Study on residual stress distribution of 2024-T3 and 7075-T6 aluminum dissimilar friction stir welded joints

Guo, Yueling; Ma, Yue; Zhang, Xiushuo; Qian, Xudong; Li, Jian

doi:10.1016/j.engfailanal.2020.104911

Cited by 34 publications

(12 citation statements)

References 34 publications

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“…Residual stress profiles generated by the neutron diffraction method indicated that the transverse and the normal tensile stresses were present on the 7075 sides. However, the 2024 side exhibited compressive stresses [33].…”

Section: 4mentioning

confidence: 99%

Microstructural and Mechanical Behaviors of Friction Stir Welded Dissimilar AA6082-AA7075 Joints

Sezhian¹,

Giridharan²,

Pushpanathan³

et al. 2021

Advances in Materials Science and Engineering

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In this research, microstructural events and mechanical behaviors in dissimilar friction stir welding (FSW) of aluminium (Al) alloy AA6082-AA7075 joints have been evaluated to apply aerospace, defense, and military sectors. FSW parametric effects have a more significant impact on the mechanical performances and microstructure of produced joints. FSW tool rotational speed, welding speed, and tool plunge speed were chosen to make the weld joints. The rotational tool speeds of 1600 rpm and 2300 rpm, welding speeds of 40 mm/min and 60 mm/min, and tool plunge speeds of 20 mm/min and 30 mm/min were set as the upper and lower limits. A constant axial force of 5 kN was maintained throughout the joint fabrication process. A taper pin-profiled tool was utilized to produce the butt welded joints. Mechanical properties of microhardness, tensile strength, yield strength, elongation, and bending strength of the joints were analyzed. The response of the stir zone microstructure to processing parameters was evaluated using optical microscopy (OM) and fractographic analysis of a tensile specimen shown by scanning electron microscope (SEM). The weld joints produced at 2300 rpm, tool traveling rate of 40 mm/min, and tool plunge speed of 30 mm/min showed the greatest tensile strength of the 191 MPa hardness of 145 Hv at the weld center and also the maximum bending strength of 114.23 N/mm2 was achieved. The lowest bending strength of 25.38 N/mm2 was obtained at 1600 rpm with 60 mm/min due to inappropriate mixing of the base metals and poor joint quality. Furthermore, this study revealed that a higher tool plunge speed facilitates the formation of equiaxed grains in the thermomechanically affected zone (TMAZ) on the advancing side (AS). Additionally, the increment in tool rotational speed significantly improved the tensile strength, weld joint quality, and joint efficiency.

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Section: 4mentioning

confidence: 99%

Microstructural and Mechanical Behaviors of Friction Stir Welded Dissimilar AA6082-AA7075 Joints

Sezhian¹,

Giridharan²,

Pushpanathan³

et al. 2021

Advances in Materials Science and Engineering

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“…Further, it reported that tool rotational speed was a more dominating factor compared to tool traverse speed. Yanning et al 18 joined a dissimilar combination of AA2024-T3 and AA7075-T6 using the FSW process. The main finding was that longitudinal residual stress on AA7075-T6 was greater and tensile in nature than the AA2024-T3 side, which was relatively compressive.…”

Section: Introductionmentioning

confidence: 99%

Experimental studies on friction stir welding of aluminium alloy 5083 and prediction of temperature distribution using arbitrary Lagrangian–Eulerian-based finite element method

Pramod

Jain

Kumar³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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The present work focused on welding aluminium alloy 5083 using the friction stir welding process. Suitable welding process parameters were identified to fabricate a defect-free butt joint with a tool rotational speed of 1600 rpm, traverse speed of 20 mm/min and tilt angle of 3°. The microstructure at the nugget zone, thermo mechanically affected zone, heat-affected zone and base metal zone are examined. Mechanical properties of the weldment exhibited promising results with an average joint efficiency and hardness of 75.70% and 94.0 ± 5.0 vickers hardness, respectively. Fractography revealed ductile mode of failure in base and weld metal tensile samples. Furthermore, a 3D thermomechanical finite element model was utilized to simulate the friction stir welding process using the selected process parameters. Arbitrary Lagrangian–Eulerian-based model aided in predicting residual stress distributions and thermal history during the friction stir welding process.

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“…i.e. an asymmetric "M" shape (Guo, Ma, Zhang, Qian, & Li, 2020;Hadji, Badji, Gaceb, Kherrouba, & Rabahi, 2018;Jamshidi Aval, 2015;Zapata, Toro, & López, 2016) with the peaks at the edges of the weld and a dip in RS within the nugget. There are conflicting reports in the literature as to where the maximum residual stress is measured within the weld.…”

Section: Residual Stress (Rs)mentioning

confidence: 99%

“…There are conflicting reports in the literature as to where the maximum residual stress is measured within the weld. Guo et al (2020) and Jamshidi Aval (2015) both reported that the maximum RS occurred at the edge of the weld at the side corresponding to the stronger material, with Guo attributing this to the higher heat input at the advancing side combined with the elevated mechanical properties of AA7075 compared with AA2024. However, Zapata et al (2016) reported the maximum RS at the side corresponding to the weaker material, which was attributed to the properties, chemical composition and heat treatments of the materials used as the weaker material had higher RS when similar welding was conducted.…”

Section: Residual Stress (Rs)mentioning

confidence: 99%

“…AA6062) were examined and all produced results with a double peak, i.e. an asymmetric "M" shape (Guo et al, 2020;Hadji et al, 2018;Jamshidi Aval, 2015;Zapata et al, 2016) with the peaks at the edges of the weld and a dip in RS within the nugget, see section 2.3.9.3.4. It should however be noted that these studies all used either XRD, neutron diffraction or ultrasonic methods; the XRD studies (Jamshidi Aval, 2015;Zapata et al, 2016) are only valid for near surface measurements.…”

Section: Fatigue Testingmentioning

confidence: 99%

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Stationary shoulder friction stir welding of military aircraft sheet alloys

Puckrin¹

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Stationary Shoulder Friction Stir Welding (SSFSW) allows joining of materials without the addition of mass and could be a potential solution to expedient helicopter repair in operational theatre. This research considers the suitability for SSFSW of two aluminium alloys commonly used within the Merlin helicopter airframe, AA8090 and BS L165. Techniques including optical microscopy, hardness, tensile and fatigue testing were used to characterise the two alloys and to establish a baseline for comparison with the welded specimens. The welds were performed in four configurations, with each welded both parallel and perpendicularly to the material’s rolling direction. This was in an effort to establish: the alloy’s suitability for SSFSW in both similar and dissimilar welds; the effect of changing the alloy positioned on the advancing side; and the influence of the material rolling direction on the quality of the weld. Techniques similar to those used in the material characterisation were used to determine the quality of each configuration. Encouraging tensile and fatigue strength results were achieved, especially for the similar materials welds with BS L165 welded parallel to the rolling direction achieving over 100% UTS weld efficiency. Inconsistent quality including the presence of kissing bonds was, however, observed. When welding parallel to the rolling direction, stronger welds were produced with BS L165 positioned on the advancing side. The presence of kissing bonds made analysis of those welded perpendicular to the rolling direction inconclusive. The material rolling direction also had an effect on the weld, as demonstrated through differences in weld appearance, degree of mixing of materials and tensile and fatigue test results. Additionally, a relationship between hardness and tensile strength was determined which revealed close correlation between the governing equation and the test results, with only 7% scatter. This will allow for prediction of tensile strength, based on the measured hardness, when the materials are joined using SSFSW.

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Study on residual stress distribution of 2024-T3 and 7075-T6 aluminum dissimilar friction stir welded joints

Cited by 34 publications

References 34 publications

Microstructural and Mechanical Behaviors of Friction Stir Welded Dissimilar AA6082-AA7075 Joints

Microstructural and Mechanical Behaviors of Friction Stir Welded Dissimilar AA6082-AA7075 Joints

Experimental studies on friction stir welding of aluminium alloy 5083 and prediction of temperature distribution using arbitrary Lagrangian–Eulerian-based finite element method

Stationary shoulder friction stir welding of military aircraft sheet alloys

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