The friction stir alloying (FSA) procedure successfully produced dissimilar joints between AZ61 magnesium alloy and mild steel with Al-CNT additions. Before welding, Al-CNT additives were placed in a gap between the AZ61 and steel specimens. The experimentation was performed using different welding speeds while tool rotational speed was kept constant for varying weight percentages of carbon nanotubes (CNT) in Al powder. The influence of additives and welding speed on tensile strength and characterisation across the welding interface was studied. Tensile strength of joint with 3% CNT improved up to 222 MPa. Al-rich intermetallic compounds were found at the welding contact, while the formation of Al 2 MgC 2 carbide was detected, which contributed to CNT strengthening effects all to improved welding strength.
As an energy-efficient solid-state joining technique, friction stir welding (FSW) shows enormous advantages compared to conventional fusion welding methods. This work comprehensively reviewed the recent studies on FSW of commonly-used metals including Al, Mg, Fe, Ti and their alloys, with a particular focus on thermal cycles experienced during FSW. The role played by thermal cycles was comparatively summarised for different metals, trying not only to understand the physical effect of welding conditions on joints' microstructural evolution and mechanical properties, but also provide a guide for engineers to take proper FSW strategies when facing different metals, which has not been discussed in detail in other reviews. Finally, several ideas were proposed for a possible advancement in FSW of the investigated metals.
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