Friction stir welding of dissimilar aluminum alloys and steels: a review

Wan, Long; Huang, Yongxian

doi:10.1007/s00170-018-2601-x

Cited by 138 publications

(46 citation statements)

References 110 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…If the heat generated is too high, the aluminum may reach its melting point which will not result in a sound joint; if the heat generated is not enough to stir the steel into aluminum, it will result in a joint with many defects. Thus, process parameters, such as tool rotational speed, welding speed, pin depth, and tilt angle, play a crucial role in deciding the weld quality [1,2].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Effect of Tilt Angle and Pin Depth on Dissimilar Friction Stir Lap Welded Joints of Aluminum and Steel Alloys

2019

View full text Add to dashboard Cite

Automobile, aerospace, and shipbuilding industries are looking for lightweight materials for cost effective manufacturing which demands the welding of dissimilar alloy materials. In this study, the effect of tool rotational speed, welding speed, tilt angle, and pin depth on the weld joint were investigated. Aluminum 5052 and 304 stainless-steel alloys were joined by friction stir welding in a lap configuration. The design of the experiments was based on Taguchi’s orthogonal array for conducting the experiments with four factors and three levels for each factor. The microstructural analysis showed tunnel defects, micro voids, and cracks which formed with 0° and 1.5° tilt angles. The defects were eliminated when the tilt angle increased to 2.5° and a mixed stir zone was formed with intermetallic compounds. The presence of the intermetallic compounds increased with the increase in tilt angle and pin depth which further resulted in obtaining a defect-free weld. Hooks were formed on either side of the weld zone creating a mechanical link for the joint. A Vickers hardness value of HV 635.46 was achieved in the mixed stir zone with 1000 rpm, 20 mm/min, and 4.2 mm pin depth with a tilt angle of 2.5°, which increased by three times compared to the hardness of SS 304 steel. The maximum shear strength achieved with 800 rpm, 40 mm/min, and a 4.3 mm pin depth with a tilt angle of 2.5° was 3.18 kN.

show abstract

Section: Introductionmentioning

confidence: 99%

“…It is evident from the abovementioned studies [1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17,18,19,20] that the selection of process parameters plays a significant role in determining the robustness of the weld. The objective of this study was to investigate the effect of tilt angle and pin depth on the welded joint.…”

Section: Introductionmentioning

confidence: 99%

Effect of Tilt Angle and Pin Depth on Dissimilar Friction Stir Lap Welded Joints of Aluminum and Steel Alloys

2019

View full text Add to dashboard Cite

show abstract

“…Another feature that can be identified from the figure is that all passes suffer from the hooking defect typically found in lap configuration of FSP. Hooking is a common feature in lap joints [37][38][39]. Here, the AS curls towards the nugget forming a hook, while the RS rises up, leading to a reduction in joint efficiency in lap joints.…”

Section: Distribution Of Mgco 3 After Fspmentioning

confidence: 99%

Foaming of friction stir processed Al/MgCO₃ precursor via flame heating

Shandley

Maheshwari

Siddiquee

et al. 2020

Mater. Res. Express

View full text Add to dashboard Cite

In the recent years, metal foams have become promising candidate materials in the engineering sector owing to their light weight and excellent energy absorption properties. Friction stir processing (FSP) has emerged as a cost-effective route to fabricate metal foam precursors from bulk substrates. Although the short processing time in FSP is able to provide high productivity, the cost of the foaming agent, TiH 2 in the case of aluminum foams is still high. This paper introduces flame heating to achieve localized foaming of aluminum alloy AA5754 to explore the possibility of using magnesium carbonate as a foaming agent stirred using multi-pass FSP. A specially designed slot based strategy using two plates arranged in lap configuration is devised to stir the foaming agent and understand the material movement after each subsequent pass. Microscopy techniques were carried out to evaluate the distribution of the foaming agent after each pass and the resulting microstructure of the processed plates as well as the morphology of the foamed sample. EDX results showed higher Mg and O content around the pore walls.

show abstract

“…Al/Fe IMCs are usually at the interface of aluminum and steel as FeAl 3 , Fe 2 Al 5 , FeAl 2 , FeAl, and Fe 3 Al [25][26][27][28][29][30]. Mechanical properties of FSW joints depend essentially on thickness and chemical composition of IMCs.…”

Section: Intermetallic Compounds (Imcs)mentioning

confidence: 99%

Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Safeen

Spena

2019

Metals

View full text Add to dashboard Cite

Joining of aluminum alloys through friction stir welding (FSW) is effectively employed in several industries (e.g., aeronautics and aerospace) since it guarantees proper weld strength as compared to other joining technologies. Contrarily, dissimilar FSW of aluminum alloys and steels often poses important issues in the selection of welding parameters due to the difficulty to join different materials. Improper welding parameters give rise to the formation of intermetallic compounds, and internal and external defects (e.g., tunnel formation, voids, surface grooves, and flash). Intermetallic compounds are brittle precipitates of Al/Fe, which chiefly initiate crack nucleation, whereas internal and external defects mainly act as stress concentration factors. All these features significantly reduce joint strength under static and dynamic loading conditions. With reference to the literature, the influence of main welding parameters (rotational speed, welding speed, tool geometry, tilt angle, offset distance, and plunge depth) on the formation of intermetallic compounds and defects in FSW of aluminum alloys and steels is discussed here. Possible countermeasures to avoid or limit the above-mentioned issues are also summarily reported.

show abstract

Friction stir welding of dissimilar aluminum alloys and steels: a review

Cited by 138 publications

References 110 publications

Effect of Tilt Angle and Pin Depth on Dissimilar Friction Stir Lap Welded Joints of Aluminum and Steel Alloys

Effect of Tilt Angle and Pin Depth on Dissimilar Friction Stir Lap Welded Joints of Aluminum and Steel Alloys

Foaming of friction stir processed Al/MgCO₃ precursor via flame heating

Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Contact Info

Product

Resources

About

Friction stir welding of dissimilar aluminum alloys and steels: a review

Cited by 138 publications

References 110 publications

Effect of Tilt Angle and Pin Depth on Dissimilar Friction Stir Lap Welded Joints of Aluminum and Steel Alloys

Effect of Tilt Angle and Pin Depth on Dissimilar Friction Stir Lap Welded Joints of Aluminum and Steel Alloys

Foaming of friction stir processed Al/MgCO3 precursor via flame heating

Main Issues in Quality of Friction Stir Welding Joints of Aluminum Alloy and Steel Sheets

Contact Info

Product

Resources

About

Foaming of friction stir processed Al/MgCO₃ precursor via flame heating