Stir Welded Aluminium Research Articles

Effect of Pin Length and Compression Force in Double Side Friction Stir Welding on Tensile Strength of AA1100

Friction Stir Welding (FSW) is solid state welding without additives and does not produce pollution. There are two FSW welding methods, namely single side (FSW) and double side (DFSW). The FSW process in previous studies using aluminum materials, especially AA 1100 type, has not obtained optimum joint strength. Therefore, it is necessary to conduct a research study on improving the quality of tensile strength of welding results using the DFSW method on AA1100. The purpose of this study is to determine the effect of variations in pin length and compressive force on the maximum tensile strength of the results of Double Side Friction Stir Welding Aluminum Alloy 1100 welding joints. The method used in this research is experimental. The welding process uses Double Side Friction Stir Welding, by varying two independent variables namely pin length 1.5 mm, 2 mm, 2.5 mm and compressive force 30 kg, 35 kg, 40 kg, 45 kg. The controlled variables used include travel speed (10 mm/min), heating temperature (250℃), shoulder diameter (25 mm), heating plate width (10 mm), and Aluminum AA1100 plate thickness (3.5 mm), with butt joint type welding. The data analysis used is Factorial Design of Experiment (DOE). The results of this study indicate that pin length and compressive force affect the tensile strength of AA1100 material welds. The maximum tensile strength value of DFSW welding results is 90.16 MPa or 80.5% of the tensile strength of the parent material. The maximum tensile strength value was obtained from the interaction of 2 mm pin length and 45 kg compressive force.

Effect of variations in tool offset friction stir welding aluminum 5083 on tensile strength and hardness

Effect of variations in tool offset friction stir welding aluminum 5083 on tensile strength and hardness

Investigation of Microstructural and Mechanical Characteristics of Friction Stir Welded Aluminum Alloy 7075-t6

Investigation of Microstructural and Mechanical Characteristics of Friction Stir Welded Aluminum Alloy 7075-t6

Relationship between mechanical behavior and process factors in friction stir welding aluminum alloys

The friction stir welding (FSW) procedure is the main topic of this research study among the various welding techniques. The study focuses on the interaction between the mechanical properties of 3003 aluminum alloy and the process parameters (rotation speed, welding speed, and dwell time) in the form of rolled plates of 2 mm thickness, end-to-end and welded at 90° and 45°. The welds were made by varying the speed of rotation (1000, 2000 rpm) and setting the tool feed at 500 mm/min. This experimental approach is also based on varying the tilt of the welding tool from 0° to 2°. It has been shown that the studied parameters play an important role in the characterization and optimization of the above mentioned weld joints. Therefore, and based on the results obtained, the use of the 90° joint remains the best in terms of strength.

Morphology Study of the Corrosion Rate on Weld Joint of Double Side Friction Stir Welding Aluminum Alloy AA6061

DSFSW welding uses the rotating of a tool in the workpiece to create heat owing to friction between workpiece and tool to be connected. Corrosion is influenced by the presence of high heat owing to friction and a non-uniform cooling rate. The heat transforms the metal in the Heat Affected Zone (HAZ) and Weld Metal (WM) region, which can result in flaws such porosity, kissing bond, fractures, voids (from welding penetration), and flash as well as changes to the microstructure. Changes in the microstructure of welded joints can affect the resistance of welded joints to corrosion. The purpose of this study is to experimentally analyze the main causes of failure of AA6061 DSFSW joints based on welding temperature, weld defects, microstructure, corrosion rate and morphology of the corroded surface. Temperature testing using thermocouple to analyze the temperature, welding joint defects using DSLR camera and radiography test, microstructure using optical microscope, corrosion rate using AUTOLAB PGSTAT and morphology of corroded surface using SEM. The temperature analysis results show that the advancing side has a higher temperature than the retreating side, due to friction between the tool and base metal accompanied by the opposite welding direction. Visual inspection shows that all specimens and welding positions produce flash that is quite rough on the top (1G) and bottom (4G) surfaces and radiographic test results show incomplete fusion in 4 specimens. Microstructure shows a change in shape and size resulting in recrystallization in the form of fine grains. The highest corrosion rate is found in specimen B 1G welding position of 0.63856mm/year and the lowest corrosion rate in specimen A of 0.058567mm/year. SEM test results show the type of corrosion that occurs in DSFSW welding joints is pitting corrosion.

Double side friction stir welding effect on mechanical properties and corrosion rate of aluminum alloy AA6061

Friction Stir Welding (FSW) is a solid-state welding method that has diffusion and different metal structures can blend well. Friction stir welding (FSW) has a weakness, one of which is the lack of flexibility the welding process is only carried out on one side of the plate being welded, so it is not applied on thick materials. Double side friction stir welding is a double working process in which the plate to be welded is subjected to friction from two tools on opposite sides. In the DS-FSW welding process, the dimensions and geometry of the tool and pin greatly affect the quality of the joint. This study to determine the mechanical properties and corrosion rate of Double side friction stir welding aluminum 6061 with variation rotation speed and axis of top and bottom tools. The results of this radiographic test can be seen that specimen 4 welded with variations in speed and tool position has defects in the form of incomplete fusion (IF). The results of microstructural observations showed that the heat caused by the welding process resulted in recrystallization in the form of fine grains in the stirring area and there was no phase change. The highest hardness value in the welding area is specimen B. The largest bending value at the 1G welding positions is specimen D, which is 41.86 MPa with a strain value of 13.23%, while the smallest value at the 4G welding position is specimen A, which is 38.18 MPa with a strain value of 5.03%. The fracture and crack surfaces showed that crack initiation, propagation and material stirring failure occurred in all test specimens, even though the impact test specimen was cut in a small area of Incomplete Fusion, but the test results showed that there was still a surface of the parent metal that had not been stirred. The corrosion test method uses three electrode cells with corrosion media as a substitute for seawater with a salinity of 3.5% NaCl, result of corrosion test is specimen B at the 1G welding position has the highest corrosion rate value of 0.63856 mm/year and specimen An at the 1G welding position has the lowest corrosion rate of 0.058567 mm/year.

Effect of Pin Profile Tool on Friction Stir Welding Alumunium

This purpose of this study was to determine the effect of the pin profile tool on the results of friction stir welding aluminum. When compared to conventional welding, friction stir welding uses less energy, is non-consumable, and does not produce dangerous gas emissions, so the process becomes environmentally friendly. The variation of the tool with two profile pins, namely the straight thread pin tool (STPT) with a hardness number of 55 HRC and the tapered pin tool (TPT) with a hardness number of 54 HRC. The parameters used in both tools are 1125 rpm, a tilt angle of 20, and a 30 mm/min welding speed. The material used is Aluminum 1060, which has a size of 50x120x5 mm on one side. The friction stir welding test uses a visual, a radiography, and a macrostructure test. The results showed that the influence of the pin profile on the aluminum welding results with the tapered pin tool (TPT) has a defect in the form of a lack of fusion, so if it refers to PN-EN ISO 25239-5, then it is not permitted. In the straight thread pin tool (STPT) type, there are only imperfections in the form of a flash. The flash in the root area is due to the pin profile and welding speed, which disrupts the weld deposition flow. When viewed from the macrostructure results, there are no defects. Better results are obtained with the straight thread pin tool (STPT).

Analisa Variasi Putaran Friction Welding Terhadap Kekerasan Logam Aluminium Paduan Seri 1100-H18

Research in aluminum splicing continues to be improved, so that the joining process becomes easier and to increase hardness. Friction stir welding (FSW) aluminum joining process. The purpose of this study was to find out more clearly about the mechanical properties of the hardness of the specimen. The material used is aluminum alloy 1100-H18 series. The research method is friction welding with Vertical Milling as a turning tool. The tests were carried out in different rounds, namely; 660 rpm; 1115 rpm; 1750 rpm and 2720 rpm with a fixed tool feed rate of 20 mm/minute. The results of the Vickers test show that the hardness of the Base Metal (BM) area at 660 rpm is the highest at 101.4 and the lowest is 97.62 at 1115 rpm. The highest average hardness value of 94.98 occurs at 1115 rpm and the lowest is 75.18 at 2720 rpm. A significant effect on the hardness of the specimen due to the rotational speed of the tool spindle (electrode), the higher the rotation, the higher the heat generated and the rate of The slow cooling in the HAZ and SZ regions will be greater, as a result the hardness in the HAZ and SZ regions will decrease.

Influence of pin profile on formability of friction stir-welded aluminum tailor-welded blanks: an experimental and finite element simulation analysis

In sheet metal forming processes, the forming limit diagram is frequently employed as a criterion for predicting necking initiation. This is one of the most useful and effective methods for the evaluation of the formability of tailor-welded blanks. The goal of this study was to determine the formability of friction stir-welded (FSW) aluminium alloy 6061-temper 6 (AA6061-T6) and aluminium alloy 2017-temper 6 (AA2017-T6) by employing five dissimilar tool pin profiles. To evaluate the limiting dome height, five different combinations of dissimilar blanks were used in experimental and simulation experiments. Material characteristics such as density, elastic modulus, and all multilinear behaviors of blanks were manually assigned for simulation from the test results of true stress versus true strain plots. The punch with die supports was considered as a rigid body, whereas the metallic blanks were considered as plastic material. To carry out the simulation, the entire blank was divided into three zones. The results obtained from the experimental and simulation results showed that the straight square tool pin profile is the optimal tool pin profile for the formability of FSW AA6061-T6 and AA2017-T6. The tested height values obtained from the limiting dome height were 20.5 and 20.9 mm in experimentation and simulation, respectively. The straight cylindrical tool pin profile exhibited the worst formability properties in both experimentation and simulation.

Material Flow and Mechanical Properties of a Non-Keyhole Friction Stir Welded Aluminum Alloy with Improved Sleeve Bottom Geometry

Non-keyhole friction stir welding (N-KFSW) is a technique that can fabricate a welding joint without a keyhole through a one-time welding process. The Al–Mg–Si alloy was chosen as a research object, and the N-KFSW technique was investigated by numerical and experimental methods. Firstly, the sleeve bottoms of the N-KFSW welding tool system were innovatively optimized in this study. The optimal sleeve bottom with an 80° angle between the spiral groove and the sleeve inner side wall allowed avoiding the incomplete root penetration defect at the bottom of the stir zone (SZ), which was verified by numerical results and the C-shaped line height. Then, using a 3 mm-thick aluminum alloy as the experimental material, the material flow and joint formation characteristics and mechanical properties at 110, 150 and 190 mm/min welding speeds were studied and compared. The results showed that the SZ presented a drum shape due to the action of the clamping ring and the threads on the side wall of the sleeve. The SZ width decreased from 7.17 to 6.91 mm due to the decreased heat input. From 70 to 210 mm/min welding speed, the maximum tensile strength of the joint was 250 MPa at 190 mm/min, and the joint with relatively higher strength fractured at the heat-affected zone.

Investigation on Mechanical and Tribological Behavior of Double Pass Friction Stir Welded Aluminium Joints

Investigation on Mechanical and Tribological Behavior of Double Pass Friction Stir Welded Aluminium Joints

Structure and Mechanical Properties of Double Side Friction Stir Welded Aluminium AA6061 with the Addition of Cu Powder

The research objective is to investigate the formation of new compounds and the mechanical properties of Double Side Friction Stir Welding (DS-FSW) welding with Cu particle reinforcement. Aluminum alloys of AA6061 and 12 μm Cu powder were chosen as the main materials. The addition of Cu particles is conducted in single groove and double groove. The DS-FSW process uses CNC milling with a feed rate of 80 mm/minute and 1000 rpm of tool rotation. Observation of the microstructure was carried out by using optical metallography, and X-ray diffraction. Microhardness testing was done to determine the mechanical properties of the material. The results showed that the increase in the hardness value of 23.39% occurred in the double groove material. MMCs detected were Al2Cu, and AlCu2Mn.

Unified Principal S\u2013N Equation for Friction Stir Welding of 5083 and 6061 Aluminum Alloys

With the popularization of friction stir welding (FSW), 5083-H321 and 6061-T6 aluminum alloy materials are widely used during the FSW process. In this study, the fatigue life of friction stir welding with two materials, i.e., 5083-H321 and 6061-T6 aluminum alloy, are studied. Fatigue tests were carried out on the base metal of these two materials as well as on the butt joints and overlapping FSW samples. The principle of the equivalent structural stress method is used to analyze the FSW test data of these two materials. The fatigue resistances of these two materials were compared and a unified principal S–N curve equation was fitted. Two key parameters of the unified principal S–N curve obtained by fitting, Cd is 4222.5, and h is 0.2693. A new method for an FSW fatigue life assessment was developed in this study and can be used to calculate the fatigue life of different welding forms with a single S–N curve. Two main fatigue tests of bending and tension were used to verify the unified principal S–N curve equation. The results show that the fatigue life calculated by the unified mean 50% master S–N curve parameters are the closest to the fatigue test results. The reliability, practicability, and generality of the master S–N curve fitting parameters were verified using the test data. The unified principal S–N curve acquired in this study can not only be used in aluminum alloy materials but can also be applied to other materials.

Influence of Exposure to Environment on Degradation of a Friction Stir Welded Aluminum Alloy

We carried out a comparative study on both the stress corrosion response and corrosion damage characteristics of aluminum alloy 2219, both the base material and a friction stir welding (FSW) counterpart upon exposure to exfoliation corrosion (EXCO) solution. The results reveal that the test specimen containing an FSW joint reveals better electrochemical corrosion resistance than that taken from the base metal. When test specimens upon exposure to EXCO solution are concurrently subjected to a tensile stress, since the mechanical properties of the FSW joint are lower than the base metal, a test specimen containing an FSW joint is more easily prone to the early initiation of fine microscopic cracks. This makes the test specimen containing the FSW joint to be less resistant to stress corrosion damage than that taken from the base metal for the various levels of applied stress and exposure time to EXCO solution. The average corrosion depth of the test specimen containing the FSW joint is less than that of the base metal, while the maximum corrosion depth of it is greater than that of the base metal. This reveals that test specimen containing the FSW joint is more susceptible to damage and degradation than test specimen taken from the base metal.

Grain Size Optimization Using PSO Technique for Maximum Tensile Strength of Friction Stir-Welded Joints of AA1100 Aluminium

An attempt has been made to characterize the friction stir-welded aluminium (AA 1100) joints in terms of the different processing parameters, like rotation speed of the tool (TRS), speed of welding (WS) and plunge depth (PD). In addition, the heat-affected zone (HAZ) has also been analysed in terms of the grain structure and grain orientation to throw light on the quality of the joint. The TRS is maintained at 1100–1500 rpm, WS at 20–60 mm/min and PD at 4.1–4.5 mm within a temperature range of 420–480 °C. Results show tensile and yield strength increase with increase in TRS and WS. Microhardness of the HAZ is the lowest among all the zones, indicating it to be the weakest region which represented the fracture location in the joint. Microstructural observations further reveal grain refinement at the joint and coarsening of grains away from the joint. Particle swarm optimization technique has been adopted for obtaining the optimal set of parameters to get suitable grain size for maximum tensile strength and ductility which govern the quality of welding. This research finds application in the automotive, ship building and aerospace industries as the optimization technique helps to achieve the best output with minimum supply of inputs without compromising the weld quality.

Optimization of Process Parameters to Maximize Ultimate Tensile Strength and Hardness of Underwater Friction Stir Welded Aluminium Alloys using Fuzzy Logic

Optimization of Process Parameters to Maximize Ultimate Tensile Strength and Hardness of Underwater Friction Stir Welded Aluminium Alloys using Fuzzy Logic

Machine Learning Approach for Defects Identification in Dissimilar Friction Stir Welded Aluminium Alloys AA 7075-AA 1100 Joints

Machine learning approaches are now applied in various manufacturing industries. Various machine learning algorithms can be implemented for prediction of the particular mechanical properties like Ultimate Tensile Strength (UTS), Elongation percentage and fracture strength of the given mechanical component and also image processing algorithms can be applied for defects detection in the mechanical components. In our recent work, we have used a novel machine learning approach for the detection of the surface defects in dissimilar Friction Stir Welded joints by using Local Binary Pattern (LBP) algorithm. The results obtained are satisfying and it is concluded that the LBP can be implemented in the detection of surface defects.

Evaluating The Effect of The Pin’s Length to The Strength of Double Sides Friction Stir Welded Aluminum

Based on previous research, it is believed that the double side friction stir welding will improve the obtained joint. It is hoped the length of the pin broaden the strain hardened area (especially the interference zone) which in turn will produce the stronger joints. From tensile test data, the tensile strength does increase by the length of the pin. The maximum tensile strength of 183 MPa acquired from the 6.5 millimeter pin which is equal to 75% joint efficiency whilst the lowest is 42 MPa resulted by the 2.5 millimeter pin. The hardness test confirmed the existing of the strain hardening phenomenon, which was shown by harder materials at interference zone. Other supporting evidence is the micro structure photo. The photos showed that not only exhibits strain hardening the interference zone also yields finer dispersed micro structure that will provide stronger joint.

The Effects of Welding Parameters on Macro and Micro-Structure of Friction Stir Welded Aluminium

Friction stir welding (FSW) is considered as state-of-the-art technology for joining aluminium alloys (AA). Several welding parameters with different rotational and travel speed combinations are used to produce good friction stir welded AA6063 pipe butt joint. The weld quality is then evaluated by optical microscope through observations of the macro and microstructure. The different welding parameters give finer grain structure on the weld nugget zone instead of irregular size of grain structure on the thermo-mechanically affected zone (TMAZ) and heat affected zone (HAZ). Thus, it would be useful for predicting mechanical performances (fracture) of FSW pipe butt joints.

A Coupled Rigid-viscoplastic Numerical Modeling for Evaluating Effects of Shoulder Geometry on Friction Stir-welded Aluminum Alloys

Shoulder geometry of tool plays an important role in friction-stir welding because it controls thermal interactions and heat generation. This work is proposed and developed a coupled rigid-viscoplastic numerical modeling based on computational fluid dynamics and finite element calculations aiming to understand these interactions. Model solves mass conservation, momentum, and energy equations in three dimensions, using appropriate boundary conditions, considering mass flow as a non-Newtonian, incompressible, viscoplastic material. Boundary conditions of heat transfer and material flow were determined using a sticking/sliding contact condition at tool / workpiece interface. Thermal history, as well as shear stress and rotational speed fields, forces and torque values for three shoulder geometry conditions were calculated. Numerical results of thermal history, torque and forces during welding showed good correlation with experimentally measured data.