Mechanical, micro-, and macrostructural analysis of AA7075–T6 fabricated by friction stir butt welding with different rotational speeds and tool pin profiles

Abstract

Friction stir welding (FSW) is a solid state welding process for joining aluminium alloys, has been employed in different industries, and is a new and promising welding process that can produce low-cost and high-quality joints of heat-treatable aluminium alloys because this process uses a non-consumable tool to generate frictional heat in the abutting surfaces and can eliminate some welding defects such as crack and porosity. The various parameters such as rotational speed, welding speed, axial force, and attack angle play vital roles in the FSW process in order to analyse the weld quality. In this research, the impact of processing parameters such as different rotational speed and tool pin profiles on the mechanical, micro-, and macrostructural properties during the FSW process involving the butt jointing of AA7075 T6 is investigated. It is important to note that four-flute and taper threaded pin profiles are utilized and the mechanical characteristics are determined by comparing the ultimate strength, percentage of elongation, and microhardness profiles for different rotational speeds and tool pin profiles.

Investigation of the effects of critical process parameters of friction stir welding of polyethylene

“…Friction stir welding (FSW) is a novel solid-state welding process for the joining of metallic alloys and composites; it has numerous potential applications in manufacturing situations [1,2]. Considered to be one of the most significant welding processes, FSW has the advantage of non-consuming fabrication of continuous linear welds, the most common form of weld joint configuration.…”

Ultrasonic Measurements of Residual Stresses Caused by Severe Thermomechanical Deformation during FSW

“…Nevertheless, no plastic deformation takes place in this zone. (2) TMAZ wherein the material has been plastically deformed by the FSW tool, [29,30]. These three different microstructral textures, arising from the FSW process, lead to the microstructural inhomogeneity in the weld zone.…”

Fracture analysis of dissimilar Al‐Al friction stir welded joints under tensile/shear loading

“…Kasman and Kahraman investigated the influence of FSW input parameters on the microstructure and mechanical properties of AA5083‐H111 joint. In another research work, Bahemmat and co‐workers investigated the effect of pin profile and pin rotational speed on the microhardness, microstructure, elongation, and tensile strength of AA7075‐T6 joint made by FSW technique. Some researchers tried to optimize the FSW process of aluminum alloys from different aspects, such as tailor welding, minimizing the residual stress, etc.…”