Joining Aerospace Aluminum 2024-T4 to Titanium by Friction Stir Extrusion

Evans, William T.; Cook, Gerald; Strauss, Alvin M.

doi:10.1007/978-3-319-52383-5_9

Cited by 5 publications

(3 citation statements)

References 10 publications

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“…It is claimed that the process creates a better dissimilar material joint by eliminating the issues of IMCs. It is 89 showed that successful joints were produced at TRS: 700 r/min and WS: 38.1 mm/min with up to 70% shear strength of parent material. Further, the groove geometry is a vital parameter for joint strength.…”

Section: Other Friction-based Hybrid Processesmentioning

confidence: 97%

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Solid-state joining of aluminum to titanium: A review

Gadakh¹,

Badheka

Mulay

2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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The dissimilar material joining of aluminum and titanium alloys is recognized as a challenge due to the significant differences in the physical, chemical, and metallurgical properties of these alloys, where the increasing demands for high strength and lightweight alloys in aerospace, defense, and automotive industries. Joining these two alloys using the conventional fusion techniques produces commercially unacceptable sound joints due to irregular, complex weld pool shapes, cracking and low strength, high residual stresses, cracks, and microporosity, and the brittle intermetallic compounds formation leads to poor formability or inferior mechanical properties. The formation of intermetallic compounds is inevitable but it is less severe in solid-state than in the fusion welding process. Hence, this article reviews on aluminum–titanium joining using different solid-state and hybrid joining processes with emphasis on the effect of process parameters of the different processes on the weld microstructure, mechanical properties along with the type of intermetallic compounds and defects formed at the weld interface. Among the various solid-state welding processes for aluminum–titanium joining, the following grades of aluminum and titanium alloys were employed such as cp Ti, Ti6Al4V, cp Al, AA1xxx, AA 2xxx, AA5xxx, AA6xxx, AA7xxx, out of which Ti6Al4V and AA6xxx alloys are the most common combination.

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Section: Other Friction-based Hybrid Processesmentioning

confidence: 97%

“…Evans et al 89 successfully created AA 2024-T4 to cp Ti lap joints using the friction stir extrusion (FSE) process. In their earlier work, they applied the same process to join Al-steel.…”

Section: Other Friction-based Hybrid Processesmentioning

confidence: 99%

Solid-state joining of aluminum to titanium: A review

Gadakh¹,

Badheka

Mulay

2021

Proceedings of the Institution of Mechanical Engineers, Part L:

View full text Add to dashboard Cite

show abstract

“…With this modified FSW technique, all frictional heat is generated by the rotation of the probe at much higher rotational speeds than traditional FSW. While the conventional FSW tool typically rotates at 1000-2000 RPM for welding aluminum (where both the shoulder and the pin rotate at the same speed) [24][25][26][27], the SS-FSW probe rotates at 3000-5000 RPM while the shoulder is stationary. Accordingly, welding can progress faster and at lower heat inputs.…”

Section: Introductionmentioning

confidence: 99%

Microstructure evaluation of dissimilar AA2024 and AA7050 aluminum joints made by corner stationary-shoulder friction stir welding

et al. 2022

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Fillet welds made by the corner stationary-shoulder friction stir welding process between AA7050-T7451 and AA2024-T4 sheets were characterized using different metallographic techniques and mechanical testing. Robotic welds of an aircraft’s skin-to-internal stiffeners were examined using Barker’s electrolytic and Keller’s etching techniques and correlated with electron backscattered diffraction results and energy-dispersive microprobe analysis. The composition and grain orientation maps and material flow lines demonstrated excellent weld quality in spite of the apparent inhomogeneities in the stir zone where mechanical mixing was complete. Welded joint efficiencies were in the 85–92% of the base metals and were acceptable in terms of resistance to crack initiation and propagation and corrosion resistance, even with softening of the heat-affected zones. It was concluded that several optical and electron microscopy techniques are needed to characterize these dissimilar aluminum welds fully and that post-weld mechanical and thermal treatments could even further improve their quality.

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Feasibility Study of Compaction and Sintering of Commercially Pure Titanium using Friction Stir Processing

Fortier¹,

Kumar²,

Komarasamy³

et al. 2018

IJCET

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Manufacturing of a component through powder metallurgy (PM) route involves at least three critical steps: powder blending, compaction, and sintering. Overall, the PM route takes 4 to 8 steps to get to the final product. Moreover, it requires a huge amount of capital investment to perform every step of the manufacturing process via PM route. Friction stir processing (FSP) is a derivative of friction stir welding which has emerged as a generic microstructural modification tool in last one decade. The aim of the current work was to explore the possibility of decreasing the number of steps required in the manufacturing of a product using the PM technique. Using the FSP method, the manufacturing process is reduced to two steps and the mechanical properties of the final product are significantly improved. In this study, commercially pure titanium (Ti) powder was used. The two-step process appeared extremely efficient and it involved: 1) constraining the Ti-powder in a die and using a punch to consolidate it in a final disk-like geometry, 2) next, the consolidated disk-shaped product was processed using FSP tool and methods. Initial mechanical characterization results show peak hardness of the FSP processed Ti-powder product to be approximately 436 HV0.3 with average hardness measured at about 251 HV. The electron backscattered diffraction of the FSP-assisted sintered region showed equiaxed grains with average grain size to be 440 ±254 nm. The initial result indicates FSP can be used as a manufacturing tool for consolidating powders in to bulk solid form.

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Joining Aerospace Aluminum 2024-T4 to Titanium by Friction Stir Extrusion

Cited by 5 publications

References 10 publications

Solid-state joining of aluminum to titanium: A review

Solid-state joining of aluminum to titanium: A review

Microstructure evaluation of dissimilar AA2024 and AA7050 aluminum joints made by corner stationary-shoulder friction stir welding

Feasibility Study of Compaction and Sintering of Commercially Pure Titanium using Friction Stir Processing

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