Basic Tool Design Guidelines for Friction Stir Welding of Aluminum Alloys

Hoyos, Elizabeth; Serna, María Camila

doi:10.3390/met11122042

Cited by 13 publications

(10 citation statements)

References 107 publications

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“…The AA 6xxx series (Al, Mg, and Si) alloys are frequently used in transportation and aerospace industries due to good corrosion resistance, excellent extrusion performance, and weldability [22][23][24]. Yuan et al [25] used two different tools with the same shoulder feature and different pin geometries, a conventional pin and off-center pin feature, to produce a similar FSSW lap joint of 1 mm thickness AA6016-T4.…”

Section: Introductionmentioning

confidence: 99%

Friction Stir Spot Welding of Different Thickness Sheets of Aluminum Alloy AA6082-T6

et al. 2022

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Friction stir spot welding (FSSW) is one of the important variants of the friction stir welding (FSW) process. FSSW has been developed mainly for automotive applications where the different thickness sheets spot welding is essential. In the present work, different thin thickness sheets (1 mm and 2 mm) of AA6082-T6 were welded using FSSW at a constant dwell time of 3 s and different rotation speeds of 400, 600, 800, and 1000 rpm. The FSSW heat input was calculated, and the temperature cycle experience during the FSSW process was recorded. Both starting materials and produced FSSW joints were investigated by macro- and microstructural investigation, a hardness test, and a tensile shear test, and the fractured surfaces were examined using a scanning electron microscope (SEM). The macro examination showed that defect-free spot joints were produced at a wide range of rotation speeds (400–1000 rpm). The microstructural results in terms of grain refining of the stir zone (SZ) of the joints show good support for the mechanical properties of FSSW joints. It was found that the best welding condition was 600 rpm for achieving different thin sheet thicknesses spot joints with the SZ hardness of 95 ± 2 HV0.5 and a tensile shear load of 4300 ± 30 N.

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Section: Introductionmentioning

confidence: 99%

Friction Stir Spot Welding of Different Thickness Sheets of Aluminum Alloy AA6082-T6

et al. 2022

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“…The shape and characteristics of tool material have been developed for high integrity casting performance to unwanted effect mixing that influences the outcomes joint interface. The tool is designed to create composites, remove casting defects, and refine microstructure with excellent toughness and strength [18]. However, the fabrication of such a tool is significantly challenging and how the FSW process influences the various mechanical effects and associated product defects, especially component material joining, for utilising both high melting temperature and high strength alloys [19].…”

Section: Fsw Tool Materialsmentioning

confidence: 99%

Assessment of Friction Stir Welding: An Overview

Hasnol

Zaharuddin

Ali

et al. 2023

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Friction stir welding (FSW) has an advanced technique in solid-state conditions that joins from different materials compared to the fusion welding process and is eco-friendly. This ignificant advancement involves aluminium (Al) alloys which facilitate the FSW of distinguished flow patterns in the weld zone. Technically, heat energy and stirred material resulted in softening areas, affecting joint efficiency, mechanical properties, and metallurgical characterisation. This paper has concerns comprehensively covering and summarising the development and application of the topic in different aspects of the performance and quality of the FSW welded joint. The proper tools can create sufficient heat under the shoulder for excellent performance to deal with the welding parameter. All these tools have their literature and journal, which extensive discussion.Furthermore, alloy positioning, defect formation,rotational speed and transverse feed are essential analytical tools for FSW to control the significant weld quality. Furthermore, the mechanical properties associated with microstructural evolution highly dependent on welding technique have remarkably contributed to product development. Finally, a previous study has shown the interest in the topic to enhance the knowledge for further investigation with emerging technology for future recommendations in the FSW discipline.

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“…The tool has two main parts, shoulder and pin, both playing a crucial role in the welding process. The first is responsible for the heat generation and applies a downward forging force [20], and because the function of the pin is to transport the plasticized material along the joint [21], it can be designed with different geometries. In literature different tool types can be found, the pin can be cylindrical, conical, and threaded, and, moreover, the shoulder can have a different outer surface shape, such as concave, convex, scroll, etc.…”

Section: Selection Of a Welding Processmentioning

confidence: 99%

Sustainability Score Comparison of Welding Strategies for the Manufacturing of Electric Transportation Components

et al. 2023

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Sustainability scores can be used to assess manufacturing strategies, going one step beyond a standard economic assessment. This work uses a previously proposed methodology to evaluate two of the most common welding processes for aluminium alloys that are specifically used in the fabrication of components for the transport industry based on their advantages in generating lightweight and dimensionally efficient parts. For comparison and as proof of concept, two welding methods were selected: Friction Stir Welding (FSW) and Gas Tungsten Arc Welding (GTAW). FSW attained a higher overall sustainability score. Values were calculated for an existing aluminium product, which was part of the opening and closing system of an electric train door, and the final score was 0.78 from FSW compared to 0.69 from GTAW, which was 11% higher in FSW compared to the conventional arc welding process. The analysis carried out included economic, physical, social, and environmental impacts. Finally, an example pertinent to a current EV component is described and considered along with a plan to determine the best welding process for a particular application, and with the calculations, the score obtained for GTAW was 0.43 and 0.68 for FSW, which was 36% higher that the result for the conventional arc welding process.

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Basic Tool Design Guidelines for Friction Stir Welding of Aluminum Alloys

Cited by 13 publications

References 107 publications

Friction Stir Spot Welding of Different Thickness Sheets of Aluminum Alloy AA6082-T6

Friction Stir Spot Welding of Different Thickness Sheets of Aluminum Alloy AA6082-T6

Assessment of Friction Stir Welding: An Overview

Sustainability Score Comparison of Welding Strategies for the Manufacturing of Electric Transportation Components

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