Investigation on the Effect of Tool Pin Profiles on Mechanical and Microstructural Properties of Friction Stir Butt and Scarf Welded Aluminium Alloy 6063
Abstract:Abstract:In the present study, friction stir welding (FSW) of butt and scarf joints of Al 6063-T6 were investigated. Five different tool pin profiles (cylindrical, tapered cylindrical, square, triangular, and hexagonal) were applied for performing welding. Scarf joint, being a new joint configuration, was used and effect of pin profiles was investigated on this type of joint configuration. The effect of pin profiles on microstructure, micro-hardness, impact and tensile properties of friction stir welded Al 606… Show more
“…79 It is important to study effects of microstructure at different zones on mechanical properties of the weld joint.Figure 10.Different micro-structural zones of FSW. 80 …”
Friction stir welding (FSW) is one among solid-state welding processes that can be employed for producing joints between dissimilar combinations with more ease than that of fusion welding processes. Several high coupled physical phenomena have addressed FSW as an extremely complex process. It is around three decades of invention, optimization of the parameters have been carried out even today by many researchers all over the world to obtain sound joints. This article focuses mainly on the research developments in the dissimilar FSW (DFSW), with the factors that are involved in joint fabrication between dissimilar materials. From the literature, it is found that the most influential factors in deciding the quality of the joints are pin profile, shoulder shape, welding speed and tool rotational speed. In addition, all other parameters will provide incremental support to it. The study on microstructure in different zones and the mechanical properties of welded specimens are elaborated from the available literature. Special attention is given to the reinforcement of micro- and nano- sized solid particles in the DFSW process. Future studies of DFSW are discussed based on the untracked studies that are not available in the literature.
“…79 It is important to study effects of microstructure at different zones on mechanical properties of the weld joint.Figure 10.Different micro-structural zones of FSW. 80 …”
Friction stir welding (FSW) is one among solid-state welding processes that can be employed for producing joints between dissimilar combinations with more ease than that of fusion welding processes. Several high coupled physical phenomena have addressed FSW as an extremely complex process. It is around three decades of invention, optimization of the parameters have been carried out even today by many researchers all over the world to obtain sound joints. This article focuses mainly on the research developments in the dissimilar FSW (DFSW), with the factors that are involved in joint fabrication between dissimilar materials. From the literature, it is found that the most influential factors in deciding the quality of the joints are pin profile, shoulder shape, welding speed and tool rotational speed. In addition, all other parameters will provide incremental support to it. The study on microstructure in different zones and the mechanical properties of welded specimens are elaborated from the available literature. Special attention is given to the reinforcement of micro- and nano- sized solid particles in the DFSW process. Future studies of DFSW are discussed based on the untracked studies that are not available in the literature.
“…Cylindrical or conical pin profiles which may have features like threads or threads with flats have been used for dissimilar Al alloy combinations as shown in Figure 8. When used without threads a smaller surface is provided to the material, while the threaded and flat features on it increase the contact area while threads guide material flow around the pin in a rotational as well as a translation direction [14,16,47,82]. The polygonal pin profiles produce pulses in the flow during material stirring and mixing, leading to material adhering to the pin [83][84][85][86].…”
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.
Friction stir welding (FSW) has matured considerably since its introduction in 1991. Over the last decades, it has indeed branched and been applied in different fields, such as automotive, aerospace, railway, and shipbuilding. This article aims to survey the basic knowledge related to the conventional FSW of aluminum alloys in order to provide a tool for understanding the friction stir processes. The review covers the five basic process parameters: rotational speed, welding speed, tool geometry, tilt angle, and plunge depth. Furthermore, it presents the related equations and recommended ranges of those parameters to facilitate the process design step for industrial implementation. A sample of 30 published articles was drawn for that purpose. The current article also discusses the main five properties most researchers are interested in, namely, microstructure, microhardness, tensile strength, residual stresses, and distortion.
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