasonic vibration could increase the material's plastic flow, change the steel structure's flow path, and significantly increase the steel particles' flow range near the pin tool. Compared with conventional FSLW, the changes in the macro/microstructure of U-FSLW joints were closely related to the welding thermal cycle and material flow.

Microstructure and Mechanical properties of CMT welded AA6063-T6/B4C/ES metal matrix composite using ER5356 filler wire

Aluminium alloy 6063-T6 is a popular choice among different industrial sectors as it portrays various desirable properties like moderate strength, improved corrosion resistance, better weldability and formability etc. These advantages make AA6063-T6 a common choice for matrix in a metal matrix composite. Mostly conventional fusion welding methods like Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG) seem preferable options for welding aluminium and its alloys but it remains a challenge to use them to weld aluminium metal matrix composite. A modified version of MIG i.e. CMT welding, can be explored to overcome the challenges. In this study, an aluminium metal matrix composite has been fabricated with AA6063-T6 as matrix and two reinforcements −one organic, i.e., Eggshell (ES) and one inorganic, i.e., Boron Carbide (B4C), using the conventional stir casting method. CMT welding has been performed on plates cut out from the composites. Microstructure, hardness, tensile strength and residual stress of weld joint of composite have been observed. From micrographs, it is observed that a finer grain has been formed at the Fusion Zone (FZ) in comparison to the Heat Affected Zone (HAZ) and Parent Material (PM). XRD analysis at the fusion line has identified several intermetallic stoichiometric compounds (Al12Mg17, Mg2Si, CaMgSi, CaO, B2O3) and reinforcement B4C and CaCO3 within the matrix volume. The FZ exhibits higher hardness than the HAZ and the PM. Further, the tensile strength of the FZ exceeds that of the unwelded composite due to the presence of metastable strengthening phases of Mg2Si in the FZ, along with reinforcement (B4C and ES) particles. Residual stress analysis reveals tensile stress in the FZ and more compressive stress in the HAZ than in the PM.

Comparative study of metallic foil friction stir welded and conventional friction stir welded AZ61 Mg alloy butt joints: Biomedical and engineering applications

Metallic Foil Friction Stir Welding (MFFSW) was newly developed from the Friction Stir Welding (FSW) technique. Magnesium (Mg) alloys were the most trending alloys in the aerospace, automobile, and biomedical industries. This study aims to investigate the variation in mechanical, corrosive, microstructural, and fractographic properties of MFFSW as a process innovation when compared with FSW. The metallic foil of pure manganese (Mn) with a thickness of 500 μm was inserted between two AZ61 Mg alloys. The tensile strength, impact strength, and hardness were noted as mechanical properties of the output. Potentiodynamic corrosion tests were performed to reveal the corrosion properties. An optical microscope was used to examine a distinct transverse section of the weld. Fractography tests with scanning electron microscopic analysis were conducted on destructive tensile specimens. The ultimate tensile strength, impact energy, yield strength, and microhardness increased to 16%, 32%, 12%, and 19.17%, respectively, compared to FSW. MMFSW shows a lower elongation of up to 33% than FSW. MMFSW (9.61 mm/A) shows a lower corrosion rate than FSW (11.02 mm/A), which employs improved corrosion properties. Optical microscopy images of the stir zone in both MFFSW and FSW revealed that adding a Mn alloying element improved grain growth uniformity and eliminated unexpected grain growth patterns. Hence, the experiment’s conclusion shows that MFFSW has the edge over FSW for mechanical and corrosion properties. Thus, the Mn strip improves the properties of MFFSW.

Improving bonding strength of medium-thick Al-Cu dissimilar joint by a novel splat cooling assisted double side friction stir welding

To obtain a high-strength medium-thick Al-Cu dissimilar joint, a novel splat cooling assisted double side friction stir welding (SDS-FSW) is proposed. The microstructure and tensile properties of conventional double-side friction stir welding (DS-FSW) and the novel SDS-FSW joints under optimal welding parameters are systematically compared, it shows that the utilization of in-process splat cooling significantly reduces the welding peak temperature and the high-temperature dwell time. The in-process splat cooling causes significant grain refinement in the welding nugget zone (WNZ) of the Al-Cu dissimilar SDS-FSWed joint, it exists the lower recrystallization fraction and the higher KAM value. Although both DS-FSW and SDS-FSW joints fracture at the Al-Cu interface, the DS-FSW joint represents a brittle fracture characteristic, while the SDS-FSW joint represents a mixed ductile-brittle fracture mode. Under the drive of the mechanical stirring of the tool and the welding thermal cycle, the aluminium atoms and copper atoms diffuse to the copper base material and aluminium base material, respectively. Since copper diffuses in aluminium at a higher diffusion rate than aluminium diffuses in copper, and the solubility of copper in aluminium is much smaller than that of aluminium in copper, thus the Al2Cu becomes the first phase with the nucleation and growth. As the welding temperature and time continue to increase, Al2Cu reaches the supersaturation state, and the Al4Cu9 phase is produced between the Cu (Al) and the Al2Cu phase. In the end, the interface forms the stable double-layer IMCs structure (Al2Cu/Al4Cu9). The optimal tensile strength of the SDS-FSWed joint is 159 MPa, which is increased by 42% compared to the DS-FSWed joint at the same welding parameter. This was mainly because in-process splat cooling contributed to forming a thinner IMCs layer at the A-Al-Cu interface. It reveals that the application of in-process splat cooling is a versatile method to thin the IMCs layer at the Al-Cu medium-thick DS-FSW process.

Synergistic effects of cold rolling and age hardening on the hardness and tensile characteristics of AA6061 hybrid composites

The present study involves the fabrication of aluminium alloy 6061 matrix hybrid composites with varying weight fractions of silica sand and copper particles by employing the conventional stir casting method. The combined influence of age hardening (AH) and low temperature thermomechanical treatment (LTMT) on the hardness and tensile properties of AA6061 hybrid composites was investigated. The uniform dispersion of the particles in the matrix was confirmed by microstructure analysis and the improvement of Brinell hardness values. The composites exhibited higher tensile strength and hardness than the base alloy. Both AH and LTMT enhanced the properties of the hybrid composites and a comparison between them revealed the best results for LTMT hybrid composites. The LTMT hybrid composite with 3 wt% silica sand and 3 wt% copper (3S3C) subjected to 12% rolling deformation and aged at 100 °C had the highest hardness and tensile strength of 144.26 HV and 290 MPa respectively. The hardness and tensile strength of AA6061-3S3C hybrid composite subjected to LTMT in peak aged condition showed an improvement of 125 and 97% respectively when compared with those of AA6061 alloy. Fracture surface analysis of the thermomechanical treated composites in peak aged condition showed a mixed mode of failure dominant with the ductile fracture.

Double side friction stir Z shape butt lap welding of dissimilar titanium aluminum alloys

Achieving excellent mechanical performance of medium-thick Ti/Al dissimilar joints is important in many industrial applications. However, due to the inherent heat generation mode associated with conventional friction stir welding (FSW), it is impossible to achieve sound medium-thick Ti/Al dissimilar joints. Although double side friction stir welding (DS-FSW) has been reported to solve the problems of conventional FSW. The inherent problems of forming hook structure and interface cracking in the center of the DS-FSW joints significantly weaken the joint performance. Therefore, an innovative double-side friction stir Z shape butt-lap welding (DS-FSZW) process was proposed to eliminate the inherent problems of conventional DS-FSW. The research objective of this work was to reveal the physical mechanisms of the novel DS-FSZW by the combination of numerical simulation and experimental characterization for optimizing the welding parameters. The influence of tool shoulder diameter on the heat generation, heat transfer, plastic material flow, microstructure evolution and mechanical properties of medium-thick dissimilar Ti/Al DS-FSZW joint has been systematically studied. The results indicate that the innovative DS-FSZW process lowers the axial force compared to the conventional DS-FSW, and the centerlines of the first and the second sides welds are staggered. Those are beneficial to inhibiting the cracking of the first-side weld at the interface. In addition, the DS-FSZW method eliminates the hook structures and cracks at the center of the conventional DS-FSW joint and also adds a lap joining interface, which significantly enhances the tensile strength of the joint from 150.7 MPa to 262.5 MPa, which is increased by 74%. Optimization of the shoulder diameter of DS-FSZW from 18 mm to 12 mm reduces the welding heat input and significantly thins the thickness of the IMCs layers at the Ti/Al interface. This helps to suppress the cracking at the Ti/Al lap interface and refine the grains. As a result, thus the tensile strength of the DS-FSZW joint increases from 262.5 MPa to 312.5 MPa, which is increased by 19%. The medium-thick Ti/Al dissimilar DS-FSZW joint at the tool shoulder diameter of 12 mm fracture at the SZ. It proves that the novel DS-FSZW is a suitable welding method for joining medium-thick dissimilar Ti to Al alloys.

Effect of rotational speed and penetration depth on Al-Mg-Si welded T-joints through underwater and conventional friction stir welding

The present work deals with the effect of penetration depth on welding T-joints through conventional friction stir welding (FSW) as well as underwater friction stir welding (UFSW). Various set of parameters have been used such as tool rotational speeds of 1000, 1400, and 1800 rpm, and depths of penetration, such as 6, 7, and 8 mm. In UFSW, lower heat generation prevents the development of complex intermetallic compounds and defects in welding. Additionally, in the weld region, a rapid cooling rate in UFSW generates fine microstructural particles. Mechanical and microstructural characteristics has been compared in both UFSW and FSW. There was a substantial grain size effect on mechanical properties. The stir zone shows comparatively finer grains with average grain size of 49.76 µm at 1800 rpm and 7 mm depth of penetration. It was seen that the tensile strength of UFSW was 189.9 MPa and the nugget zone hardness was 70 VHN, compared to the FSW that has 175.2 MPa and 62 VHN, respectively, obtained at a rotation speed of 1800 rpm and a travel speed of 60 mm/min. The joints tested at various penetration depths show a significant number of uniform and equiaxed dimples. The presence of ductile rupture and the formation of dimples suggest that the joints were effectively bonded and tested at different strain rates.

Enhancing corrosion resistance of the nugget in a 2519-T87 aluminum alloy friction stir welded joint via tungsten inert gas arc

The corrosion resistance of the nugget zone (NZ) in two 2519-T87 aluminum alloy joints obtained by conventional friction stir welding (FSW) and tungsten inert gas arc-assisted FSW (TIG-FSW) was evaluated by immersion corrosion tests and electrochemical measurements. The results show that TIG arc significantly enhances the corrosion resistance of the nugget, the maximum corrosion depth is reduced by about 59.6%, and the polarization resistance is increased by about 14.5%. The mechanism was discussed based on microstructural examination. TIG-FSW decreases the area fraction of coarse intermetallic compounds (IMCs) with an equivalent diameter larger than 2.0 μm and increases the number of submicron IMCs, avoids the accumulation of IMCs, leads to low local electrochemical activity, and consequently enhances the corrosion resistance of the NZ.

Fabrication and characterisation of AZ91D/TCP reinforced composites by stir casting method

ABSTRACT This study focuses on fabricating and characterizing ceramic composites using AZ91D magnesium alloy reinforced with Tricalcium Phosphate (TCP) particles. Uniform distribution of TCP within the matrix was achieved through conventional stir casting. TCP particles, averaging 63µ, were incorporated at weight fractions ranging from 5% to 15%. Cast into grey cast iron molds, cylindrical rods measuring 14 mm in diameter and 100 mm in length were produced. Investigating the impact of different weight percentages of reinforcements on particulate distribution, matrix-particulate interfacial reactions, and mechanical properties, the study utilized SEM and EDS analyses, revealing uniform TCP distribution indicative of successful fabrication. Evaluation of both reinforced and unreinforced composites showcased improved mechanical properties in TCP-reinforced samples. Additionally, discussion on the factrography of compression specimens provided insights into microstructural features and deformation behavior under compression. In summary, this research significantly advances magnesium alloy-based composites, unlocking potential applications across various industries.

Microstructure, mechanical characterisation and fractography of Al2214/3%Grp/x%B4Cp hybrid metal matrix composites

ABSTRACT This experimental investigation reports the impact of boron carbide (B4Cp) particles on Al2214/3%Grp/xB4Cp hybrid metal matrix composites (HMMCs) at a constant weight percentage of Grp (3 wt.%) and x wt.% of B4Cp particles (x = 1.5, 3, 4.5, and 6) produced by a conventional stir casting metallurgical route with bottom pouring facilities. The scanning electron microscope (SEM) combined with the energy dispersive X-ray spectroscope (EDX) shows reasonable uniform distributions of particles in the matrix phase, and a spectrum of elements present in hybrid composites with various intensities. The X-ray diffraction (XRD) analysis was performed for the phase characterisation of hybrid composites. Further, the mechanical properties of Al2214 alloy and Al2214/3%Grp/xB4Cp hybrid composites were studied. The experimental results of the hybrid composite revealed improved hardness and tensile properties with the addition of wt.% B4C particles. The tensile fractured surface (SEM) micrographs revealed the root causes and mechanisms of failures in hybrid composites.

A Novel Procedure for Friction Stir Welding Aluminium to Copper by Using an Aluminium Run-On Plate

Conventional friction stir welding of aluminium to copper often results in the formation of deleterious intermetallic compounds. In order to overcome this concern, an innovative procedure consisting of using an aluminium run-on plate is presented. Long continuous aluminium-copper welds, without any defect, were obtained by this procedure. The run-on plate inhibits the formation of intermetallic compounds around the pin by allowing the use of high tool offset, without the formation of discontinuities at the interface. The generation of an aluminium volume around the tool, which detaches very small copper particles from the copper plate, gives rise to stir zones composed of a uniform distribution of copper particles in an aluminium matrix and with a minimal formation of intermetallic compounds. Comparing to the conventional welds, a significant improvement in the mechanical strength was achieved by welding with this non-conventional procedure.

Effect of Water Cooling on the Microhardness of Friction Stir Welded High-Density Polyethylene Sheets: Experimental Study

The objective of the current work is to analyze the influence of water cooling of high density polyethylene (HDPE) sheet welding by friction stir process (FSW) on mechanical strength, based on microhardness tests. In the present work, the process using the conventional tool (C-FSW) is presented with the new procedure developed for FSW for HDPE, called water conventional friction stir welding (W-FSW). Test results for water-cooled and non-cooled welded samples were compared. HDPE sheets were initially welded by FSW process, and intensive water cooling was performed to weld after the tool exceeded the initial welding position by 30mm. The tool rotation speed of 1100 rpm and welding speed of 26 mm/min was used. The results were compared and evaluated with the hardness tests. A decrease in the hardness was observed when the sheets were treated by quenching, especially in the weld cores. It was found that the average hardness was much lower than that of untreated welded plates. Additionally, there is a region outside the core that has more or less the same stiffness value. The use of intensive quenching and conventional tooling has proven to be of great importance in improving surface finish, reducing defects, and increasing the mechanical strength of welds. The resulting recrystallization modified the hardness and thus increased the efficiency of the joint. These findings indicate the welding quality of the studied polyethylene.

Investigation of tool offset on the microstructure and mechanical properties of AA6061-T6/PC Friction Stir Butt Welding joint

Conventional friction stir welding (FSW) is mostly applied to lap welding, which is suitable to join metal/polymer materials. In this paper, solid-state friction stir butt welding (FSBW) technology is utilized to bond the sheets with the plates of 2 mm thickness of 6061-T6 aluminum alloy (AA6061-T6) and polycarbonate (PC) in a joint design. The effects of tool offset on the temperature evolution, surface morphology, microstructural characteristics, and mechanical properties of the dissimilar joints are investigated. A sound dissimilar join with the average highest tensile strength of around 14.23 MPa is attained at the offset of 3.5 mm. Microstructural characteristics indicate an effective mechanical interlocking structure (Al anchor). The mixed fragments of polymer and metal are formed with a chaotic interface along the joint line, improving the mechanical properties of welding joints. Furthermore, a novel friction stir V shape butt welding (V-FSBW) is proposed to join dissimilar plates. The maximum tensile strength and improvement rate of the V-FSBW joint compared with conventional FSBW are 18.42 MPa and 29.4%, respectively. Results indicate that the tool offset significantly affects the welding joints, and V-FSBW can effectively increase the mechanical properties of the dissimilar AA6061-T6/PC joints.