Research of Friction Stir Welding (FSW) and Electron Beam Welding (EBW) Process for 6082-T6 Aluminum Alloy

Abstract

The paper presents the results of the joining tests of the EN AW-6082 T6 alloy. The materials were joined using the EBW high-energy (electron beam welding) and friction stir welding (FSW) methods. In the case of FSW welding, the following parameters were used: the linear speed was 355 mm/min, and the rotational speed of the welding tool was 710. In the case of EBW welding, the following parameters were used: accelerating voltage U = 120 kV, beam intensity I = 18.7 mA, welding speed v = 1600 mm/min and, in the case of a smoothing weld, U = 80 kV, beam intensity I = 17 mA, and welding speed v = 700 mm/min. Comprehensive microstructural tests of all welded joints (MO, SEM and TEM) and mechanical property tests (tensile and hardness tests) were carried out. The topographies of the fractures after the tensile test were also examined. Based on the results, it was found that the strength properties of the EBW joint were reduced by 23% and the FSW joint by 38% compared to the base material. A decrease in elongation was also noted, with an FSW elongation of 7.2% and an elongation of 2.7% for EBW. In the case of the EBW joint, magnesium evaporation was found in the weld during welding, while in the FSW joint, the dissolution of the Mg2Si particles responsible for strengthening the material during heat treatment to the T6 state was observed.

A Review of Recent Developments in Friction Stir Welding for Various Industrial Applications

“…Noga et al [104] used electron beam welding as well as an FSW setup to connect an EN AW6082 T6 alloy. A rotational speed of 710 rpm and a welding speed of 355 mm/min were used for the FSW.…”

“…The mechanical strength of the joints was lower than that of the parent metal. FSW had a higher peak elongation (7.2%) than an EBM-welded workpiece (2.7%), despite the fact that EBM-welded workpieces had higher mechanical strength and brittleness than FSW-welded samples [104]. Liu et al [105] investigated the microstructural evolution of AA1050 Al alloy FSW.…”

Deformation Behavior of an Extruded 7075 Aluminum Alloy at Elevated Temperatures

“…Aluminum and its alloys are widely acknowledged for their outstanding performance: for example, desirable strength/weight ratio, excellent formability, low cost, exceptional corrosion resistance, and recyclability [ 1 , 2 ]. Therefore, aluminum and its alloy applications are increasingly adopted, and they are being used in aerospace and automotive fields, which can efficiently realize weight loss, reduce fuel consumption, and prevent environmental pollution [ 3 , 4 ].…”

Mechanical Properties and Interfacial Characterization of Additive-Manufactured CuZrCr/CoCrMo Multi-Metals Fabricated by Powder Bed Fusion Using Pulsed Wave Laser

“…Multi-metal parts were conventionally fabricated by joining processes such as welding [ 6 , 7 , 8 , 9 ]. However, these joining technologies were mainly applied when fabricating large components with a multi-metal interface and simple geometry.…”