Improved weld macrosection, microstructure and mechanical properties of 2024Al-T4 butt joints in ultrasonic vibration enhanced friction stir welding

Liu, Xiaochao; Wu, Chuansong; Padhy, G.K.

doi:10.1179/1362171815y.0000000021

Cited by 100 publications

(43 citation statements)

References 22 publications

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“…The overall result of these two effects may increase the heat input slightly. UAFSW expanded the plastically deformed region [24] and improved the material ow [25], thus it improved lap shear force and hardness of the joints [25]. UAFSW also suppressed the formation of voids and tunnel defects [24,26].…”

Section: Literature Reviewmentioning

confidence: 99%

Effect of copper donor material-assisted friction stir welding of AA6061-T6 alloy on downward force, microstructure, and mechanical properties

Bhukya

Maniscalco

et al. 2022

Int J Adv Manuf Technol

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In this research, Copper (Cu) donor material assisted friction stir welding (FSW) of AA6061-T6 alloy was studied. Cu assisted FSW joints of AA6061-T6 alloy were prepared at a constant tool rotational rate of 1400 rpm and various welding speeds at 1 mm/s and 3 mm/s. The Cu donor material of different thickness (i.e., 20%, 40%, and 60%) with respect to the workpiece thickness was selected to assist the FSW joining at the plunge stage. It is observed that the downward force generated in the FSW process was gradually decreased after introducing Cu donor material with incremental thicknesses with respect to workpiece at the plunge stage. Post-weld analysis was characterized in terms of microstructure, and mechanical properties. The results of microstructure analysis at the stir zone (SZ) show the formation of ner grains due to dynamic recrystallization and plastic deformation. Microhardness tests reveal that the hardness decreased from the base metal (BM) to the SZ across the heat affected zone (HAZ) and thermo-mechanically affected zone (TMAZ). The lowest value of hardness appeared in the TMAZ and HAZ where tensile failure occurs. With increasing welding speed, the average hardness in the SZ decreased due to lower heat input and faster cooling rate. Tensile test plots show no signi cant change in ultimate tensile strength with or without Cu donor material. Fractography of tensile tested samples shows both ductile and brittle like structure for given welding parameters. This proposed work of FSW with Cu donor material is promising to increase tool life due to the decrement of the downforce during plunge and throughout the welding stage. Meanwhile, the inclusion of donor material did not compromise the weld quality in terms of the mechanical properties and micro-hardness. What Is Your Main Contribution To The Field?The main contribution in this research is on the novel and solid experimental approaches to examine whether donor material can assist friction stir welding (FSW) processes. To investigate this research question, Copper (Cu) was adopted as the donor material to assist the FSW of Al 6061. Through comparing experiments with and without donor material inclusion in FSW, it was found that the donor material induces drastic decreasing in downward force during FSW processes, which will increases the lifetime of the FSW tools. Meanwhile, the post-weld analysis identi ed no signi cant change occurred in the mechanical properties and microstructure of the welded joints, which is desired for industrial applications. The implementation of the donor material is promising to increase the lifetime of the FSW tools without compromising the mechanical properties FSW joints. The proposed approach is also economical for industrial application due to its effective potential to enhance the life of friction stir tools. What is novel? In theory, in experimental techniques, or a combination of both?This paper presents the novel experimental approach of introducing a Copper (Cu) donor material during the initial stage of friction sti...

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Section: Literature Reviewmentioning

confidence: 99%

Effect of copper donor material-assisted friction stir welding of AA6061-T6 alloy on downward force, microstructure, and mechanical properties

Bhukya

Maniscalco

et al. 2022

Int J Adv Manuf Technol

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“…Liu et al 95 exhibited an improved microstructure of butt weld joints created using a friction welding process boosted with ultrasonic vibrations. 2024Al-T4 butt joints were experimentally examined along with metallographic/X-ray visualizations which revealed better microstructure and grains formation.…”

Section: Welding With Vibration Assistancementioning

confidence: 99%

An insight into ultrasonic vibration assisted conventional manufacturing processes: A comprehensive review

Kumar¹,

Kumar²,

Singh³

et al. 2022

Advances in Mechanical Engineering

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Conventional manufacturing processes such as casting, forming, welding, machining, etc., have been optimized using different improvement techniques in the last few decades. The alterations in these processes have led to more efficient and productive manufacturing practices for the industry. One of these modification techniques is the deployment of ultrasonic vibrations in conventional manufacturing processes. In the last few decades, ultrasonic vibration assistance to manufacturing processes has seen an uprise and was the point of attraction for different research groups. Several improvements by utilizing ultrasonic vibration in manufacturing practices have been reported by the authors in the past. In this article, an attempt has been made to review all the reported techniques for different conventional processes viz. casting, forming, machining, and welding. The article outlines different research findings from the extensive work on ultrasonic vibration assistance showcasing the improved mechanical and morphological properties. The improvisation in the performance parameters viz. friction reduction, stress reduction, tool wear, surface finish, and grain structure has been witnessed by ultrasonic assistance in contrast to simple manufacturing processes. The outcomes have been summarized along with the optimized set of parameters from various studies.

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“…Blaha and Langenecker found that the use of ultrasonic vibration could reduce the yield stress and promote the plastic deformation of the metals [ 150 ], which was similar to heat softening. While the heat energy is uniformly absorbed by the metals, the ultrasonic energy can only be absorbed by the crystal defects in the metal [ 151 ]. Moreover, the plastic deformation of metals only depends on dislocation movement.…”

Section: Low-heat-input Weldingmentioning

confidence: 99%

Review of Techniques for Improvement of Softening Behavior of Age-Hardening Aluminum Alloy Welded Joints

et al. 2021

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The softening phenomenon of age-hardening aluminum alloy-welded joints is severe during conventional fusion welding, which increases the likelihood of stress and strain concentration in the joint during the period of service, significantly reduces the mechanical properties compared to the base metal, and represents an obstacle to the exploration of the potential structural performance. This review paper focuses on an overview of the softening phenomenon. Firstly, the welding softening mechanism and the characteristics of age-hardening aluminum alloys are clarified. Secondly, the current main research methods that can effectively improve joint softening are summarized into three categories: low-heat-input welding, externally assisted cooling during welding, and post-weld treatment. The strengthening mechanism and performance change rule of age-hardening aluminum alloy joints are systematically analyzed. Finally, this paper considers the future development trends of further research on joint softening, and it is expected that interest in this topic will increase.

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Improved weld macrosection, microstructure and mechanical properties of 2024Al-T4 butt joints in ultrasonic vibration enhanced friction stir welding

Cited by 100 publications

References 22 publications

Effect of copper donor material-assisted friction stir welding of AA6061-T6 alloy on downward force, microstructure, and mechanical properties

Effect of copper donor material-assisted friction stir welding of AA6061-T6 alloy on downward force, microstructure, and mechanical properties

An insight into ultrasonic vibration assisted conventional manufacturing processes: A comprehensive review

Review of Techniques for Improvement of Softening Behavior of Age-Hardening Aluminum Alloy Welded Joints

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