Friction stir welding (FSW) is a solid state welding used for joining similar and dissimilar aluminum alloys which are hard to weld by conventional fusion welding processes. In this study friction stir lap welding (FSLW) Joints are made for similar aluminum alloys (AA1100 to AA1100) and(AA6061to AA6061) sheets of 3mm thickness and those alloys have low to medium strength and have difference in melting temperature and other physical properties.FSLW processes were carried out by conventional technique. The friction stir lap welding of similar aluminum alloys was carried out by varying the welding parameters, such as tool rotation speeds (1000, 1250 and 1600pm) and travel speeds (35, 75 and 100mm) and pin length of ( 5.4 mm) with using cylindrical threaded pin geometry or profile. Many tests and inspections were performed such as X-Ray radiographic and tensile shear test .Microhardness and microstructure observations by using optical and SEM were carried out at the best welding parameters. The above tests were used to evaluate the weld quality and joint efficiency under different welding parameters. The best welding parameters appeared in FSLW were 1250rpm and travel speed 100 mm/min. It was found that higher hardness value was (94.38HV) for 6061-T6 and 49HV for 1100-H112 in stir zone for both FSLW joints of AA6061-T6 and AA1100-H112 and that decrease toward the HAZ and base metals of AA1100 and AA6061.Space with a font size 6
In this study the friction stir lap welding was carried out by a new technique (diffusion bonding phenomenon) between (AA1100 and low carbon steel C10 sheets of 3mm and 1mm thickness respectively. These alloys have difference ranges in melting temperature and other physical properties. Different parameters were used: tool rotation speeds (630, 1250) rpm, travel speeds (80, 32) mm/min. and pin length (2.8,3) mm using cylindrical threaded pin. Many tests and inspections were performed such as tensile shear test and X-Ray diffraction tests. Microhardness and microstructure observations were conducted by using optical and SEM. The above tests were used to evaluate the weld quality and joint efficiency under different welding parameters. Best result for FSLW by diffusion phenomenon appear in (low carbon steelC10 / AA1100-H112) joint at 1250rpm in 32 mm/min. with 2.8mm pin length and the maximum tensile shear strength was (3.9)KN.It was found that the highest micro hardness was (138HV) at the interface between the low carbon steel and AA1100.
Friction stir spot welding (FSSW) method was performed for welding of aluminum alloys AA6061-T6 with pure aluminum AA1100 sheets having thicknesses of 2.4 and 3 mm respectively. FSSW procedure was accomplished at varied tool rotational speeds (1000, 1600, and 2000 rpm). The dwell time was (2, 4, and 6 sec) and the geometry of the tool pin was threaded cylindrical pin with a cylindrical and straight shoulder.
The aluminum alloy AA6061-T6 sheet was overlapped on the pure aluminum AA1100 sheet. The tensile shear test was investigated for all specimens. It was deduced that the value of the maximum shear force is 1.95 kN. This value was obtained at the following welding factors: 2000 rpm spindle rotational speed, 4 sec dwell time and threaded cylindrical pin profile, the two other factors which were pin length and plunging time were kept as constant parameters through the tests at 3.2 mm and 40 sec respectively. It was also concluded that the fracture happens in the nugget zone mode at the highest lap-shear load.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.