Friction Stir Welding: a Versatile Process for Light Metal Applications

Abstract

Friction stir welding is a solid-state process that could be beneficially used for joining and repair of light metal alloys in transportation and defense applications. In this study, various applications, processes, and resulting properties of friction stir welds have been explored. First, the effects of various processing parameters on the resulting weld microstructures were studied. Second, tensile properties and fatigue crack growth mechanisms in friction stir welded 6061-T6 alloys were investigated. Fatigue crack propagation responses of the base and friction stir processed materials were studied in ambient conditions using compact tension specimens and multiple stress ratios, R=0.1, 0.5, and 0.7. Third, various exploratory studies were conducted to determine the feasibility of novel friction stir welding techniques for joining of dissimilar materials, porosity reduction, creation of in-situ metal-matrix composites for local reinforcement, and welding of die casting alloys. These findings will be systematically presented and discussed.

Effect of process parameters on corrosion rate of friction stir welded aluminium SiC–Gr hybrid composites

“…11 Friction stir welding is an eco-friendly process with no toxic fumes generated, and there is no need for any shielding gas. 12,13 The welding is carried out at temperature below the melting temperature, and thus, the distortion is minimal and the properties of the material in the joined area are superior from any other welding process with a fine grained microstructure. [14][15][16] A limited number of process variables can be controlled, such as rotational speed, traverse speed and tool geometry, which causes a significant reduction in the process variability.…”

“…Friction stir welding is an eco-friendly process with no toxic fumes generated, and there is no need for any shielding gas 12,13. The welding is carried out at temperature below the melting temperature, and thus, the distortion is minimal and the properties of the material in the joined area are superior from any other welding process with a fine grained microstructure 14 – 16.…”