Friction stir welding window for AA6061-T6 aluminium alloy

Gadakh, Vijay S.; Kumar, Adepu

doi:10.1177/0954405413510289

Cited by 33 publications

(26 citation statements)

References 22 publications

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“…FSW is considered as a solid-state process in which the base materials are placed next to each other and then a non-consumable tool comprising shoulder and pin is placed at the center of the joint line. 25–27 Then, the joint is created due to heat generated by shoulder and stirring of plasticized materials by rotation of the tool pin with its traverse movement. 28–30 A schematic view of the FSW process for dissimilar joint of Al alloys is shown in Figure 1.…”

Section: Introductionmentioning

confidence: 99%

Mathematical modeling and optimization of friction stir welding process parameters in AA5083 and AA7075 aluminum alloy joints

Saeidi

Manafi

Givi

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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In this study, dissimilar joints of AA5083-H116 and AA7075-T6 aluminum alloys were successfully made by friction stir welding technique. The microstructure and mechanical behavior of the welded joints were investigated at different rotational and traverse speeds. A mathematical modeling was developed to demonstrate a relationship between the friction stir welding parameters and the ultimate tensile strength of the dissimilar joints. Then, the mathematical modeling was optimized by genetic algorithm in order to find the optimum condition in which the maximum tensile strength of welded joints can be achieved. Eventually, genetic algorithm results confirmed that the maximum tensile strength of welded joints is achievable in rotational and traverse speeds of 500 r/min and 50 mm/min, respectively. The maximum error between experimental data and predicted model was less than 1%.

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Section: Introductionmentioning

confidence: 99%

Mathematical modeling and optimization of friction stir welding process parameters in AA5083 and AA7075 aluminum alloy joints

Saeidi

Manafi

Givi

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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show abstract

“…Existence of such smooth and regular river pattern has indicated mechanism of cleavage fracture. Some authors claimed that such micrographs indicating shear flow of material (striations) clearly infer to brittle failure [22].…”

Section: Resultsmentioning

confidence: 99%

“…It was concluded that microstructure of the weld interface contributed to mechanical strength of the Weldment. Gadakh and Kumar [22] proposed a weldability window for FSW of AA6061-T6 alloy based on tool rotational speed and weld speed. Such weldability window provided a ready reckoner toward selecting suitable welding parameters to fabricate defect-free weldment.…”

Section: Introductionmentioning

confidence: 99%

Experimental studies on friction-stir welding of AA6061 using Inconel 601 tool

Haldar

Datta

Kumar³

2018

J Braz. Soc. Mech. Sci. Eng.

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Nickel-based superalloy Inconel 601 has been used as tool material during friction-stir butt welding of AA6061-T6 plates. The unique properties of Inconel 601 viz. excellent high-temperature strength, strong work-hardening tendency, and high resistance to wear have been reported beneficial to utilize the material for potential use of FSW tool. Welding has been carried out in different combinations of tool rotation and traverse speed; joint performance in terms of ultimate tensile strength and micro-hardness has been studied. Optical microscopy has revealed existence of fine equiaxed gains at the nugget zone promoting relatively more refined grain structure as compared to the parent material. In few specimens, welding induced defects such as weld flash, kissing bond, zigzag line and tunnel defects have been identified. Maximum tensile strength * 133 MPa has been obtained at tool rotational speed * 1120 RPM and traverse speed * 40 mm/min. Fractographic analysis has revealed two distinct types of fracture mode in the specimens which have failed before the joint and at the joint, respectively. The specimens, failed before the weld zone, have corresponded to ductile fracture mode indicating dimples and ripples. On the contrary, beach marks (wavy patterns) have been noticed in the fractographic analysis of specimens which failed at the weld zone. After completing all welding experiments, the tool has been found not affected by wear, profile distortion by plastic deformation. Hence, application of the said tool can be advised provided the cost of machining the tool with desired pin profile is compromised.

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“…In order to overcome such drawbacks, friction stir welding (FSW), a solid-state welding technique, can be used. 7–10 In FSW, the blanks are joined by the action of a rotating tool with a pin getting in contact with the top surface of the sheets and then moving along the welding line with a proper tilt angle. The combined effect of tool rotation and translation involves heat generation by friction between tool and sheets, inducing a strong plastic deformation of the workpiece by promoting its complex mixing across the joint.…”

Section: Introductionmentioning

confidence: 99%

“…The combined effect of tool rotation and translation involves heat generation by friction between tool and sheets, inducing a strong plastic deformation of the workpiece by promoting its complex mixing across the joint. 8–12 As a consequence, a plasticised region is created around the tool so that the material is extruded from the leading side (advancing side (AS)) to the trailing side (retreating side (RS)) of the weld. Kumar and Kailas 13 investigated the mechanism of weld formation and the role of FSW tool in such mechanism.…”

Section: Introductionmentioning

confidence: 99%

Development of double-side friction stir welding to improve post-welding formability of joints in AA6082 aluminium alloy

Simoncini

Cabibbo

Forcellese

2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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An innovative welding methodology, defined as double-side friction stir welding, was developed in order to obtain joints in 2-mm-thick sheets in AA6082 aluminium alloy. Such approach consists in performing the friction stir welding process on both sheet surfaces: the first welding operation is followed by a second one performed by putting the rotating tool in contact with the sheet surface opposite to the one welded by the first pass. The effect of the welding parameters, tool configuration and sheet positioning on the mechanical properties, microstructure and post-welding formability was analysed and discussed in detail. In order to evaluate the advantages offered by the new welding methodology, the experimental results obtained using the double-side friction stir welding were compared with those given by the conventional process.

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Friction stir welding window for AA6061-T6 aluminium alloy

Cited by 33 publications

References 22 publications

Mathematical modeling and optimization of friction stir welding process parameters in AA5083 and AA7075 aluminum alloy joints

Mathematical modeling and optimization of friction stir welding process parameters in AA5083 and AA7075 aluminum alloy joints

Experimental studies on friction-stir welding of AA6061 using Inconel 601 tool

Development of double-side friction stir welding to improve post-welding formability of joints in AA6082 aluminium alloy

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