Friction stir lap joining aluminum and magnesium alloys

Chen, Y.C.; Nakata, Kohei

doi:10.1016/j.scriptamat.2007.10.033

Cited by 243 publications

(115 citation statements)

References 19 publications

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“…However, Dubourg et al [8] investigated the lap joints of aluminum alloys of AA2024-T3 and AA7075-T6 using FSW where the welded joint is stronger than the comparable riveted or resistance spot welded lap joints for the major aluminium alloys. Al-Si and Mg-Al-Zn alloys were lap joined using friction stir welding by Chen and Nakata [9] where the stirring pin is plunged into the lower metal to produce a bonding mechanism of mechanical mixing that enhances bonding strength and the lower welding speed avoids cracks and improves the joint strength. Later on, Cao et al [10] made lap joints on AZ31B-H24 magnesium alloy and A2198-T4 aluminum alloy using an FSW process where the fracture occurred at the heat affected zone The predominant problems that aerospace and automotive industries generally face in metal welding processes are poor weld quality and strength of the weld.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Welding Parameters for Friction Stir Lap Welding of AA6061-T6 Alloy

Rathinasuriyan¹,

Ramaiyan²,

Shanbhag³

et al. 2018

MME

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Friction Stir Welding (FSW) is currently used in many aircraft and aerospace sheet metal structures involving lap joints and there has been growing interest in recent years in utilizing this process for joining aluminum alloys. In this paper, Friction Stir Lap Welding (FSLW) of the 6061-T6 aluminum alloy was carried out to obtain the optimum welding condition for maximum shear strength where the rotational speed, axial load, and welding speed were taken as process parameters. An L-9 orthogonal array, a Taguchi Method with consideration of three levels and three factors was designed and executed for conducting trials. Analysis of variance (ANOVA) and Signal to Noise (S/N) ratio were employed to investigate the influence of different welding parameters on the shear strength and obtain the optimum parameters. The Fisher-Test was also implemented to find the design parameter which had the most important effect on the characteristic of quality. The results indicated that the tool rotational speed had the maximum percentage contribution (51%) on the response (shear strength) followed by the welding speed (38%) and the axial load (8%) while the percentage of error was 3%. However, to confirm the main effects for the means and S/N ratios of the experiment, theoretical shear strength values were computed to predict the tensile strength. The maximum shear strength of 60 MPa was achieved and the effectiveness of the method was confirmed. The optimum parameter combinations that provided higher shear strength were: rotational speed of 1200 rpm, welding speed of 45 mm/min and the axial load of 11.5 kN.

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Section: Introductionmentioning

confidence: 99%

Optimization of Welding Parameters for Friction Stir Lap Welding of AA6061-T6 Alloy

Rathinasuriyan¹,

Ramaiyan²,

Shanbhag³

et al. 2018

MME

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“…It was found that the cylindrical conical pin and correct sheet positioning increased the weld nugget extension and improved the mechanical properties of the joint. Chen et al [13] used micro X ray method to analyze phase transition in the FSLW joints of aluminum and magnesium alloys, and found a conversion zone between stir zone and lower sheet metal. This zone contained intermetallic compounds Al12 Mg13, Al3 Mg2, and Mg2 Si at lower welding speed and resulted in defects free region and improved the joint strength.…”

Section: Introductionmentioning

confidence: 99%

“…From the literature review [3][4][5][6][7][8][9][10][11][12][13][14][15][16], it is understood that the FSW parameters play major role in deciding the quality of the joints. Though lot of research works have been carried out to understand the effect of FSLW parameters individually on mechanical properties and microstructural charactertics, no attempt has been made so far to study the combined effect of all the parameters in a scientific method.…”

Section: Introductionmentioning

confidence: 99%

Identifying Combination of Friction Stir Welding Parameters to Maximize Strength of Lap Joints of AA2014-T6 Aluminum Alloy

Rajendrana

Srinivasan

Balasubramanian

et al. 2017

Archives of Mechanical Technology and Materials

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A B S T R A C TAA2014 aluminum alloy (Al-Cu alloy) has been widely utilized in fabrication of lightweight structures like aircraft structures, demanding high strength to weight ratio and good corrosion resistance. The fusion welding of these alloys will lead to solidification problems such as hot cracking. Friction stir welding is a new solid state welding process, in which the material being welded does not melt and recast. Lot of research works have been carried out by many researchers to optimize process parameters and establish empirical relationships to predict tensile strength of friction stir welded butt joints of aluminum alloys. However, very few investigations have been carried out on friction stir welded lap joints of aluminum alloys. Hence, in this investigation, an attempt has been made to optimize friction stir lap welding (FSLW) parameters to attain maximum tensile strength using statistical tools such as design of experiment (DoE), analysis of variance (ANOVA), response graph and contour plots. By this method, it is found that maximum tensile shear fracture load of 12.76 kN can be achieved if a joint is made using tool rotational speed of 900 rpm, welding speed of 110 mm/min, tool shoulder diameter of 12 mm and tool tilt angle of 1.5•.

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“…2,3) Recently, a new solid-state joining technology of the friction stir spot welding (FSSW), which is a derivative process of the friction stir welding (FSW), 4) has been developed as a widespread technique and successfully applied for producing lap-joints of aluminum alloys. [5][6][7] Compared with the traditional RSW process, FSSW can avoid severe heating and cooling cycles induced during welding process. Furthermore, the heat affected zone (HAZ) and residual stresses associated with the welds are relatively small.…”

Section: Introductionmentioning

confidence: 99%

“…9) Therefore, FSSW as well as FSW is now a simple and indispensable process to acquire better joining strength and vibration fracture resistance for the lightweight structural metals. 6,7,10,11) Since the failure of FSSW-joined structural components depends on the stress to approach a critical weakest link of the welding spot, the variability of failure strength is fairly correlated with the welding qualities of joints, including microstructural homogeneity, bond formation and bond width. [12][13][14] However, few current reports focus on assessing the failure mechanism of FSSW aluminum alloys under mechanical loading for various probe penetration depth.…”

Section: Introductionmentioning

confidence: 99%

Weibull Statistics for Evaluating Failure Behaviors and Joining Reliability of Friction Stir Spot Welded 5052 Aluminum Alloy

et al. 2009

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Friction stir spot welding (FSSW) was applied to make lap-joints of 5052 rolled (5052-R) aluminum alloys. The resulting microstructural observation, microhardness, tensile shear failure load and failure morphologies are reported, including a brief look into failure behaviors in the present study. The metallurgical bonded TMAZ region with a plastic metal flow is obviously created around the probe, and the microhardness is significantly increased at the TMAZ region for FSSW-joined 5052 aluminum alloys. The FSSW lap-joints with an obvious metallurgical bonded TMAZ region generally display a higher failure load and ductile failure morphologies with dimples fracture. In addition, the failure load of FSSW lap-joints was increased with increasing the probe penetration depth and the welding time. Based on the data fluctuation of tensile shear failure load, the Weibull model provided a statistical analysis method for assessing the minimum failure, the failure mechanism and the joining reliability for the FSSW lap-joints. Through the statistical analysis of the Weibull distribution function, FSSW-joined aluminum alloys with a wear-out failure model are recognized as reliable lap-joints for further engineering application.

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Friction stir lap joining aluminum and magnesium alloys

Cited by 243 publications

References 19 publications

Optimization of Welding Parameters for Friction Stir Lap Welding of AA6061-T6 Alloy

Optimization of Welding Parameters for Friction Stir Lap Welding of AA6061-T6 Alloy

Identifying Combination of Friction Stir Welding Parameters to Maximize Strength of Lap Joints of AA2014-T6 Aluminum Alloy

Weibull Statistics for Evaluating Failure Behaviors and Joining Reliability of Friction Stir Spot Welded 5052 Aluminum Alloy

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