Effect of Backing Plate Materials in Micro-Friction Stir Butt Welding of Dissimilar AA6061-T6 and AA5052-H32 Aluminum Alloys

Park, SeongHwan; Joo, Younghwan; Kang, Myung Chang

doi:10.3390/met10070933

Cited by 13 publications

(7 citation statements)

References 15 publications

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“…Reinforcement particles in the MMC were chosen to be SiC and the AA6061 alloy was both the MMC matrix and the monolithic material, to which the MMC plate was friction stir welded. FSW was conducted in the present experiment on 8-mm-thick plates which were significantly thicker than other friction stir welded Al/Al MMC plates described in several previous publications [6][7][8][9][10][11][12]. The microstructure of the as-received and friction stir welded plates is characterized in this work using optical microscopy and scanning electron microscopy (SEM).…”

Section: Introductionmentioning

confidence: 98%

“…Since Al-base MMCs are more expensive than traditional aluminum alloys, there is a clear economical reason to use them only in the most critical parts of a product, whereas other parts can be made of conventional monolithic alloys. This necessitates joining of dissimilar materials, which can conveniently be done using friction stir welding (FSW) [1][2][3][4][5][6]. In the FSW process, a rotating tool generates heat due to friction, which softens and plasticizes materials to be joined.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Microstructure and Mechanical Properties of Friction Stir Welded AA6061/AA6061 + 40 vol% SiC Plates

Señorís-Puentes¹,

Serrano²,

González-Doncel³

et al. 2021

Metals

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The feasibility of butt friction stir welding (FSW) of a metal matrix composite (MMC) with a very high SiC particle content to a monolithic aluminum alloy is tested in this work. It is demonstrated for the first time that sound FSW joints can be obtained between an AA6061 aluminum plate and a thick MMC plate consisting of AA6061 reinforced with 40 vol% SiC particles. The joints withstand tensile testing, with ductile failure taking place in a soft region of the heat-affected zone on the alloy side. Metallographic examination of the MMC side after FSW reveals curved bands, where both the frequency of SiC particles and hardness are significantly lower than those in any other region on the MMC side. It is suggested that these bands are produced by transporting the alloy material to the MMC side, where the alloy is mechanically mixed with the MMC.

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Section: Introductionmentioning

confidence: 98%

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Friction Stir Welded AA6061/AA6061 + 40 vol% SiC Plates

Señorís-Puentes¹,

Serrano²,

González-Doncel³

et al. 2021

Metals

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“…Existing literature has explored the use of various backing plate materials such as copper, mild steel, aluminium, titanium, asbestos, and granite to attain defect-free welds without resorting to secondary processing techniques like postweld heat treatment. [15][16][17][18][19][20][21] Open literature has investigated the utilization of diverse backing plates in conventional FSW, examining their impact on joint properties. The effect of using aluminium, steel, Ti-6Al-4V, and ceramic backing plates (BP) was studied for FSW of 25.4 mm thick AA6061 plates.…”

Section: Introductionmentioning

confidence: 99%

Backing plate material selection for optimizing joint performance in friction stir welded aluminium honeycomb

Dutta,

Pal,

Panda

2024

Jnl of Sandwich Structures & Materials

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Aluminium honeycomb core is a thin-walled cellular structure extensively used in crash resistance applications in automotive industry. To overcome current challenges in adhesive-bonded honeycomb, new fabrication route using micro friction stir lap welding has been proposed. With a specific energy absorption capacity as high as 28.2 kJ/kg in flatwise impact testing, fabricated honeycomb demonstrated its potential for industrial applications. The structure exhibited no weld cracks or cell wall delamination, unlike adhesive-bonded honeycombs. However, in friction stir welding of thin sheets (0.5 mm), achieving an optimized heat input is challenging due to limited scope for variation in process parameter and tool design. Therefore, control of heat outflow by proper selection of backing plate material is the alternative approach for achieving desirable joint performance. Experiments with backing plates having a range of thermal diffusivities demonstrated that joint produced with mild steel backplate exhibited maximum shear-tensile strength. Conversely, joint with aluminium backplate exhibited poor plastic flow of material. Effective sheet thickness and lap width were predominantly affected by heat accumulation in weld, resulting in different failure modes.

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“…Dissimilar weld efficiency is typically measured against the weaker of the two parent materials (Bandhu, Kumar, Nishant, & Thakur, 2017;Park et al, 2020;Venkateswara Rao & Senthil Kumar, 2020). When considering 6 relevant 4 studies in the literature it was found that the weld efficiency of germane dissimilar materials varied between 42.9% and 94% for the most successful welds produced, with an average (of the 6 results considered) of 71.5%.…”

Section: Tensile Strength and Ductilitymentioning

confidence: 99%

“…Dissimilar weld efficiency is typically measured against the weaker of the two parent materials (Bandhu et al, 2017;Park et al, 2020;Venkateswara Rao & Senthil Kumar, 2020), however AA8090 and BS L165 have comparable minimum UTS specifications and extremely similar measured UTS values. The difference in measured UTS for the two parent materials falls within the uncertainty of the measurement (refer to sections 3.4.2, 4.1.3.2 and 4.2.3.2) and so the materials can be considered to have equivalent measured UTS (when compared with the relevant orientation).…”

Section: Tensile Testingmentioning

confidence: 99%

Stationary shoulder friction stir welding of military aircraft sheet alloys

Puckrin¹

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Stationary Shoulder Friction Stir Welding (SSFSW) allows joining of materials without the addition of mass and could be a potential solution to expedient helicopter repair in operational theatre. This research considers the suitability for SSFSW of two aluminium alloys commonly used within the Merlin helicopter airframe, AA8090 and BS L165. Techniques including optical microscopy, hardness, tensile and fatigue testing were used to characterise the two alloys and to establish a baseline for comparison with the welded specimens. The welds were performed in four configurations, with each welded both parallel and perpendicularly to the material’s rolling direction. This was in an effort to establish: the alloy’s suitability for SSFSW in both similar and dissimilar welds; the effect of changing the alloy positioned on the advancing side; and the influence of the material rolling direction on the quality of the weld. Techniques similar to those used in the material characterisation were used to determine the quality of each configuration. Encouraging tensile and fatigue strength results were achieved, especially for the similar materials welds with BS L165 welded parallel to the rolling direction achieving over 100% UTS weld efficiency. Inconsistent quality including the presence of kissing bonds was, however, observed. When welding parallel to the rolling direction, stronger welds were produced with BS L165 positioned on the advancing side. The presence of kissing bonds made analysis of those welded perpendicular to the rolling direction inconclusive. The material rolling direction also had an effect on the weld, as demonstrated through differences in weld appearance, degree of mixing of materials and tensile and fatigue test results. Additionally, a relationship between hardness and tensile strength was determined which revealed close correlation between the governing equation and the test results, with only 7% scatter. This will allow for prediction of tensile strength, based on the measured hardness, when the materials are joined using SSFSW.

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Effect of Backing Plate Materials in Micro-Friction Stir Butt Welding of Dissimilar AA6061-T6 and AA5052-H32 Aluminum Alloys

Cited by 13 publications

References 15 publications

Microstructure and Mechanical Properties of Friction Stir Welded AA6061/AA6061 + 40 vol% SiC Plates

Microstructure and Mechanical Properties of Friction Stir Welded AA6061/AA6061 + 40 vol% SiC Plates

Backing plate material selection for optimizing joint performance in friction stir welded aluminium honeycomb

Stationary shoulder friction stir welding of military aircraft sheet alloys

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