Effects of processing parameters on mechanical, material flow and wear behaviour of friction stir welded 6101-T6 and 7075-T651 aluminium alloys

Abolusoro, Olatunji P.; Akinlabi, Esther Titilayo

doi:10.1051/mfreview/2019026

Cited by 19 publications

(7 citation statements)

References 35 publications

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“…However, more material interaction occurred at the 1250 rpm rotational speed than in the 1550 rpm and 1850 rpm. The microstructures vary across the length and breadth of the weld zone and generally formed three types of regions which agree to the findings of some researchers on dissimilar FSW of aluminium alloys [40][41][42][43][44]. The regions can be classified into mixed flow, mechanically mixed and unmixed region.…”

Section: Microstructuresupporting

confidence: 87%

Tool rotational speed impact on temperature variations, mechanical properties and microstructure of friction stir welding of dissimilar high-strength aluminium alloys

Abolusoro

Akinlabi

Kailas

2020

J Braz. Soc. Mech. Sci. Eng.

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Temperature variations during friction stir welding result from the heat generated by the frictional action of a rotating tool on the workpiece. This temperature distribution affects the mechanical behaviour and ultimately the quality of welds produced. The study of the correlations between process parameter, temperature, mechanical properties and microstructure has become imperative in order to promote welds devoid of defects and possessing sound mechanical properties and to establish a temperature feedback control for effective components designs for industrial applications. This work studied the impact of tool rotational speed on temperature profile, mechanical behaviour and microstructure of friction stir welding of dissimilar aluminium alloy 6101-T6 and 7075-T651. Processing parameters of three different rotational speeds with values 1250 rpm, 1550 rpm and 1850 rpm and a constant travel speed of 50 mm/min were employed. The temperature profile was measured with one end of thermocouple wires embedded in the plates and the other end connected to a data capturing software device. The temperature profile indicates that the temperature rises with time and is higher at the retreating sides than at the advancing side of the weld. The tensile test results show that the ultimate tensile strength decreases as the temperature increases. Microstructural observations of weld zone revealed non-uniformity in material flow. However, more material penetration into each other occurred more at 1550 rpm.

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Section: Microstructuresupporting

confidence: 87%

Tool rotational speed impact on temperature variations, mechanical properties and microstructure of friction stir welding of dissimilar high-strength aluminium alloys

Abolusoro

Akinlabi

Kailas

2020

J Braz. Soc. Mech. Sci. Eng.

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“…At 950 min −1 , the unthreaded tool pin macrograph shows partial mixing and blending which resulted in wormhole or void, Figure a, b. This can be attributed to less interaction between the pin and material as a result of less area of contact which cause nonuniformity in material flow . More material mixing was observed in the same parameter for the threaded tool, Figure a.…”

Section: Resultsmentioning

confidence: 99%

Impact of tool profile on mechanical behavior and material flow in friction stir welding of dissimilar aluminum alloys

Abolusoro

Akinlabi

Kailas

2020

Materialwissenschaft Werkst

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The tool pin geometry used in friction stir welding of any material affects the transportation and mixing of the materials at the joint interface during the welding process. This further affects the mechanical properties of the joint. Tapered threaded and unthreaded tool pin profiles were investigated in this research work. The relationship between the material mixing characteristics and mechanical properties of each pin profile were evaluated. The results indicate that more materials mixing occurred in the nugget zone of the welds at lower rotational speed with the threaded tool pin than the unthreaded tool pin. However, at medium rotational speed, more volume of materials was swept into each other better in the unthreaded tool pin than the threaded pin. The tensile strengths of welds with the threaded tool pin were higher than the unthreaded tool pin. Although the two tool pins exhibit similarities in hardness variations across the weld zones however, higher average values of hardness were obtained at the nugget zone for welds performed with the tapered threaded tool pin. These could be as a result of better material mixing and higher opposition to grain dislocations across the dividing lines in the welds from the threaded tool pin.

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“…The highest wear resistance occurred at a rotational speed of 1850 rpm and a welding speed of 65 mm/min. In contrast, improved material mixing occurred in the NZ of the welded specimens at 1250 rpm and 110 mm/min [15].…”

Section: Introductionmentioning

confidence: 87%

Effect of Welding Settings on Mechanical Characteristics, Microstructural Features, and Corrosion Performance in Friction Stir Welding of Dissimilar Aa6082-T6/7075-T6 Joints

Afify,

Gamil

2024

Journal of Al-Azhar University Engineering Sector

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This research explores the influence of welding settings (tool rotational speed, travel speed) on mechanical characteristics (tensile, micro-hardness), microstructure, and corrosion performance of dissimilar butt joints between aluminum alloys AA7075-T6 and AA6082-T6, which were fabricated by friction stir welding (FSW). The study considers three varied tool rotational speeds (1600, 2000, and 2300 rpm) in conjunction with three varied tool travel speeds (30, 40, and 50 mm/min). The butt joints were created by welding plates that were 6 mm thick. The welded specimens underwent characterization through optical microscopy, SEM, tensile testing, micro-hardness testing, and corrosion testing. Macroscopic observations of the samples revealed a range of stir zone shapes and defects that resulted from both inadequate and excessive heat input during the welding process. Analysis of the microstructure and results from the tensile testing indicated that the specimens produced using FSW settings of 2000 rpm and 40 mm/min achieved a peak ultimate tensile strength, demonstrating a value of 150 MPa. The micro-hardness values exhibited variations corresponding to changes in rotational speed, attaining a peak value of 240 HV at a rotational speed of 2300 rpm and a travel speed of 40 mm/min. The best mixing of the joined materials was achieved at a maximum welding rotational speed (2300 rpm) and medium travel speed (40 mm/min). A corrosion analysis of welded joints was conducted using a potentiodynamic polarization test in a solution containing 3.5% sodium chloride (NaCl). The welded zone (WZ) exhibits a reduced corrosion current density (Icorr), attributed to the occurrence of galvanic corrosion. The performance of corrosion within the WZ is impacted by the rotational speed and tool travel speed. Lowering the speed of the rotation tool leads to a decrease in the corrosion rate. Optimal corrosion resistance is achieved in the joint created at 2300 rpm and 30 mm/min, attributable to the suitable density and size of precipitates.

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Effects of processing parameters on mechanical, material flow and wear behaviour of friction stir welded 6101-T6 and 7075-T651 aluminium alloys

Cited by 19 publications

References 35 publications

Tool rotational speed impact on temperature variations, mechanical properties and microstructure of friction stir welding of dissimilar high-strength aluminium alloys

Tool rotational speed impact on temperature variations, mechanical properties and microstructure of friction stir welding of dissimilar high-strength aluminium alloys

Impact of tool profile on mechanical behavior and material flow in friction stir welding of dissimilar aluminum alloys

Effect of Welding Settings on Mechanical Characteristics, Microstructural Features, and Corrosion Performance in Friction Stir Welding of Dissimilar Aa6082-T6/7075-T6 Joints

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