Effect of tool travel and rotation speeds on weld zone defects and joint strength of aluminium steel lap joints made by friction stir welding

Movahedi, M.; Kokabi, Alireza; Reihani, S.M. Seyed; Najafi, Hamidreza

doi:10.1179/1362171811y.0000000092

Cited by 92 publications

(52 citation statements)

References 20 publications

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“…Lee et al [14] did experiments on friction stir lap joint between Al 5083 and St-12 mild steel and reported that 2-μm IMC layers with the composition of Fe 3 Al, Fe 4 Al 13 can actually contribute to the joint strength. This statement was further verified by Movahedi et al [5], and they reported that intermetallic compound layer with a thickness of less than 2 μm will not degrade joint quality. Watanabe et al [15] joined SS400 mild steel to A5083 Al alloy with the thickness of 2 mm.…”

Section: Introductionsupporting

confidence: 52%

“…One of the typical desired pairs is aluminum alloy and advanced high-strength steel. Successful and reliable joints between these two materials are hardly achievable using traditional fusion welding techniques due to their great differences in physical and mechanical properties as well as the formation of the large amount of brittle intermetallic compounds (IMCs) [2][3][4][5][6], which aggravates crack initiation and significantly deteriorates joint.…”

Section: Introductionmentioning

confidence: 99%

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Microstructural evolution during friction stir welding of dissimilar aluminum alloy to advanced high-strength steel

Lan

Liu

2015

Int J Adv Manuf Technol

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One type of advanced high-strength steel, transformation-induced plasticity (TRIP) 780 steel, has been successfully welded to aluminum alloy Al 6061-T6 using friction stir welding (FSW) technique. The major Al-Fe interface in the steel side has been analyzed in detail under various welding conditions, where a thin layer of intermetallic compound (IMC) with a thickness of less than 1 μm can be generally observed and the composition was identified to be either FeAl or Fe 3 Al. This thin IMC layer can be shown to be beneficial for joint strength. Optical microscopy and scanning electron microscopy showed the weld nugget was distributed with sheared-off steel fragments encompassed IMC layers or simply IMC particles. Finally, a stirred-over steel strip embedded in the aluminum matrix was revealed, which would determine the failure mode and is crucial to joint quality based on tensile test results.

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Section: Introductionsupporting

confidence: 52%

Section: Introductionmentioning

confidence: 99%

Microstructural evolution during friction stir welding of dissimilar aluminum alloy to advanced high-strength steel

Lan

Liu

2015

Int J Adv Manuf Technol

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“…Researchers have also studied Al/steel friction stir lap welding (FSLW) joint [18][19][20][21][22]. Kimapong and Watanabe [18] carried out that the maximum shear load of FSLW joint of 5083 aluminum alloy and SS400 mild steel could reach about 77% of aluminum alloy base metal.…”

Section: Introductionmentioning

confidence: 99%

“…The FeAl, FeAl 3 and Fe 2 Al 5 IMCs existed in the interface corresponding to different tool tilt angles. Movahedi et al [19] found that IMC layer with a thickness of less than 2 µm will not degrade joint quality. Similar results were suggested by Lee et al [20] and they reported that 2 µm IMC layers with the composition of Fe 3 Al, Fe 4 Al 13 could contribute to the joint strength.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Al/Steel Friction Stir Lap Weld

Wan

Huang

2017

Metals

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Abstract:The friction stir welding tool with convex pin tip was designed to realize the lap joining of 6082-T6 aluminum alloy and Q235A steel. With decreasing welding speed and increasing rotation speed, the basic constitutions of mixed stir zone changed from α-Fe fine grains, thin intermetallic compound (IMC) and Al/Fe composite structure to hook-like and chaotic mixed layered structure, resulting in joint deterioration. The maximum shear load can reach 7500 N and is predominately affected by the morphology of the IMC layers, which in turn depend on rotation speed, welding speed and other parameters. Nano-hardness decreases from about 3.9 GPa in the upper steel surface layer to about 1.3 GPa in the steel base material. Microhardness profile reveals that the maximum hardness occurs at the interface zone. The morphology of layered structure, FeAl 3 IMC thickness and steel grain size can be controlled by choosing suitable welding parameters and tool shape.

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“…Movahedi et al [32] identified that defects at the weld nugget can be reduced by decreasing welding speed; contemporarily, weld strength can be increased by decreasing welding speed. Kasman [33] reported that mechanical properties were more sensitive to welding speed than rotational speed in welding of dissimilar Aluminum alloys AA6082-T6 and AA5754-H111.…”

mentioning

confidence: 99%

Predicting the tensile strength, impact toughness, and hardness of friction stir-welded AA6061-T6 using response surface methodology

Safeen

Hussain

Wasim

et al. 2016

Int J Adv Manuf Technol

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In this research an attempt has been made to develop mathematical models for predicting mechanical properties including ultimate tensile strength, impact toughness, and hardness of the friction stir welded AA 6061-T6 joints at 95% confidence level. Response surface methodology with central composite design having four parameters and five levels has been used. The four parameters considered were tool pin profile, rotational speed, welding speed and tool tilt angle. Three confirmation tests were performed to validate the empirical relations. In addition, the influence of the process parameters on ultimate tensile strength, impact toughness, and hardness were investigated. The results indicated that tool pin profile is the most significant parameter in terms of mechanical properties; tool with simple cylindrical pin profile produced weld with high ultimate tensile strength, impact toughness, and hardness. In addition to tool pin profile, rotational speed was more significant compared to welding speed for ultimate tensile strength and impact toughness; whereas, welding speed showed dominancy over rotational speed in case of hardness. Optimum conditions of process parameters have been found at which tensile strength of 92%, impact toughness of 87%, and hardness of 95% was achieved in comparison to the base metal. This research will contribute to expand the scientific foundation of friction stir welding of Aluminum alloys with emphasis on AA 6061-T6. The results will aid the practitioners to develop a clear understanding of the influence of process parameters on mechanical properties, and will allow the selection of best combinations of parameters to achieve desired mechanical properties.

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Effect of tool travel and rotation speeds on weld zone defects and joint strength of aluminium steel lap joints made by friction stir welding

Cited by 92 publications

References 20 publications

Microstructural evolution during friction stir welding of dissimilar aluminum alloy to advanced high-strength steel

Microstructural evolution during friction stir welding of dissimilar aluminum alloy to advanced high-strength steel

Microstructure and Mechanical Properties of Al/Steel Friction Stir Lap Weld

Predicting the tensile strength, impact toughness, and hardness of friction stir-welded AA6061-T6 using response surface methodology

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