Effect of Temperature and Material Flow Gradients on Mechanical Performances of Friction Stir Welded AA6082-T6 Joints

Ma, Xinyan; Xu, Shuangming; Wang, Feifan; Zhao, Yaobang; Meng, Xianghai; Xie, Yuming; Wan, Long; Huang, Yongxian

doi:10.3390/ma15196579

Cited by 20 publications

(9 citation statements)

References 35 publications

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“…The reduction in heat input reduces the loss of strength, while insufficient material flow at the bottom joint leads to forming of small-sized cavities that reduce elongation. 65 It worth noticing is that grain boundaries hinder the occurrence of crack propagation within the microstructure, and therefore, stress and strain distribution improve resulting in the development of ductility. 66 An adequate and continuous IMC layer with adequate thickness is another critical factor to improve the strength of the weld interface during the P-FSSW process.…”

Section: Resultsmentioning

confidence: 99%

Advances in simulation and experimental study on intermetallic formation and thermomechanical evolution of Al–Cu composite with Zn interlayer: Effect of spot pass and shoulder diameter during the pinless friction stir spot welding process

Abdollah-zadeh

Bagheri

Vaneghi

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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In this study, the pinless friction stir spot welding of aluminum–copper composite with Zn interlayer was analyzed under experimental measurement and finite element method. The role of shoulder diameter, 16, 18, and 20 mm, and the number of spot pass, one to three pass, on microstructure, mechanical properties, and thermal history of weld samples were investigated. Based on the obtained results, there is a good agreement between numerical data and experimental analyses. It was shown that the heat source, due to plastic deformation and friction, increased as the shoulder diameter was increased, whereas the stress distribution in the weld samples was reduced. In addition, the thickness of the Zn interlayer at the joint interface changes when shoulder size increases from 16 to 20 mm, due to high temperature and intermixing between materials. From the microstructure analysis, the grain size in the joint zone gradually decreases as the spot pass increases from 1 to 3. It was concluded that the shoulder diameter of 16 mm with three spot passes showed the best result of 7.45 kN. Depending on X-ray diffraction analyses of the fracture surfaces, three primarily intermetallic phases including the Al2Cu, CuZn5, and CuZn2 were determined in the weld interfaces. Based on finite element method analysis, the axial compressive stresses showed the lowest profile as the shoulder diameter of the tool is 16 mm. Finally, the ductile fracture was detected as the main fracture mechanism for the joint sample with optimal joining conditions.

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Section: Resultsmentioning

confidence: 99%

Advances in simulation and experimental study on intermetallic formation and thermomechanical evolution of Al–Cu composite with Zn interlayer: Effect of spot pass and shoulder diameter during the pinless friction stir spot welding process

Abdollah-zadeh

Bagheri

Vaneghi

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…During FSP, a non-consumable rotating tool with a pin and a shoulder is used to process a single piece of material, resulting in specific property enhancements [2][3][4]. The shoulder generates heat, because of friction, to plasticize the material, while the rotating tool pin inside the material causes the flow of material under elevated temperature conditions [5][6][7][8]. This frictional heat causes the flow of work-piece material around the tool periphery [9].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Multi-Pass Friction Stir Processing on the Microstructure Evolution and Mechanical Properties of IS2062 Steel

Raja,

Su,

2024

Metals

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The motive of present work is to explore the variation in the material characteristics of steel upon multi-pass friction stir processing. Steel plates (IS2062) that were 3 mm thick, were subjected to friction stir processing in a multi-pass manner. The selected transverse speed was 150 mm/min, along with a tool rotation of 800 RPM when using a tungsten carbide tool (shoulder diameter—10 mm). Steel plates were processed using the single-pass, double-pass, and triple-pass travel of the rotating tool to observe the impact of multi-pass processing on the properties of steel plates. Multi-pass friction stir processing resulted in a higher micro-hardness of 175 VHN after the second pass, in comparison to the unprocessed metal, which had a micro-hardness of 130 VHN, owing to the collective effect of the plastic flow of the material due to the rotation of the tool and frictional heat, which also leads to grain refinement. The second pass evidenced an average grain size of 22 microns, whereas the unprocessed material had an average grain size of 57 microns. The results of EBSD and SEM characterization showed reasonably improved material properties of the processed work materials.

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“…The results showed that the size of the incoherent intermetallic particles and the volume fraction decreased towards to the center of the layer. Ma et al [21] investigated the effects of temperature on mechanical performances of friction-stir-welded aluminum alloy joints. It was found that the reduction in the gradient along the thickness due to the pinhole increased heat input and material flow at the bottom.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Performance and Microstructural Evolution of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Rods

et al. 2023

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Rotary friction welding (RFW) is a green manufacturing technology with environmental pollution in the field of joining methods. In practice, the welding quality of the friction-welded parts was affected by the peak temperature in the weld joint during the RFW of dissimilar plastic rods. In industry, polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) are two commonly used plastics in consumer products. In this study, the COMSOL multiphysics software was employed to estimate the peak temperature in the weld joint during the RFW of PC and ABS rods. After RFW, the mechanical performance and microstructural evolution of friction-welded parts were investigated experimentally. The average Shore A surface hardness, flexural strength, and impact energy are directly proportional to the rotation speed of the RFW. The quality of RFW is excellent, since the welding strength in the weld joint is better than that of the ABS base materials. The fracture occurs in the ABS rods since their brittleness is higher than that of the PC rods. The average percentage error of predicting the peak temperature using COMSOL software using a mesh element count of 875,688 for five different rotation speeds is about 16.6%. The differential scanning calorimetry curve for the friction-welded parts welded at a rotation speed of 1350 rpm shows an endothermic peak between 400 to 440 °C and an exothermic peak between 600 to 700 °C, showing that the friction-welded parts have better mechanical properties.

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Effect of Temperature and Material Flow Gradients on Mechanical Performances of Friction Stir Welded AA6082-T6 Joints

Cited by 20 publications

References 35 publications

Advances in simulation and experimental study on intermetallic formation and thermomechanical evolution of Al–Cu composite with Zn interlayer: Effect of spot pass and shoulder diameter during the pinless friction stir spot welding process

Advances in simulation and experimental study on intermetallic formation and thermomechanical evolution of Al–Cu composite with Zn interlayer: Effect of spot pass and shoulder diameter during the pinless friction stir spot welding process

The Influence of Multi-Pass Friction Stir Processing on the Microstructure Evolution and Mechanical Properties of IS2062 Steel

Mechanical Performance and Microstructural Evolution of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Rods

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