The Influence of Tool Tilt Angle on 1050 Aluminum Lap Joint in Friction Stir Welding Process

Abstract

In this paper, the effect of tool tilt angle on tensile-shear failure load and weld zone properties for 1050 aluminum plates, welded by friction stir lap welding, were investigated. For this purpose, tool tilt angle was varied from 0• to 5• under the constant other parameters, such as tool geometry, tool rotation speed of 1200 rpm and tool travel speed of 30 mm/min. The tensile-shear test was employed to test the mechanical properties of the joint. Optical microscope examinations, microhardness and temperature measurements were also performed in weld zone of lap joints. According to overall results, the tool tilt angle has a reasonable influence on the joint soundness and weld defect formation. If the tool axis was perpendicular to plate surface or a larger tool tilt angle was used, such configurations had harmful effect for the weld zone. In such case the tensile-shear failure load dropped from 4853 N to 2799 N. Recorded peak temperatures varied from 381• C to 438• C in the weld center. The measured mean hardness values of the stir and heat-affected zones were 31.5 HV and 28.3 HV, respectively, which are lower than that of aluminum 1050 base metal (40.7 HV).

Experimental Investigation of Friction Stir Welding on 6061-T6 Aluminum Alloy using Taguchi-Based GRA

“…However, in this joining technique, the process parameters play a vital role in affecting the mechanical plus the metallurgical properties of the weldment [14][15][16][17]. The higher tool rotational and the lower traverse speeds are the source of producing adequate heat for joining the base metal and those are the highest statistical influence on hardness, tensile strength, and peak temperature relative to other parameters [18][19][20]. On the other hand, the tool pin profile is governing the material movement and significantly influence the flow of plasticized material.…”

Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

“…The friction stir welding (FSW) process is a solid-state welding technology used in many industries recently for several reasons, such as high productivity, low defects related to melting, and high welding strength [1]. A rotational non-consumable tool penetrates inside the weld seam in the FSW process to join workpieces [2].…”

“…They studied joint configuration with pin-less and regular FSW tools. On the other hand, Barlas [1] investigated the total-contact TTA on FSW of AA1050 aluminum alloy in joint lap configuration.…”

Effect of Process Factors on Tensile Shear Load Using the Definitive Screening Design in Friction Stir Lap Welding of Aluminum–Steel with a Pipe Shape

“…Trueba Jr. et al [ 21 ] reported that the FSW tool shoulder with a raised helical design produces the best welds in terms of surface quality and mechanical properties in butt-welded aluminum 6061-T6 plates using six differently designed tools of Ti-6Al-4V material. Research has been conducted on process-parameter-related tools to reduce defects and increase the mechanical strength of FSW joints [ 27 , 28 ]. The normal force must be varied in the following four stages: tool plunge stage, dwell stage, welding stage, and tool retreating stage.…”

“…FSLW is more difficult than butt FSW. Many studies have been conducted on FSLW between Al alloys [ 11 , 13 , 28 , 34 ]. Significant research has been conducted on FSLW of Al–Mg [ 12 ], Al–Cu [ 30 , 35 ], Al–Ni [ 31 ], etc.…”