Statistical Investigations on Friction Stir Welded Aluminum Tailored Blanks for a Robust Process Window

Abstract

The multifarious applications of aluminum alloys in different industrial domains are based on the mechanical properties as well as the light weight characteristics, which allow energy saving for the products in use. Nevertheless aluminum alloys are considered to be difficult to weld by conventional welding processes. This paper deals with cost-effective friction stir welding of thin sheet aluminum alloys in thicknesses of about 1 mm to widen the possible range of applications. Based on former studies results will be shown how an optimized tool geometry increases the mechanical properties of friction stir welded parts. The characteristics of these friction stir welded thin sheets will be analysed in a statistical evaluation in order to detect the interactions and dependencies of the process parameters. By highlighting the main process parameters and their significances a process window for friction stir welded blanks of AA5182 and AA6016 is presented.

Mechanical behaviour of similar and dissimilar AA5182-H111 and AA6016-T4 thin friction stir welds

“…Since the grain in the TMAZ is very refined (Fig. 7a and b), softening in this zone as to be related with the evolution of the strengthening precipitates during welding [13,4,[8][9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24]. The grain structure in the HAZ of the S66 weld (Fig.…”

“…Until now, FSW industrial application had mostly been restricted to the construction of large components in shipbuilding and aerospace and aeronautics industry [6,7]. The application of this process in the automotive industry is relatively recent and has one of its main fields of interest for the production of aluminium tailored welded blanks (TWB) from very thin sheets [8][9][10][11][12][13]. In fact, some difficulties continue to restrict the application of TWBs in industry [14][15][16][17] such as, the difficulty in welding some materials (Al alloys and HSS), the strength reduction in the weld line and the poor formability of the TWBs.…”

“…Giera et al [12] performed a statistical investigation on FSW of the AA5182 and AA6016 alloys in similar TWBs. They established window process parameters for joining 1 mm thick plates of both alloys.…”

Effect of friction stir welding process parameters on mechanical and metallurgical behavior of AA6061-T6 and AA2017-T6 tailored blanks

“…Giera et al [13] used statistical evaluation to determine the dependencies and interactions of the process parameters for FSW aluminium alloys of AA5182 and AA6016 TWBs and optimized the tool geometry to increase the mechanical properties. Palanivel et al [14] used different welding speeds to examine the metallurgical and mechanical properties of TW blanks made of aluminium alloys TW blanks.…”