A study to estimate the tensile strength of friction stir welded AA 5059 aluminium alloy joints

Abstract

Friction stir welding (FSW) is an important welding technique where in, and optimizing the process parameters will improve the joint strength of the welds. The FSW process and tool parameters play a major role in determining the joint strength. In this paper, an attempt has been made to establish an empirical relationship between the FSW process parameters (rotational speed, welding speed, and axial force) and predicting the maximum tensile strength of the joint. Statistical tools such as design of experiments, analysis of variance, and regression analysis are used to develop the relationships. A non-heat treatable aluminum alloy Aluminium Association 5059 of 4 mm thickness was used as the base material. Response surface methodology is employed to develop the mathematical model. Analysis of variance technique is used to check the adequacy of the developed mathematical model. The developed mathematical model can be used effectively at 95 % confidence level. The effect of FSW process parameter on mechanical property of Aluminium Association 5059 aluminum alloy has also been analyzed in detail.

Effect of pin profiles on the mechanical properties of friction-stir-welded AA5383 and AA7075

“…Some researchers also used a square tool and reported a value of 211 MPa for a 700-min -1 tensile strength when welding aluminum alloys AA5383 and AA7075. 29 Similar tensile-strength values were obtained and reported for friction-stirwelded aluminum alloys.…”

“…Thus it can be concluded that mechanical properties of the welded samples the researchers using square tool is reported as 70 HRB for 700 min -1 Rockwell hardness value of welded aluminum alloys 5383 and 7075 alloys. 29 Similar kind of hardness values is obtained and researcher reported friction stir welded aluminium alloys.…”

Impact of shoulder concavity on non-tool-tilt friction stir welding of 5052 aluminum alloy

“…By contrast, the hardness within the weld area exhibits a decrease for all the three joints. During the FSW of cold-worked aluminum alloys, the welding heat enables annealing and recovery to take place, and hence induces the formation of softening region with lower hardness than BM [16][17][18]. Since some strength recovery has occurred in the nugget zone and thermo-mechanically affected zone due to the grain refinement strengthening and strain strengthening effects, as commonly confirmed in the FSW of other non-heat treatable aluminum alloys [2,6,9], the joints all have the lowest hardness zones at the HAZs.…”

Process Parameters Optimization for Maximizing Tensile Strength in Friction Stir-Welded Carbon Steel

“…Then, the microstructural examinations were carried out on those alloys [10] and [11]. Later, the process parameter optimization studies were reported on friction stir-welded aluminium and its alloys [12] and [13]; other studies including corrosion analysis and tensile strength optimization were also reported for aluminium [14] to [16] and magnesium alloys [17] but nowadays the research focus is on high-temperature materials. A feasibility study related to friction stir welding of mild steel was initially presented by Linert et al [18], in which defect-free welds were successfully produced, but excessive tool wear was reported; the paper emphasized the need to work on the geometry of the tool in order to eliminate the issue of tool wear.…”