New Approaches to Friction Stir Welding of Aluminum Light-Alloys

Cabibbo, Marcello; Forcellese, Archimede; Santecchia, Eleonora; Paoletti, Chiara; Spigarelli, S.; Simoncini, Michela

doi:10.3390/met10020233

Cited by 32 publications

(18 citation statements)

References 72 publications

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“…For the welds displayed in (a) and (c), a wave-like structure on the advancing side (AS) can be seen, which is in line with literature reporting on similar weld zones in [4] and [21]. It is well documented that SPD in FSW leads to the transportation of matter, leaving these wavy features in both the thermo-mechanically affected zone (TMAZ) and the stir zone (SZ) [21,22]. Here, by direct comparison of the similar and dissimilar joints in (a) and (c), the differing initial material conditions become visible.…”

Section: Microstructural Evolutionsupporting

confidence: 86%

Microstructural and mechanical properties of AlSi10Mg: Hybrid welding of additively manufactured and cast parts

Krochmal

Rajan²,

Moeini³

et al. 2022

Journal of Materials Research

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Welding and joining of hybrid components consisting of additively manufactured (AM) parts and conventionally processed parts offer new opportunities in structural design. In the present study, AlSi10Mg specimens were fabricated using two different manufacturing processes, i.e., laser-based powder-bed fusion of metals (PBF-LB/M) and casting, and welded by means of friction stir welding (FSW). Material strength of dissimilar welded joints was found to be governed by the as-cast material, which is characterized by a very coarse microstructure resulting in inferior hardness and tensile properties. During fatigue testing, cast-cast specimens performed slightly better than their hybrid AM-cast counterparts with respect to lifetime, being rationalized by most pronounced strain inhomogeneities in the AM-cast specimens. With the aim of cost reduction, FSW can be employed to fabricate graded large parts as long as the AM as-built material is placed in the region demanding superior cyclic load-bearing capacity. Graphical abstract

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Section: Microstructural Evolutionsupporting

confidence: 86%

Microstructural and mechanical properties of AlSi10Mg: Hybrid welding of additively manufactured and cast parts

Krochmal

Rajan²,

Moeini³

et al. 2022

Journal of Materials Research

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“…The Friction Stir Welding (FSW) method is becoming more popular due to the very high quality of the joints being produced. It is even comparable to laser beam welding [10,11]. Moreover, the FSW does not require any filler metal, which makes the joint lighter [12,13].…”

Section: Introductionmentioning

confidence: 94%

The Influence of Tool Shape and Process Parameters on the Mechanical Properties of AW-3004 Aluminium Alloy Friction Stir Welded Joints

2021

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The purpose of the following study was to compare the effect of the shape of a tool on the joint and to obtain the values of Friction Stir Welding (FSW) parameters that provide the best possible joint quality. The material used was an aluminium alloy, EN AW-3004 (AlMn1Mg1). To the authors’ best knowledge, no investigations of this alloy during FSW have been presented earlier. Five butt joints were made with a self-developed, cylindrical, and tapered threaded tool with a rotational speed of 475 rpm. In order to compare the welding parameters, two more joints with a rotational speed of 475 rpm and seven joints with a welding speed of 300 mm/min with the use of a cylindrical threaded pin were performed. This involved a visual inspection as well as a tensile strength test of the welded joints. It was observed that the value of the material outflow for the joints made with the cylindrical threaded pin was higher than it was for the joints made with the tapered threaded pin. However, welding defects in the form of voids appeared in the joints made with the tapered threaded tool. The use of the cylindrical tool resulted in higher values for about 37% of mechanical properties compared with the highest result for the tapered threaded joint. As far as the parameters were concerned, it was concluded that most of the specimens were properly joined for a rotational speed of 475 rpm. In the joints made with a welding speed of 300 mm/min, the material was not stirred properly. The best joint quality was given for a rotational speed of 475 rpm as well as a variety of welding speed values between 150 and 475 mm/min.

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“…Friction Stir Welding (FSW) technology combines heat input from friction and extreme plastic deformation to produce highquality joints in aluminum and other alloy systems (Haghshenas and Gerlich, 2018;Cabibbo et al, 2020;Chen et al, 2020;Wang et al, 2020;Ahmed et al, 2021). The technology has been successful in low melting temperatures and low-strength materials such as aluminum and aluminum alloys.…”

Section: Introductionmentioning

confidence: 99%

Elastic properties of the non-mixing copper donor assisted material in friction stir welding of aluminum alloys using nanoindentation

et al. 2023

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Friction stir welding of high-strength materials such as steels is the impeded by the lack of the vast heat input needed to start the process. Contact friction is considered the most dominant source of heat generation for FSW steels which tends to cause severe wear conditions of the tool hear. To relieve the extreme wear conditions that occur on the tool heads because of FSW steels, we introduce the non-mixing Cu donor stir material to friction stir welding of aluminum alloys. The elastic properties of the Cu donor assisted friction stir welded aluminum alloys are measured using nanoindentation. The hardness and elastic modulus were measured for two regions, the base metal (BM) and the stir zone (SZ). The measurements were conducted for 20% and 60% Cu non-heat treated (NHT) and heat-treated (HT) samples. The nanomechanical properties were measured using nanoindentation with the continuous stiffness method (CSM) in depth control. The HT samples are softer than the NHT samples as expected. However, the 20% Cu NHT and HT samples depicted the same hardness at the SZ. Similar results were observed for the 60% Cu donor stir samples. It therefore concluded that the SZ is softer than the BM for the 20% and 60% Cu donor stir material as expected. The hardness of the weld at the SZ is similar to the hardness of the Al6061-T6 plate, suggesting that the Cu donor stir material did not impact the hardness properties of the Al6061-T6 plate due to the depletion of the Cu donor stir material during the welding process, an important result of the concept of the donor material. The elastic moduli of the Cu donor stir welded samples vary between 75~85 GPa at a depth of indentation of ~4600 nm, which are different from the elastic moduli of Cu 110 (117.2 GPa) and similar to the elastic modulus of aluminum alloys (68.9 GPa), an important outcome.

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New Approaches to Friction Stir Welding of Aluminum Light-Alloys

Cited by 32 publications

References 72 publications

Microstructural and mechanical properties of AlSi10Mg: Hybrid welding of additively manufactured and cast parts

Microstructural and mechanical properties of AlSi10Mg: Hybrid welding of additively manufactured and cast parts

The Influence of Tool Shape and Process Parameters on the Mechanical Properties of AW-3004 Aluminium Alloy Friction Stir Welded Joints

Elastic properties of the non-mixing copper donor assisted material in friction stir welding of aluminum alloys using nanoindentation

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