Friction Stir Welding of Dissimilar Aluminum Alloy Combinations: State-of-the-Art

Abstract

Friction stir welding (FSW) has enjoyed great success in joining aluminum alloys. As lightweight structures are designed in higher numbers, it is only natural that FSW is being explored to join dissimilar aluminum alloys. The use of different aluminum alloy combinations in applications offers the combined benefit of cost and performance in the same component. This review focuses on the application of FSW in dissimilar aluminum alloy combinations in order to disseminate research this topic. The review details published works on FSWed dissimilar aluminum alloys. The detailed summary of literature lists welding parameters for the different aluminum alloy combinations. Furthermore, auxiliary welding parameters such as positioning of the alloy, tool rotation speed, welding speed and tool geometry are discussed. Microstructural features together with joint mechanical properties, like hardness and tensile strength measurements, are presented. At the end, new directions for the joining of dissimilar aluminum alloy combinations should guide further research to extend as well as to improve the process, which is expected to raise further interest on the topic.

Dissimilar Metal Welding

“…This special issue of Metals covers sixteen articles [5][6][7][8][9][10][11][12][13][14][15][16][17][18][19][20] focused on dissimilar metal joining techniques. Some of the published reports have confirmed the increasing interest in solid state welding processes, in particular friction based welding [6][7][8][9][10] and electromagnetic pulse welding [11,12], due to benefits related to the properties and achievable microstructure, and to energy and environmental considerations. Other papers dealt with fusion welding techniques, mainly laser based [13][14][15][16], among others [5,17], and brazing processes [18,19].…”

“…More specifically, a thorough review article proposed by Patel et al, has shed light on the potential of friction stir welding (FSW) in dissimilar welding of distinct aluminium alloys [6], commenting on microstructure, mechanical properties, corrosion and fatigue behaviour. The authors discussed in detail, aspects related to the processing parameters and setup, in terms of placement of the adjoining materials and tool offsets.…”

Review on Friction Stir Processed TIG and Friction Stir Welded Dissimilar Alloy Joints

“…Most industries are opting towards using dissimilar alloys in producing various components. This option is meant to reduce the costs that are involved in using similar alloys [3]. In as much as this approach is a cost-saving measure, however, there are also challenges associated with it.…”

Microstructure and Mechanical Properties of Friction Stir Welded Joint of an Aluminum Alloy Sheet 6005A-T4

“…Therefore, the solid-state welding method, friction stir welding, invented in 1991, was widespread employed for aluminum welding owing to its abilities to overcome the mentioned-above disadvantages [8][9][10][11][12][13]. The hybrid technique [14,15], recrystallization mechanisms [16][17][18], residual stresses [19][20][21][22][23][24], crack growth behavior [25,26], corrosion susceptibility [27], during friction stir welding has been the focus.…”