Friction Stir Welding of Non-Heat-Treatable High-Strength Alloy 5083-O

Abstract

5083 aluminum alloy is increasingly used because of its excellent corrosion resistance, high work-hardening rate, and strength. In order to improve its weldability and feasibility, material behavior, material flow, and defects induced while friction stir welding 5083 should be studied. In this study, they were investigated by thermo-structural analysis. The flow stress of 5083-O has a high rate of sensitivity among high temperatures and wide strain rate ranges. Therefore, the details of the mechanical properties of 5083-O at high temperatures and wide strain rate ranges were investigated to obtain reasonable analysis results using a precise flow stress model. The tool/workpiece interface temperature during FSW is critical for accurate analysis results. This study used special equipment to measure tool temperature in order to investigate the interface temperatures precisely, and then the obtained data were used for optimization and verification of the thermal boundary conditions for analysis modeling. Using the developed model, the material behavior and material flow during FSW of 5083-O were analyzed. The tool and workpiece interface temperatures, flow stresses, strain rates, and velocities were investigated with the cylinder and threaded probes in detail. One of the analysis results indicated that the material flow rate on the rear side of a probe directly affected defect generation while joining.

Cold-Rolling Strain Hardening Effect on the Microstructure, Serration-Flow Behaviour and Dislocation Density of Friction Stir Welded AA5083

“…The versatility of this strain-hardened alloy renders it ideal for applications related to the automotive industry [3] and for the fabrication of marine structures, pipelines, and aircraft components [4]. Given the problems encountered in the fusion welding of Al alloys, such as porosity [5], cracking [6], and dissolution of precipitation phases [7,8], a solid joining technique known as friction stir welding (FSW) was carried out for the joining of Al alloys [9][10][11][12][13]. In 1991, this welding process was introduced by The Welding Institute [14].…”

Progress in Thermomechanical Analysis of Friction Stir Welding

“…It should be mentioned that, the FSW process should be modeled as a fully coupled thermomechanical analysis. Thus, some other literature was also focused on the stress and strain distributions [111]. Since the application of FSW is increasing in different industries, the need for thermomechanical analysis of FSW for different materials is increasing.…”

“…Values of the residual stress across the welding cross-section: (a) the transverse velocity of 280 mm/min and the rotational speed of 1250 r/min, (b) the transverse velocity of 530 mm/ min and the rotational speed of 1250 r/min, (c) the transverse velocity of 787 mm/min and the rotational speed of 1250 r/min[115] Stress distributions at the tool and the workpiece interface[111] Strain distribution across the workpiece cross-section rotational speed of 1000 and 60 mm/s[116] …”

Recent Achievements in Rotary, Linear and Friction Stir Welding of Metals Alloys

“…In more detail, the contributions have concerned the following topics.The effect of cold rolling performed after friction stir welding (FSW) on the mechanical properties and formability of joints in AA5754-H114 aluminum alloy [1].The microstructure evolution of the welded joints of AA6082-T6 obtained using the bobbin friction stir welding process with a focus on grain refinement [2].The characteristic features of the entry and exit defects in the weld structure and formation mechanism of them during the BFSW process. The issue was investigated using stacked layers of multi-colored plasticine for the material flow detection [3].The thermo-structural analysis of material behavior, material flow, and defect generation during the friction stir butt-welding of 5083-O sheets [4].The characterization of the dissimilar friction stir weld of Ti-6242 S and Ti-54M in terms of microstructure, microhardness, fracture morphology, and material migrating from the retreating (RET) side to the advancing (ADV) one [5].The characterization of the interface of friction stir lap welding joints of 6082-T6 aluminum alloy and Q235A steel [6].The investigation of the microstructure evolution and properties response of a friction-stir-welded copper-chromium-zirconium alloy [7].The study of the influence of the process parameters on the vertical force generated during friction stir welding of AA6082-T6 aluminum alloy sheet blanks [8].The role of mechanical connection in friction stir keyholeless spot welding of AZ31B Mg alloy, Mg99.50, DP600, and non-zinc-coated DP600 lap welding [9].The application of a fully coupled thermo-mechanical model together with an enhanced friction law for the simulation of an FSW process with a cylindrical threaded pin tool [10].The identification of the chemical composition of etchant reagents for metallographic examination of the friction-stir welded A6082-T6 alloy [11].The study of an advanced meshfree computational framework to be used for the determination of optimal process parameters for the friction stir welding of an AA6061-T6 butt joint [12].The numerical modeling approach to the study of the linear friction welding of 30CrNiMo8 high strength steel Hero chain [13].…”

“…The thermo-structural analysis of material behavior, material flow, and defect generation during the friction stir butt-welding of 5083-O sheets [4].…”