Abstract:To reduce environmental impacts and ensure competitiveness, the fabrication and construction sectors focus on minimizing energy and material usage, which leads to design requirements for complex structures by joining of similar and dissimilar materials. Meeting these industrial demands requires compatible materials with improved properties such as good weight-to-strength ratios, where aluminum (Al) and its alloys are competing candidates for various complex applications. However, joining Al with fusion welding… Show more
“…5 a comparison between two samples drawn from FSW_3 and FSW_8, respectively, is shown: sample FSW_3 presents the best quality among the ones drawn from un-reinforced joints, while sample FSW_8 obtained with the addition of particles and with the highest rotational and translational speeds exhibits the biggest wormhole defect. In accordance with different studies [14], [28], [29], the presence of a wormhole defect is due to a wrong managing of the process parameters, such as the rotational speed and advancing speed, since its bad control promotes an insufficient material flow and with this a lack of consolidation arousing the formation of the after-mentioned flaw. Microstructural analyses performed by OM demonstrated the presence of the typical zones characterizing these solid-state joints, as well as the evolution of the microstructure across them.…”
Section: Macrostructural and Microstructural Analysissupporting
confidence: 60%
“…The authors detected a metallurgical reaction as an effect of the reinforcing addition, thus promoting an increase of the tensile properties of the joint; however, they found that the selection of specific process parameters, in this case low rotational speed, is fundamental to obtain the desired increase in the static mechanical characteristics. Recently, Vimalraj et al [14] performed a review on the advantages and disadvantages of the use of reinforcing particles into the groove of dissimilar joints during the process; they emphasize the remarkable effect induced by the process parameters on the particles dispersion and, in turn, on the mechanical properties of the joints. Moreover, the authors pointed out that more studies need to be done in terms of comparison of different dissimilar joints production and on the optimization of amount, type and size of the reinforcement together with the number of welding passes.…”
Dissimilar friction stir welding joints are widely employed in the industrial field due to the excellent microstructural and mechanical properties of the resulting joints. Nevertheless, to further enhance the weld properties, the addition of reinforcement particles on the joint-line during the process has been proven effective for increasing its mechanical performance. In the present investigation, the microstructure and the impact behaviour of FSWed joints between AA2024-T351 and AA7075-T651 aluminium plates were investigated, considering the effect of different process parameters selected through a full factorial 2k design of experiments: both the rotational and translational speed of the tool, as well as the addition of Al2O3-SiC microparticles, were considered as input parameters. Unnotched 10 x 5 x 55 mm impact specimens were tested through an instrumented 50 J Charpy pendulum: total impact energy, the two complementary initiation and propagation energies as well as the peak force were correlated to the adopted process parameters. From the performed analyses, it was found that joints with reinforcing particles are prone to form wormhole defects across the stir zone that not only affect the microstructural development, but also the impact behaviour since they require less energy at break in comparison with joints fabricated without particles addition.
“…5 a comparison between two samples drawn from FSW_3 and FSW_8, respectively, is shown: sample FSW_3 presents the best quality among the ones drawn from un-reinforced joints, while sample FSW_8 obtained with the addition of particles and with the highest rotational and translational speeds exhibits the biggest wormhole defect. In accordance with different studies [14], [28], [29], the presence of a wormhole defect is due to a wrong managing of the process parameters, such as the rotational speed and advancing speed, since its bad control promotes an insufficient material flow and with this a lack of consolidation arousing the formation of the after-mentioned flaw. Microstructural analyses performed by OM demonstrated the presence of the typical zones characterizing these solid-state joints, as well as the evolution of the microstructure across them.…”
Section: Macrostructural and Microstructural Analysissupporting
confidence: 60%
“…The authors detected a metallurgical reaction as an effect of the reinforcing addition, thus promoting an increase of the tensile properties of the joint; however, they found that the selection of specific process parameters, in this case low rotational speed, is fundamental to obtain the desired increase in the static mechanical characteristics. Recently, Vimalraj et al [14] performed a review on the advantages and disadvantages of the use of reinforcing particles into the groove of dissimilar joints during the process; they emphasize the remarkable effect induced by the process parameters on the particles dispersion and, in turn, on the mechanical properties of the joints. Moreover, the authors pointed out that more studies need to be done in terms of comparison of different dissimilar joints production and on the optimization of amount, type and size of the reinforcement together with the number of welding passes.…”
Dissimilar friction stir welding joints are widely employed in the industrial field due to the excellent microstructural and mechanical properties of the resulting joints. Nevertheless, to further enhance the weld properties, the addition of reinforcement particles on the joint-line during the process has been proven effective for increasing its mechanical performance. In the present investigation, the microstructure and the impact behaviour of FSWed joints between AA2024-T351 and AA7075-T651 aluminium plates were investigated, considering the effect of different process parameters selected through a full factorial 2k design of experiments: both the rotational and translational speed of the tool, as well as the addition of Al2O3-SiC microparticles, were considered as input parameters. Unnotched 10 x 5 x 55 mm impact specimens were tested through an instrumented 50 J Charpy pendulum: total impact energy, the two complementary initiation and propagation energies as well as the peak force were correlated to the adopted process parameters. From the performed analyses, it was found that joints with reinforcing particles are prone to form wormhole defects across the stir zone that not only affect the microstructural development, but also the impact behaviour since they require less energy at break in comparison with joints fabricated without particles addition.
“…The rotating speed of the FSW tool was in the range 100 -1250 rpm with 25 mm/min transverse speed [10]. The Al plate was located on the retreating side as shown in Fig.…”
The materials with similar and dissimilar qualities are joined effectively in their solid-state by Friction Stir Welding (FSW). FSW eliminates the conventional problems and produces crack-free and completely solidified joints. In recent years the commercialization of FSW is focused on metals like Fe and Al-based alloys. However, to commercializesuch a process numerous research studies are required to characterize and establish process windows. FSW process is suitable for joining the different materials having different mechanical and chemical properties and for different material structures. In general, aerospace applications require hybrid metal joins to offer high strengthhigh ductile properties by joining varied metal alloys. FSW is the feasible way to join such metals to get high properties. This review mainly provides the feasibility ofthe FSW technique to join the different materials/alloys.
“…This technique was also influenced by the weld pass numbers, and for an increase in weld pass number better will be the mixing of reinforcement particles with the base metal. 51 Vimalraj & Kah 52 has analysed that varying TRS, WS, number of passes and direction of travelling tool can vary the joint fabrication. They also mentioned that the formation of microstructure and joint properties have favourable effects from the size, type and quantity of reinforcing nano-particles.Figure 6.Works on nanoparticle reinforcement that are considered in percentage.…”
Friction stir welding (FSW) is one among solid-state welding processes that can be employed for producing joints between dissimilar combinations with more ease than that of fusion welding processes. Several high coupled physical phenomena have addressed FSW as an extremely complex process. It is around three decades of invention, optimization of the parameters have been carried out even today by many researchers all over the world to obtain sound joints. This article focuses mainly on the research developments in the dissimilar FSW (DFSW), with the factors that are involved in joint fabrication between dissimilar materials. From the literature, it is found that the most influential factors in deciding the quality of the joints are pin profile, shoulder shape, welding speed and tool rotational speed. In addition, all other parameters will provide incremental support to it. The study on microstructure in different zones and the mechanical properties of welded specimens are elaborated from the available literature. Special attention is given to the reinforcement of micro- and nano- sized solid particles in the DFSW process. Future studies of DFSW are discussed based on the untracked studies that are not available in the literature.
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