Journal articles: 'Friction stir welding of aluminum alloys'

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Ravendra, Jujavarapu Sai, and Palukuri Veerendra. "Studies on Effect of Tool Pin Profiles and Welding Parameters on the Friction Stir Welding of Dissimilar Aluminium Alloys AA5052 & AA6063." International Journal for Research in Applied Science and Engineering Technology 10, no. 4 (April 30, 2022): 3077–89. http://dx.doi.org/10.22214/ijraset.2022.41986.

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Abstract: Friction stir welding (FSW) is a solid-state joining process that uses the frictional heat generated by the rotating tool to soften the metals to form the joint. It is an effective technique for joining dissimilar aluminum alloys and finds its application in various fields such as aerospace and automotive industries. FSW process is energy efficient and environment friendly process. This FSW can produce joints with higher mechanical and metallurgical properties. Formerly, FSW was adopted for low melting metals like aluminum alloys. The various FSW parameters play a vital role in determining the quality of the welded joint. The parameters included in the study of different tool pin profiles (circular, pentagon and taper). FEA analysis will be performed for friction stir welding of Aluminum alloy 5052 and AA6063 at different tool pin profiles using ANSYS. This paper mainly focuses on studying the effect of different tool pin profiles on the microstructure and mechanical properties of the dissimilar AA5052 and AA6063 aluminum alloy joints. The weld quality characteristics like microstructure, micro-hardness, and tensile properties of the joints are analyzed and presented for three different tool pin profiles. It is observed from the result that the joint fabricated using three different tool pin profiles exhibits the better mechanical properties when compared to other joints. Index Terms: Friction stir welding, Aluminium alloys, AA5052, AA6063, Dissimilar welding.

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Zhi-hong, Fu, He Di-qiu, and Wang Hong. "Friction stir welding of aluminum alloys." Journal of Wuhan University of Technology-Mater. Sci. Ed. 19, no. 1 (March 2004): 61–64. http://dx.doi.org/10.1007/bf02838366.

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Lee, Ho Sung, Jong Hoon Yoon, Joon Tae Yoo, and Kyung Ju Min. "Microstructure and Mechanical Properties of Friction Stir Welded AA2195-T0." Materials Science Forum 857 (May 2016): 266–70. http://dx.doi.org/10.4028/www.scientific.net/msf.857.266.

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Aluminum-copper-lithium alloy is a light weight metal that has been used as substitute for conventional aerospace aluminum alloys. With addition of Li element, it has lower density but higher strength. However these aluminum alloys are hard to weld by conventional fusion welding, since they often produce porosities and cracking in the weld zone. It is known that solid state welding like friction stir welding is appropriate for joining of this alloy. In this study, friction stir welding was performed on AA2195 sheets, in butt joint configuration in order to understand effects of process parameters on microstructure and mechanical properties in the weld zone. The results include the microstructural change after friction stir welding with electron microscopic analysis of precipitates.

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Essa, Meshal, and Fahad Salem Alhajri. "A Survey of the Parameters of the Friction Stir Welding Process of Aluminum Alloys 6xxx Series." Engineering International 9, no. 1 (June 1, 2021): 51–60. http://dx.doi.org/10.18034/ei.v9i1.548.

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Friction stir welding is a modern innovation in the welding processes technology, there are ‎several ways in which this technology has to be investigated in order to refine and make it ‎economically responsible. Aluminum alloys have strong mechanical properties when they are ‎welded by using the Friction Stir welding. Therefore, certain parameters of the welding ‎process need to be examined to achieve the required mechanical properties. In this project, a ‎literature survey has been performed about the friction stir welding process and its parameters ‎for 6xxx series aluminum alloys‎.

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Cojocaru, Radu, Lia Boțilă, Cristian Ciucă, Horia Florin Dascau, and Victor Verbiţchi. "Friction Stir Lap Welding of Light Alloy Sheets." Advanced Materials Research 814 (September 2013): 187–92. http://dx.doi.org/10.4028/www.scientific.net/amr.814.187.

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Aluminum alloys are widely used in aerospace, automotive, railway and shipbuilding industry, as materials having remarkable properties for applications in these fields. For this reason, in recent years the interest for friction stir lap welding of sheets from these alloys increased.The behaviour of welding materials from the plastic and mechanic viewpoint are different in case of friction stir lap welding compared to friction stir butt welding.The welding tools for friction stir lap welding can have different configurations and sizes compared to butt welding. The used welding parameters must be reconsidered in order to obtain a proper flow of material for obtaining a friction stir lap welded joint.In addition, it is very important how to prepare the sheets surfaces that come into contact and their placement (relative to each other).The paper presents considerations regarding friction stir lap welding, with examples/concrete results obtained in welding of similar and dissimilar light alloys (alloys of aluminum, magnesium and titanium). It also presents data on the characteristics of obtained welded joints, related with particularities of friction stir lap welding.The obtained results showed that light alloys sheets used in various industrial fields can be joined with respect of basis conditions specific for the friction stir lap welding process.

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Dube, Nitesh, Prakash Rai, Kuldeep Giri, and Himanshu Kumar Sharma. "Optimisation of Process Parameters Friction Stir Welding." International Journal of Advance Research and Innovation 4, no. 1 (2016): 168–77. http://dx.doi.org/10.51976/ijari.411626.

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Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. The FSW parameters such as tool rotational speed, welding speed, welding tool shoulder diameter, and welded plate thickness play a major role in determining the strength of the joints. Aluminium alloys have gathered wide acceptance in the fabrication of light weight structures requiring a high strength and good corrosion resistance.

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Nemenenok, B. M., I. V. Rafalski, P. E. ,. Lushchik, and A. A. Radchenko. "Methods for producing permanent joints of aluminum and titanium alloys." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 1 (April 7, 2020): 56–64. http://dx.doi.org/10.21122/1683-6065-2020-1-56-64.

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The results of the analysis of theoretical and experimental studies of methods for producing permanent joints of dissimilar metals and alloys are presented, as well as the advantages, implementation problems and prospects of using friction stir welding to join titanium and aluminum alloys. It is noted that most studies focus on friction stir welding of light metals such as aluminum, copper, magnesium and their alloys. Despite the great scientific and practical interest, the friction stir welding processes of alloys and metal-matrix composite materials based on aluminum and titanium have been studied less thoroughly and require additional attention.Given the variety and complexity of friction stir welding, the lack of a correct assessment of the reactivity, properties and design features of aluminum and titanium alloys can lead to a number of problems associated with a change in the structure of materials and defects in the welding zone, which is accompanied by the inevitable deterioration of the mechanical characteristics of the finished joints.

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Lee, Ho Sung, Ye Rim Lee, and Kyung Ju Min. "Influence of Tool Rotational Speed on the Mechanical Properties of Friction Stir Welded Al-Cu-Li Alloy." Materials Science Forum 857 (May 2016): 228–31. http://dx.doi.org/10.4028/www.scientific.net/msf.857.228.

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Aluminum-Lithium alloys have been found to exhibit superior mechanical properties as compared to the conventional aerospace aluminum alloys in terms of high strength, high modulus, low density, good corrosion resistance and fracture toughness at cryogenic temperatures. Even though they do not form low-melting eutectics during fusion welding, there are still problems like porosity, solidification cracking, and loss of lithium. This is why solid state friction stir welding is important in this alloy. It is known that using Al-Cu-Li alloy and friction stir welding to super lightweight external tank for space shuttle, significant weight reduction has been achieved. The objective of this paper is to investigate the effect of friction stir tool rotation speed on mechanical and microstructural properties of Al-Cu-Li alloy. The plates were joined with friction stir welding process using different tool rotation speeds (300-800 rpm) and welding speeds (120-420 mm/min), which are the two prime welding parameters in this process.

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El-Hafez, Hassan Abd, and Abla El-Megharbel. "Friction Stir Welding of Dissimilar Aluminum Alloys." World Journal of Engineering and Technology 06, no. 02 (2018): 408–19. http://dx.doi.org/10.4236/wjet.2018.62025.

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Song, Sang-Woo, Nam-Kyu Kim, and Chung-Yun Kang. "Dissimilar Friction Stir Welding of Aluminum Alloys." Journal of the Korean Welding and Joining Society 27, no. 5 (October 31, 2009): 10–15. http://dx.doi.org/10.5781/kwjs.2009.27.5.010.

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Kopyściański, Mateusz, Aleksandra Węglowska, Adam Pietras, Carter Hamilton, and Stanisław Dymek. "Friction Stir Welding of Dissimilar Aluminum Alloys." Key Engineering Materials 682 (February 2016): 31–37. http://dx.doi.org/10.4028/www.scientific.net/kem.682.31.

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Dissimilar aluminum alloy plates of 2017A-T451 and 7075-T651 with 6 mm thickness were friction stir butt welded. Numerous trials were conducted to determine the conditions that produce the highest weld quality. These parameters were found to be a welding speed of 112 mm/min, a rotation speed of 355 rev/min and a vertical force of 32,8 kN. The weldability and blending of the two materials were evaluated by using macro- and microstructural analysis as well as EDS mapping to show the distribution of main alloying elements within the weld. The effect of material locations, either on the advancing or retreating sides, on the microstructure and mechanical properties was also investigated. Hardness profiles differ substantially for different weld configurations. Regardless of the position of a particular alloy, the weld microstructure was composed of alternating layers of both materials. However, the layers of the 7075 alloy always exhibited smaller grain size and a larger number of secondary phase particles.

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No, Kookil, Ye Rim Lee, Jong Hoon Yoon, Joon Tae Yoo, and Ho Sung Lee. "Tensile Properties and Microstructure of Friction Stir Welded Joints 2195-T8 Aluminum Alloy." Applied Mechanics and Materials 835 (May 2016): 191–96. http://dx.doi.org/10.4028/www.scientific.net/amm.835.191.

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Friction stir welding is a widely used welding process for aluminum alloys because it avoids many of the problems of conventional fusion welding. This process is beneficial especially for lithium containing aluminum alloys in which the reactive property of element Li causes porosity and hot cracking during melting and solidification. In friction stir welding process, each region undergoes different thermo-mechanical cycles and produces a non-homogeneous microstructure. In the present study, the mechanical properties and microstructure of a 2195-T8 aluminum alloy joined with friction stir welding were investigated. The change in microstructure across the welded joint was found to correspond to microhardness measurement. The microstructure was characterized by the presence of severely deformed grains and fine recrystallized grains depending on the region. Tensile tests shows the optimum condition was obtained at the tool rotating speed of 600rpm and the traveling speed range from 180 to 300mm/min.

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Vivas, Javier, Ana Fernández-Calvo, Egoitz Aldanondo, Uxue Irastorza, and Pedro Álvarez. "Friction Stir Weldability at High Welding Speed of Two Structural High Pressure Die Casting Aluminum Alloys." Journal of Manufacturing and Materials Processing 6, no. 6 (December 12, 2022): 160. http://dx.doi.org/10.3390/jmmp6060160.

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In this work, the friction stir weldability of two structural high-pressure die casting aluminum alloys designed to manufacture thin-walled automotive components is investigated and compared. AlSi10MnMg and AlMg4Fe2 alloys were friction stir welded at a high welding speed (from 500 to 2000 mm/min) for a fixed rotation speed of 1500 RPM. The investigation was performed by studying the material flow influence on defect formation and microstructure, the mechanical properties of the welds and the forces that act during the friction stir welding process. The AlSi10MnMg alloy shows a lower incidence of defects than the AlMg4Fe2 alloy at all welding speeds investigated. Both materials present a great friction stir welding performance at 500 mm/min with a high joint efficiency in terms of ultimate tensile strength: 92% in AlSi10MnMg alloy and 99% in AlMg4Fe2 alloy.

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Rajendrana, C., K. Srinivasan, V. Balasubramanian, H. Balaji, and P. Selvaraj. "Identifying Combination of Friction Stir Welding Parameters to Maximize Strength of Lap Joints of AA2014-T6 Aluminum Alloy." Archives of Mechanical Technology and Materials 37, no. 1 (January 26, 2017): 6–21. http://dx.doi.org/10.1515/amtm-2017-0002.

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AbstractAA2014 aluminum alloy (Al-Cu alloy) has been widely utilized in fabrication of lightweight structures like aircraft structures, demanding high strength to weight ratio and good corrosion resistance. The fusion welding of these alloys will lead to solidification problems such as hot cracking. Friction stir welding is a new solid state welding process, in which the material being welded does not melt and recast. Lot of research works have been carried out by many researchers to optimize process parameters and establish empirical relationships to predict tensile strength of friction stir welded butt joints of aluminum alloys. However, very few investigations have been carried out on friction stir welded lap joints of aluminum alloys. Hence, in this investigation, an attempt has been made to optimize friction stir lap welding (FSLW) parameters to attain maximum tensile strength using statistical tools such as design of experiment (DoE), analysis of variance (ANOVA), response graph and contour plots. By this method, it is found that maximum tensile shear fracture load of 12.76 kN can be achieved if a joint is made using tool rotational speed of 900 rpm, welding speed of 110 mm/min, tool shoulder diameter of 12 mm and tool tilt angle of 1.5°.

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Sun, Yumeng, Wenbiao Gong, Jiacheng Feng, Guipeng Lu, Rui Zhu, and Yupeng Li. "A Review of the Friction Stir Welding of Dissimilar Materials between Aluminum Alloys and Copper." Metals 12, no. 4 (April 14, 2022): 675. http://dx.doi.org/10.3390/met12040675.

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With the rapid development of various industries, the connection of copper and aluminum is in high demand. However, as a solid-phase connection technology, friction stir welding has a potential application prospect in the connection of copper and aluminum. This paper comprehensively summarizes the most recent 20 years of the literature related to the friction stir welding of copper and aluminum. The application significance of copper and aluminum connectors is introduced, and the research field of the friction stir welding of copper and aluminum is analyzed and explored from the aspects of welding technology, microstructure and mechanical properties, as well as innovations and improvements in the welding process. In view of the research status of this field, the authors put forward their views and prospects for its future, aiming to provide a basis for researchers in this field.

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Mystica, A., S. P. Sankavi, V. Siva Sakthi, T. S. Ganesh, and V. S. Senthil Kumar. "Heat Reduction in a Tool Holder during Friction Stir Welding of Aluminium Alloy." Applied Mechanics and Materials 766-767 (June 2015): 705–11. http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.705.

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Friction stir welding is a solid state welding process that uses a rotating tool to amalgamate two metals by the frictional heat generated. Recent developments in FSW of aluminium have been exploited in aerospace, marine and transport industries. The friction stir welding on aluminium metal generates heat which has detrimental effects on the system in the long run. The heat generated, due to the friction developed, has to be reduced to provide a constant thermal environment for the tool and the workpiece. This work focuses on the conception to develop a water cooled tool holder to reduce the excess temperature thereby protecting the spindle bearing. The current paper elucidates on the design and parameters of water cooled tool holder and spring loaded seal, its implementation and the results obtained by friction stir welding of aluminum.

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Lee, Ye Rim, Kookil No, Jong Hoon Yoon, Joon Tae Yoo, and Ho Sung Lee. "Investigation of Microstructure in Friction Stir Welded Al-Cu-Li Alloy." Key Engineering Materials 705 (August 2016): 240–44. http://dx.doi.org/10.4028/www.scientific.net/kem.705.240.

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It is well known that the addition of Li to aluminum alloys offers an attractive combination of low density and high modulus, which are useful for lightweight structures of aerospace vehicles. However, microstructure of Al-Li alloys are complex, which consist of a number of equilibrium and metastable phases. In addition, Al-Li alloys are weldable but the weldability is not as good as that of other aerospace alloys. This is due to the reactive property of element Li during melting and causes porosity, cracking and low joint efficiency. In friction stir welding (FSW), rotating welding tool generates frictional heat and by keeping the tool rotating and moving speed, the heat from friction causes the plate to soften without melting. Therefore, this solid state welding is adequate to Al-Li alloys. The friction stir welded joint was divided into 9 regions and each microstructure was investigated in detail to present the microstructure evolution and material flows during friction stir welding process. The recrystallized structure is observed in nugget zone and the evidence of initiation of dynamic recrystallization is found around the boundary between thermo-mechanically affected zone (TMAZ) and nugget region. This paper describes the results of a study to investigate the microstructure change of Al-Cu-Li alloy during the friction stir welding process.

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Patel, Vivek, Wenya Li, Guoqing Wang, Feifan Wang, Achilles Vairis, and Pengliang Niu. "Friction Stir Welding of Dissimilar Aluminum Alloy Combinations: State-of-the-Art." Metals 9, no. 3 (February 26, 2019): 270. http://dx.doi.org/10.3390/met9030270.

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Friction stir welding (FSW) has enjoyed great success in joining aluminum alloys. As lightweight structures are designed in higher numbers, it is only natural that FSW is being explored to join dissimilar aluminum alloys. The use of different aluminum alloy combinations in applications offers the combined benefit of cost and performance in the same component. This review focuses on the application of FSW in dissimilar aluminum alloy combinations in order to disseminate research this topic. The review details published works on FSWed dissimilar aluminum alloys. The detailed summary of literature lists welding parameters for the different aluminum alloy combinations. Furthermore, auxiliary welding parameters such as positioning of the alloy, tool rotation speed, welding speed and tool geometry are discussed. Microstructural features together with joint mechanical properties, like hardness and tensile strength measurements, are presented. At the end, new directions for the joining of dissimilar aluminum alloy combinations should guide further research to extend as well as to improve the process, which is expected to raise further interest on the topic.

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Boțilă, Lia Nicoleta, Radu Cojocaru, Cristian Ciucă, and Victor Verbiţchi. "Processes Developed Based on Friction Stir Welding Process." Key Engineering Materials 890 (June 23, 2021): 66–75. http://dx.doi.org/10.4028/www.scientific.net/kem.890.66.

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Considering the remarkable results obtained by using friction stir welding process (FSW), ISIM Timisoara has developed research programs for the knowledge and development of processing processes based on the FSW process principle.The paper presents a synthesis of the researches and the results obtained within some of research projects carried out by ISIM Timisoara, regarding possibilities of using some of processes derived from the FSW process, which has focused mainly on two directions (areas): surface engineering (materials surface processing) and joining by friction riveting. In the field of surfaces engineering, there are presented some results that represent own contributions of ISIM Timisoara, regarding: friction stir processing as well as coating with functional layers from lightweight alloys of steel substrates (by friction with consumable tool).Regarding friction riveting, two methods are presented: classic friction riveting, respectively friction riveting with hybrid effect (mechanical grip and friction welding).The paper shows very good results obtained to FSP processing (for cast aluminum alloys), to friction riveting with hybrid effect (for aluminum and copper alloys) and to friction riveting (for aluminum alloy), but also some limitations of these friction processing methods.Also in the paper are presented new research directions that are currently being addressed, respectively that will be addressed in the next period at ISIM Timisoara, regarding new variants of application of FSW welding.

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Constantin, Marius Adrian, Ana Boşneag, Monica Iordache, Eduard Niţu, and Doina Iacomi. "Numerical Simulation of Friction Stir Welding of Aluminum Alloys: A Brief Review." Applied Mechanics and Materials 809-810 (November 2015): 467–72. http://dx.doi.org/10.4028/www.scientific.net/amm.809-810.467.

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Friction Stir Welding (FSW) is the latest innovative and most complex process which is widely applied to the welding of lightweight alloys, such as aluminum and magnesium alloys, and most recently, titanium alloys, copper alloys, steels and super-alloys. Friction stir welding is a highly complex process comprising several highly coupled physical phenomena. The experiments are often time consuming and costly. To overcome these problems, numerical analysis has frequently been used in the last ten years. In this paper is presented a brief review of scientific papers in recent years on numerical simulation of Friction Stir Welding of aluminum alloys. The main elements analyzed by FSW simulation, and briefly in this paper are: temperature and residual stress distribution; work tool geometry (size and shape of the pin); distribution of equivalent plastic deformation; main areas resulted after welding; distribution of microstructure (grain size); parameters and optimization of the FSW process.

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Kaunitz, Wails Grant. "A Review of Using Response Surface Methodology in Friction Stir Welding." International Journal of Advance Research and Innovation 7, no. 1 (2019): 106–10. http://dx.doi.org/10.51976/ijari.711916.

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Friction Stir Welding (FSW) is a comparatively new joining process that has exhibited many advantages over traditional arc welding processes, including greatly reducing distortion and eliminating solidification. Friction stir welding used to join high strength joints aluminum pipes. The present work explains review and overview of Response Surface Methodology in Friction stir welding which contain the basic connotation of the process, mechanical properties and Suggested model in FSW process. This paper gives the review of basic concepts of response surface methodology in Friction Stir Welding for alloys on process parameters. It is established that response surface methodology in FSW of alloys is appropriate an increasingly overripe technology with many commercial applications.

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Muhammad, Wali, Wilayat Hussain, Hamid Zaigham, and Nouman Zubair. "Evolution of Fatigue Crack Growth Phenomena in Friction Stir Welded AA2xxx Alloys." Key Engineering Materials 875 (February 2021): 227–37. http://dx.doi.org/10.4028/www.scientific.net/kem.875.227.

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Aluminum 2xxx alloys have been one of the primary materials for the structural applications of aerospace and transportation industry because of their performance, manufacturing and reliable inspection techniques. Welding is very important in the manufacturing process of structural parts and is now known as the most vital process in the manufacturing route. A relatively new process of joining of materials is friction stir welding process, which was invented by The Welding Institute (TWI) in the UK in 1991. The friction stir welding is mainly employed in aerospace, marine and transportation fields that have high safety requirements. The failure by fatigue is the dominant failure mode for structural weld joints. Since fatigue failure of parts accounts for 50 to 90% of all failures, it is of great significance to understand the fatigue properties of friction stir welded joints. The aim of this overview is to summarize the current research on fatigue crack growth behavior of friction stir welded AA2xxx alloys and critical attention is payed to the damage tolerance performance of friction stir welded aluminum joints that can be affected by welding process parameters, residual stress, stress ratio, environment and post weld treatments.

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Wahid, Mohd Atif, Zahid A. Khan, Arshad Noor Siddiquee, Rohit Shandley, and Nidhi Sharma. "Analysis of process parameters effects on underwater friction stir welding of aluminum alloy 6082-T6." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233, no. 6 (July 25, 2018): 1700–1710. http://dx.doi.org/10.1177/0954405418789982.

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In friction stir welding of heat treatable aluminum alloys, the thermal cycles developed during the joining process result in softening of the joints which adversely affect their mechanical properties. Underwater friction stir welding can be a process of choice to overcome this problem due to low peak temperature and short dwell time involved during the process. Consequently, this article presents a study pertaining to the underwater friction stir welding of aluminum alloy 6082-T6 with an aim to develop a mathematical model to optimize the underwater friction stir welding process parameters for obtaining maximum tensile strength. The results of the study reveal that the tool shoulder diameter (d), tool rotational speed (ω), welding speed (v), and second-order term of rotational speed, that is, ω2, significantly affect the tensile strength of the joint. The maximum tensile strength of 241 MPa which is indeed 79% of the base metal strength and 10.7% higher than that of conventional (air) friction stir welding joint was achieved at an optimal setting of the underwater friction stir welding parameters, that is, tool rotational speed of 900 r/min, the welding speed of 80 mm/min, and a tool shoulder of 17 mm. The article also presents the results of temperature variation, the macrostructural and microstructural investigations, microhardness, and fractography of the joint obtained at the optimal setting for underwater friction stir welded (UFSWed) joint.

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Jaiganesh, V., D. Srinivasan, and P. Sevvel. "Optimization of process parameters on friction stir welding of 2014 aluminum alloy plates." International Journal of Engineering & Technology 7, no. 1.1 (December 21, 2017): 9. http://dx.doi.org/10.14419/ijet.v7i1.1.8906.

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Aluminum Alloy 2014 is a light weight high strength alloy used widely in the aerospace and also in other industries. 2014 is the second most popular of the 2000-series aluminium alloys, after 2024 aluminium alloy. However, it is difficult to weld, as it is subject to cracking. Joining of 2014 aluminium alloy in friction stir welding which is based on frictional heat generated through contact between a rotating tool and the work piece. Determination of the welding parameters such as spindle speed, transverse feed , tilt angle plays an important role in weld strength. The whole optimization process is carried out using Taguchi technique. The SEM analysis is done to check the micro structure of the material after welding by electron interaction with the atoms in the sample. Tensile test have been conducted and the s-n ratio curve is generated. The test is conducted and analysed on the basis of ASTM standards.

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Elatharasan, G., and V. S. Senthil Kumar. "Metallurgical Studies on the Friction Stir Welding of Dissimilar A356 and A413 Alloys." Advanced Materials Research 488-489 (March 2012): 345–49. http://dx.doi.org/10.4028/www.scientific.net/amr.488-489.345.

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Friction stir welding is a technique useful for joining aluminum alloys that are difficult to weld. In recent years, however the focuses has been on welding dissimilar aluminum alloys, and analyze their mechanical properties and micro-structural characteristics. In the present study, the less investigated welding of cast aluminum alloys is considered. Cast aluminum alloys, A356 and A413, commonly used in automotive and aerospace industries, were friction-stir welded and their mechanical properties and micro-structural characteristics were analyzed. On testing their welded region, no welding defects were observed. The welded region exhibited a maximum tensile strength of 90 N/mm2 and Vickers micro-hardness of 56.8. The micro-structural observations at the nugget region revealed a refined grain structure.

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Vanama, Santosh. "Design and Fabrication of Friction Stir Welding End-Effector for an ABB IRB1410 Robot." IAES International Journal of Robotics and Automation (IJRA) 5, no. 2 (June 1, 2016): 98. http://dx.doi.org/10.11591/ijra.v5i2.pp98-104.

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<p>The paper propose modelling and fabrication of friction stir welding end-effector for ABB IRB1410 robot. A dynamically developing version of pressure welding processes, join material without reaching the fusion temperature called friction stir welding. As friction stir welding occurs in solid state, no solidification structures are created thereby eliminating the brittle and eutectic phase’s common to fusion welding of high strength aluminium alloys. In this paper, Friction stir welding is applied to aluminum sheets of 2 mm thickness. A prototype setup is developed to monitor the evolution of main forces and tool temperature during the operation. Pressure of a gripper plays a major role for tool rotation and developing torque. Fabrication of the tool has done. Force calculations are done by placing the sensors on the outer surface of gripper. Methods of evaluating weld quality are surveyed as well.</p>

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NAGURA, Ryo, and Tadashi NISHIHARA. "417 Friction Stir Welding of High-Strength Aluminum Alloys." Proceedings of the Materials and processing conference 2000.8 (2000): 303–4. http://dx.doi.org/10.1299/jsmemp.2000.8.303.

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Jonckheere, Caroline, Bruno de Meester, Anne Denquin, and Aude Simar. "Dissimilar Friction Stir Welding of 2014 to 6061 Aluminum Alloys." Advanced Materials Research 409 (November 2011): 269–74. http://dx.doi.org/10.4028/www.scientific.net/amr.409.269.

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Welding cheap and ductile 6xxx Al alloys with high strength 2xxx Al alloys is desirable for instance in specific aeronautical applications. These alloys present different rheological behaviors and melting temperatures which affect the ability to produce sound dissimilar friction stir welds. Dissimilar friction stir butt welds made of 2014-T6 and 6061-T6 Al alloys were performed with various welding parameters including shifts of the tool from the initial separation between the plates to be welded and placing one alloy either on the advancing, or on the retreating side of the weld. Temperature measurements during welding, mechanical characterization (transverse tensile tests and hardness profiles) and macrographic observations were performed. Macrographies on sections perpendicular to the welding direction reveal different metal flow patterns in the weld nugget. If the 2014 alloy is placed on the advancing side of the weld, an abrupt transition between the weld nugget and the 6061 alloy is observed on macrographs leading to premature fracture in tension. Dissimilar welds are cooler on the 6061 side of the weld, i.e. the weakest side of the weld, than the corresponding 6061 similar weld, limiting the growth of the hardening precipitates. This leads thus to higher strength of the dissimilar welds. Dissimilar welds with the weld center shifted towards the 2014 alloy present lower temperatures than unshifted welds on the 6061 side of the weld, also leading to higher strength.

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Panteleev, M. D., A. V. Sviridov, A. A. Skupov, and N. S. Odintsov. "PERSPECTIVE WELDING TECHNOLOGIES OF ALUMINUM-LITHIUM ALLOY V-1469 APPLIED TO FUSELAGE PANELS." Proceedings of VIAM, no. 12 (2020): 35–46. http://dx.doi.org/10.18577/2307-6046-2020-0-12-35-46.

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In this work, we investigated the technological features of promising technologies for laser welding and friction stir welding of high-strength aluminum-lithium alloy V-1469. The modes of laser welding and friction stir welding have been carried out. In this article, we showed the perspective welding methods provide high values of ductility and impact toughness, while the strength of welded joints is not less than 0,8 of the strength of the base material and values of low cycle fatigue is not less than 110•103 cycles. The results allows to propose laser welding and friction stir welding processes as an alternative to riveted joint for aluminum-lithium alloy V-1469 as applied to the elements of the fuselage.

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Kiter, Riyah Najim, and Hussam Jumma Chalob. "Friction Stir welding and Friction Stir Processing for 6061-T6 Aluminum Alloy." Journal of Advanced Sciences and Engineering Technologies 2, no. 1 (December 26, 2021): 40–53. http://dx.doi.org/10.32441/jaset.02.01.04.

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6061-T6 Aluminum Alloy plates were welded by using Friction Stir Welding (FSW) at different rotation and welding speeds. The effects of two factors on Ultimate Tensile Strength (UTS), which include rotation and welding speed at 2o tool tilt angle, were investigated. Ultimate Tensile strength increases with decrease the welding speeds and increases the rotational speeds. The rotation speeds have a higher effect on ultimate tensile strength when compared with the welding speeds. Friction Stir Processing (FSP, Double pass) led to increasing the ultimate tensile strength and elongation at same welding and rotation speeds. FSP lead to improve fatigue life and reduce residual stress.

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Hirata, Tomotake, T. Oguri, H. Hagino, Tsutomu Tanaka, Chung Sung Wook, Masato Tsujikawa, Yorinobu Takigawa, and Kenji Higashi. "Formability of Friction Stir Welded and Arc Welded 5083 Aluminum Alloy Sheets." Key Engineering Materials 340-341 (June 2007): 1473–78. http://dx.doi.org/10.4028/www.scientific.net/kem.340-341.1473.

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The formability in friction stir and arc welded 5083 Al alloys was investigated. The elongation in friction stir welded material under uniaxial tensile test increased with the decrease in friction heat flow during friction stir welding (FSW) and the value of dome height under biaxial bulge test increased with friction heat flow. The ductility improved according to changes in FSW condition and FS-welded alloy sheet exhibited excellent formability.

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Cho, Jae Hyung, Suk Hoon Kang, Kyu Hwan Oh, Heung Nam Han, and Suk Bong Kang. "Friction Stir Weld Modeling of Aluminum Alloys." Advanced Materials Research 26-28 (October 2007): 999–1002. http://dx.doi.org/10.4028/www.scientific.net/amr.26-28.999.

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Friction stir welding (FSW) process of aluminum alloys was investigated using a two-dimensional Eulerian formulation coupling viscoplastic flow and heat transfer and strain hardening. The thermal equation for the temperature was modified to stabilize temperature distribution using a Petrov-Galerkin method. The evolution equation for strength was calculated using a streamline integration method. Predicted strength was compared with experiments. Based on crystal plasticity, texture evolution was predicted during FSW of AA6061.

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Jata, K. V. "Friction Stir Welding of High Strength Aluminum Alloys." Materials Science Forum 331-337 (May 2000): 1701–12. http://dx.doi.org/10.4028/www.scientific.net/msf.331-337.1701.

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Cho, J. H. "Modeling Friction Stir Welding Process of Aluminum Alloys." Metals and Materials International 14, no. 2 (April 26, 2008): 247–58. http://dx.doi.org/10.3365/met.mat.2008.04.247.

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CHEN, HUIZI, JIALIN CHEN, XIANGCHEN MENG, YUMING XIE, YONGXIAN HUANG, SHUANGMING XU, and YAOBANG ZHAO. "Wire-Based Friction Stir Additive Manufacturing toward Field Repairing." Welding Journal 101, no. 9 (September 1, 2022): 249–52. http://dx.doi.org/10.29391/2022.101.019.

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36

Shah, Pratik H., and Vishvesh J. Badheka. "Friction stir welding of aluminium alloys: An overview of experimental findings – Process, variables, development and applications." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 233, no. 6 (April 14, 2017): 1191–226. http://dx.doi.org/10.1177/1464420716689588.

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The never ending appetite of the mankind to produce more and more competitive products results in continuous development of newer and newer manufacturing processes. One of such a kind, a solid state welding process highly appreciated for joining of a variety of aluminium and copper alloys, is friction stir welding. The process is also an accomplished method for joining dissimilar materials efficiently. The process finds its major application for joining hard-to-weld metals, especially the precipitation hardenable aluminium alloys and is widely adopted by industries for the welding of such aluminium alloys. However, the process has still not found an economical way for welding of steels and hence found limited applications in industries for welding steels. This paper aims at providing a comprehensive review of the work undertaken in the field of friction stir welding and provides an insight into the friction stir welding of aluminium alloys. The article pays critical attention and analytical evaluation of classification of aluminium alloys, friction stir welding process parameters, the mechanical testing and properties of the friction stir welding joints, macrostructure and microstructure evolution during friction stir welding, friction stir welding defects and industrial applications of the process. The friction stir welding process variants are discussed as well. Special accentuation has been given to (i) effect of friction stir welding parameters on the microstructure evolved and thus the ultimate mechanical properties (viz. tensile strength, hardness, fatigue strength, fracture toughness and residual stresses), (ii) the texture formation, microstructure refinement and the role of intermetallics. However, studies related to welding of dissimilar aluminium alloys, temperature, and heat transfer modeling and material flow are out of the scope of this paper. Finally, the directions of future research are examined.

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No, Koo Kil, Joon Tae Yoo, Jong Hoon Yoon, and Ho Sung Lee. "An Experimental Study of Process Parameters on Friction Stir Welded Aluminum Alloy 2219 Joint Properties." Applied Mechanics and Materials 863 (February 2017): 3–7. http://dx.doi.org/10.4028/www.scientific.net/amm.863.3.

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Aluminum alloy 2219 is widely used in aerospace applications since it has a unique combination of good weldability and high specific strength. Furthermore, it can provide a high strength after heat treatment with superior properties in cryogenic environment so they have been widely used for cryogenic fuel tank of space launch vehicles. It is known that solid state welding like friction stir welding can improve the joint properties of this alloy. Friction stir welding is a solid state welding technology which two materials are welded together by the frictional heat due to the rotation of the tool. In this study, friction stir welding was performed on aluminum alloy 2219 sheets. The range of welding parameter is four rotation speeds from 350 to 800 rpm and six travel speeds from 120 to 420 mm/min. The results include the microstructural change after friction stir welding. The microstructure was characterized and material in the stirred zone experience sufficient deformation and heat input which cause the complete dynamic recrystallization. The present work represents the strength at each process condition and the optimum friction stir welding process parameters. The optimum weld efficiency obtained in this study was 76.5 %.

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Giera, Arthur, Marion Merklein, and Manfred Geiger. "Statistical Investigations on Friction Stir Welded Aluminum Tailored Blanks for a Robust Process Window." Advanced Materials Research 6-8 (May 2005): 599–606. http://dx.doi.org/10.4028/www.scientific.net/amr.6-8.599.

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The multifarious applications of aluminum alloys in different industrial domains are based on the mechanical properties as well as the light weight characteristics, which allow energy saving for the products in use. Nevertheless aluminum alloys are considered to be difficult to weld by conventional welding processes. This paper deals with cost-effective friction stir welding of thin sheet aluminum alloys in thicknesses of about 1 mm to widen the possible range of applications. Based on former studies results will be shown how an optimized tool geometry increases the mechanical properties of friction stir welded parts. The characteristics of these friction stir welded thin sheets will be analysed in a statistical evaluation in order to detect the interactions and dependencies of the process parameters. By highlighting the main process parameters and their significances a process window for friction stir welded blanks of AA5182 and AA6016 is presented.

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Nadikudi, Bhanodaya Kiran Babu. "Effect of friction stir welding tool profiles on mechanical properties of dissimilar welded aluminum alloy plates." International Journal of Structural Integrity 12, no. 4 (March 8, 2021): 562–68. http://dx.doi.org/10.1108/ijsi-10-2020-0097.

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PurposeThe main purpose of the present work is to study the effect of tool pin profiles on mechanical properties of welded plates made with two different aluminium alloy plates.Design/methodology/approachThe welded plates were fabricated with the three different kinds of pin profiled tools such as taper cylindrical, taper threaded cylindrical and stepped cylindrical pin profiles. Tensile properties of welded plates were evaluated using tensile testing machine at room temperature. Microstructures studies were carried out using scanning electron microscope.FindingsTensile properties were improved with the use of taper threaded cylindrical pin tool in friction stir welding process when compared with taper cylindrical and stepped cylindrical pin tools. This is due to refinement of grains and mixing of plasticized material occurred with generation of sufficient heat with the taper threaded pin tool. Through these studies, it was confirmed that friction stir welding can be used to weld Al6061 and Al2014 aluminium alloy plates.Research limitations/implicationsIn the present study, the friction stir welding is performed with constant process parameters such as tool rotational speed of 900 rpm, transverse speed of 24 mm/min and tilt angle of 1°.Practical implicationsAluminium alloys are widely using in automotive and aerospace industries due to holding a high strength to weight property. These aluminium alloy blanks can be developed with friction stir welding method with better properties.Originality/valueVery limited work had been carried out on friction stir welding of aluminium alloys of Al 6061 and Al2014 with different tool pin profiles. Furthermore, this work analyzed with tensile properties of welded plates correlated with weld zone microstructures.

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Mabuwa, Sipokazi, and Velaphi Msomi. "Review on Friction Stir Processed TIG and Friction Stir Welded Dissimilar Alloy Joints." Metals 10, no. 1 (January 17, 2020): 142. http://dx.doi.org/10.3390/met10010142.

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There is an increase in reducing the weight of structures through the use of aluminium alloys in different industries like aerospace, automotive, etc. This growing interest will lead towards using dissimilar aluminium alloys which will require welding. Currently, tungsten inert gas welding and friction stir welding are the well-known techniques suitable for joining dissimilar aluminium alloys. The welding of dissimilar alloys has its own dynamics which impact on the quality of the weld. This then suggests that there should be a process which can be used to improve the welds of dissimilar alloys post their production. Friction stir processing is viewed as one of the techniques that could be used to improve the mechanical properties of a material. This paper reports on the status and the advancement of friction stir welding, tungsten inert gas welding and the friction stir processing technique. It further looks at the variation use of friction stir processing on tungsten inert gas and friction stir welded joints with the purpose of identifying the knowledge gap.

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Liu, Da Hai, Jun Chu Li, and Chun Chang. "Creep Age Formability of Friction Stir Welded 2A12 Aluminum Alloy Structures." Advanced Materials Research 753-755 (August 2013): 145–48. http://dx.doi.org/10.4028/www.scientific.net/amr.753-755.145.

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To establish the efficacy of creep age forming of the integrally friction stir welded panels, feasibility experiments were first conducted on friction stir welded rib-web panels of 2A12 aluminum alloys by using a designed air-loading age forming setup, and then related forming characteristics were investigated by using a mechanical-loading setup on the samples with and without friction stir welding joints. Results show that good age-formability can be observed from friction stir welded rib-web parts after creep age forming. The surface springback of the integral parts decreases with increasing the aging time and temperature. For 2A12 aluminum alloy, under an aging temperature of 190°C, a relatively better forming effect and strength can be reached at an aging time of about 8h. Compared with the non-welded structures, the introduction of friction stir welding will inhibit forming rate and will shorten the time of creep age forming.

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Praveen Raj Navukkarasan, A., K. Shanmuga Sundaram, C. Chandrasekhara Sastry, and M. A. Muthu Manickam. "Experimental Investigation of Dry and Cryogenic Friction Stir Welding of AA7075 Aluminium Alloy." Advances in Materials Science and Engineering 2021 (September 21, 2021): 1–21. http://dx.doi.org/10.1155/2021/9961590.

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An attempt has been made to investigate dry and cryogenic friction stir welding of AA 7075 aluminium alloy, which is predominantly availed in aerospace and defence component industries. These industries avail friction stir welding for joining two nonferrous materials, and minimal deviations and maximum strength are the preliminary and long time goal. A cryogenic friction stir welding setup was developed to conduct the joining of two aluminium alloy pipes. An increase of 0.76–42.93% and 3.79–31.24% in microhardness and tensile strength, respectively, is ascertained in cryogenic friction stir welding in correlation to dry friction stir welding of aluminium alloys. TOPSIS evaluation for the experimental run indicated tool profile stepped type, pipe rotation speed of 1000 rpm, welding speed of 50 mm/min, and axial force of 8 kN as close to unity ideal solution for dry and cryogenic friction stir welding of AA 7075 aluminium alloys. The friction stir-welded component under the cryogenic environment showcased drop in temperature, curtailed surface roughness, and fine grain structure owing to reduction in temperature differential occurring at the weld zone. A curtailment of 50.84% is ascertained in the roughness value for cryogenic friction stir welding in correlation to dry friction stir welding of AA 7075 alloy. A decrement of 21.68% is observed in the grain size in the cryogenic condition with correlation to the dry FSW process, indicating a drop in the coarse structure. With the curtailment of grain size and drop in temperature differential, compressive residual factor and corrosion resistance attenuated by 40.14% and 67.17% in the cryogenic FSW process in correlation to the dry FSW process, respectively.

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Gadallah, Nabil, Ibrahim Sabry, and M. Abdel Ghafaar. "A Summarized Review on Friction Stir Welding for Aluminum Alloys." Academic Research Community publication 4, no. 1 (February 24, 2020): 1. http://dx.doi.org/10.21625/archive.v4i1.695.

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This paper explains the precept and methodology of FSW. It covers some of the technical sides which influence the process and quality of FSW joint. Large advance has been accomplished in friction stir welding (FSW) of aluminum in every side of tool manufacture, microstructure properties estimate in the last decennia. With the development of reliable welding tools and precise control systems, FSW of aluminum has reached a new level of technical maturity. influence on butt joint arrangement is studied. Effect on welding quality of main parameters: rotation speed, travel speed, tool tilt angle, axial force and weld time has been studied. Finally, FSW is identified as an additional area for research can be carried out in the welding science.

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Kuritsyn, D. N., M. V. Siluyanova, and V. V. Kuritsyna. "Friction Stir Welding in the Aircraft Production." Materials Science Forum 992 (May 2020): 447–52. http://dx.doi.org/10.4028/www.scientific.net/msf.992.447.

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The paper presents the results of experimental development of the technology of friction stir welding to obtain a nonseparable connection of a special aerospace aluminum, titanium and magnesium alloys, high-temperature steels. Regularities and models of heat balance in the welding zone have been determined, which make it possible to predict the technological possibilities of high-speed friction welding. It is established that high-speed friction welding by mixing allows to obtain a high-quality connection at lower loads on the design of the equipment. On the basis of studies of macro-and microstructure, microhardness, level of residual stresses and strength tests, technological recommendations on the choice of welding conditions and conditions were obtained. Presented of experimental and industrial development of special equipment, high-speed friction welding, design and manufacturing of high hardness tools of complex spatial shapes for welding aircraft materials.

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Bergmann, Jean Pierre, René Schürer, and Kevin Ritter. "Friction Stir Welding of Tailored Blanks of Aluminum and Magnesium Alloys." Key Engineering Materials 549 (April 2013): 492–99. http://dx.doi.org/10.4028/www.scientific.net/kem.549.492.

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The following paper describes a feasibility study of butt joining friction stir welding between aluminum alloy AA6016 and magnesium alloys AZ91 and AM50. Because of the variety of inimitable properties according to lightweight design and constructions, the interest in aluminum and magnesium alloys is increasing in many fields of industry. Due to the low solubility of aluminum in magnesium and inverse, these alloys tend to the formation of intermetallic phases during the joining process. This leads to an increasing micro hardness within the seam, which should be avoided. By the use of joining methods with low process temperatures, the formation of intermetallic phases is reduced. According to this circumstance, friction stir welding is an excellent alternative to fusion welding techniques used to join this alloys. The main welding process variables were exposed in the studies of similar butt joints of Al/Al and Mg/Mg. These were examined in connection to their transferability to the dissimilar joints and tailored blanks. Furthermore, the influence of different tool geometry on seam quality was investigated. The effect of process variables (mainly welding speed and revolution speed) were correlated to the results of tensile strength test. The welded samples were assayed in the presence of intermetallic phases.

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Sizova, Olga, Galina Shlyakhova, Alexander Kolubaev, Evgeny A. Kolubaev, Sergey Grigorievich Psakhie, Gennadii Rudenskii, Alexander G. Chernyavsky, and Vitalii Lopota. "Microstructure Features of Aluminum Alloys Welded Joint Obtained by Friction Stir Welding." Advanced Materials Research 872 (December 2013): 174–79. http://dx.doi.org/10.4028/www.scientific.net/amr.872.174.

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The paper presents a metallographic study of aluminum alloy welds produced by friction stir welding. The weld structure is described for two alloys: Al-Cu and Al-Mg. It is shown that friction stir welding provides a fine-grained structure of the weld. The phase composition of the weld metal for the studied alloys is defined. Differences in the structure and distribution of second-phase particles in the weld metal are shown. The weld zone of Al-Cu alloy consists of equal size grains, with intermetallic particles located along the grain boundaries. The weld structure of Al-Mg alloy is banded, with alternating layers consisting of different size grains.

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Lin, Ben Yuan, P. Yuan, and Ju Jen Liu. "Temperature Distribution of Aluminum Alloys under Friction Stir Welding." Advanced Materials Research 264-265 (June 2011): 217–22. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.217.

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The temperature distribution of 6061-T6 aluminum alloy plates under a friction stir butt-welding was investigated by using experiment and numerical simulation. A real-time temperature measuring system was used to measure the temperature change in the welding process. Vickers hardness profiles were made on the cross-section of the weld after welding. A commercial software of FlexPDE, a solver for partial different equations with finite element method, was used to simulate the experimental welding process of this study. Comparison the experimental and numerical results, the temperature cycles calculated by numerical are similar to those measured by experiment. The temperature distribution profile obtained from the numerical simulation is symmetrical to the weld center and has a close correspondence with the hardness configuration and the microstructure of the weld. The region with the temperature over 300 °C is the zone of softening within the boundaries of base material and HAZ. The regions of 350 °C with minimum hardness are located near the boundary of HAZ and TMAZ. The maxima temperature about 500 °C distributes around the upper part of the weld center. However, the region above 400 °C only matches with the upper half of the weld nugget.

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Rajesh Kannan, Subburaj, J. Lakshmipathy, M. Vignesh Kumar, K. Manisekar, and N. Murugan. "Optimization Analysis of Process Parameters of Friction Stir Welded Dissimilar Joints of Aluminium Alloys." Applied Mechanics and Materials 867 (July 2017): 112–18. http://dx.doi.org/10.4028/www.scientific.net/amm.867.112.

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Friction stir welding (FSW) is one of the new technique for welding materials in solid state welding process. In this proposed work we are using FSW to join the two dissimilar alloys of aluminium. The 6mm thick aluminum plates of aluminium 5086 and aluminum 7075 plates are considered for welding. These have been considered due to their application in various fields. In this experimental process Taguchi’s L9 orthogonal array method is used for optimizing the three process parameters namely rotational speed, axial force and welding speed. To produce a better joint the tensile strength is predicted for the optimum welding parameters and also their percentage of contribution is calculated, by applying the effect of analysis of variance. Depends upon the experimental study, the rotational speed is found better over the other process parameters, which enhances the quality of the weld. The tensile strength has been found for the optimum parameters and the result found during the experiment was 290Mpa which was higher than the base metal strength of aluminium 5086 alloy. The SEM fractograph analysis was done on the optimum parameters welded joints to show the fracture behaviour of tensile test which justifies the visual inspection results of brittle and ductile failures.

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Yang, Hong Gang, and Hai Jun Yang. "Experimental Investigation on Refill Friction Stir Spot Welding Process of Aluminum Alloys." Applied Mechanics and Materials 345 (August 2013): 243–46. http://dx.doi.org/10.4028/www.scientific.net/amm.345.243.

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With the growing demand for lightweight reduction and environment protection, lightweight materials like aluminum and magnesium alloys have been widely applied in the automotive and aerospace industry. Being a solid state welding process, refill friction stir spot welding (RFSSW) is suitable for spot joining lightweight metals. In the present paper, the mechanical properties and microstructure of the RFSSW joints of 6061-T6 aluminum alloys were investigated. The influence of welding parameters, such as plunge depth, rotating speed and welding time, on tensile-shear strength was conducted through experiments. It is found that the tensile-shear strength is increased with the increase of plunge depth, rotating speed and welding time. And welding time is found to be an important key factor which affects welding quality. Research results can provide guidance for welding parameters optimization and welding quality promotion of RFSSW process of aluminum alloys.

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Abbasi, Mahmoud, Amin Abdollahzadeh, Behrouz Bagheri, Ahmad Ostovari Moghaddam, Farzaneh Sharifi, and Mostafa Dadaei. "Study on the effect of the welding environment on the dynamic recrystallization phenomenon and residual stresses during the friction stir welding process of aluminum alloy." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 235, no. 8 (June 21, 2021): 1809–26. http://dx.doi.org/10.1177/14644207211025113.

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Various methods have been proposed to modify the friction stir welding. Friction stir vibration welding and underwater friction stir welding are two variants of this technique. In friction stir vibration welding, the adjoining workpieces are vibrated normal to the joint line while friction stir welding is carried out, while in underwater friction stir welding the friction stir welding process is performed underwater. The effects of these modified versions of friction stir welding on the microstructure and mechanical characteristics of AA6061-T6 aluminum alloy welded joints are analyzed and compared with the joints fabricated by conventional friction stir welding. The results indicate that grain size decreases from about 57 μm for friction stir welding to around 34 μm for friction stir vibration welding and about 23 μm for underwater friction stir welding. The results also confirm the evolution of Mg2Si precipitates during all processes. Friction stir vibration welding and underwater friction stir welding processes can effectively decrease the size and interparticle distance of precipitates. The strength and ductility of underwater friction stir welding and friction stir vibration welding processed samples are higher than those of the friction stir welding processed sample, and the highest strength and ductility are obtained for underwater friction stir welding processed samples. The underwater friction stir welding and friction stir vibration welding processed samples exhibit about 25% and 10% higher tensile strength compared to the friction stir welding processed sample, respectively. The results also indicate that higher compressive residual stresses are developed as underwater friction stir welding and friction stir vibration welding are applied.

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Journal articles on the topic 'Friction stir welding of aluminum alloys'

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