Investigating the Effect of Considering Different Cross Section Design in Friction Stir Welded Joint Line of Dissimilar Aluminum Alloys

Document Type : Original Article

Authors

1 Department of Industrial Engineering, Velayat University, Iranshahr, Iran

2 Department of Industrial Engineering, Faculty of Industry and Mine Khash, University of Sistan and Baluchestan, Zahedan, Iran

Abstract

Using friction heat, welded joints of the Friction stir welding (FSW) process are made that are utilized to forge metal components together. Since there is no parent metal melting, several advantages are obtained by the FSW process over fusion welding. The alloys AA6XXX and AA7XXX Al are two sets of the most extensively utilized structural materials in rail transportation, automotive, and aerospace industries. The objective of present study was to investigate the effects of novel cross-sections in joint lines and further analyze the improvement in mechanical features. Due to the importance of the weld zone properties, many researchers seek to improve the mechanical behavior of the weld zone. For this, friction stir welded joint under four different new design in cross section named E1, E2, E3, E4 and one conventional cross section, E5 were conducted. Better outcomes are obtained by joints made utilizing this method based on joint quality and strength. The very good tensile features are displayed by the fabricated joints with Ultimate Tensile Strength (UTS)> 254 MPa and elongation > 7%. The highest UTS value which is occurred in E3 condition (Downward step) is 24.7% higher than required for FSW of AA6061 alloy at T6 condition in the American Welding Society (AWS) standard (186 MPa).

Keywords

Main Subjects

References

  1. Fu, B., Qin, G., Li, F., Meng, X., Zhang, J. and Wu, C., "Friction stir welding process of dissimilar metals of 6061-t6 aluminum alloy to az31b magnesium alloy", Journal of Materials Processing Technology, Vol. 218, (2015), 38-47. doi: 10.1016/j.jmatprotec.2014.11.039.
  2. Rafiee, A., Nickabadi, S., Nobarian, M., Tagimalek, H. and Khatami, H., "Experimental investigation joining al 5083 and high-density polyethylen by protrusion friction stir spot welding containing nanoparticles using taguchi method", International Journal of Engineering, Transactions C: Aspects, Vol. 35, No. 6, (2022), 1144-1153. doi: 10.5829/IJE.2022.35.06C.06.
  3. Kasman, Ş. and Yenier, Z., "Analyzing dissimilar friction stir welding of aa5754/aa7075", The International Journal of Advanced Manufacturing Technology, Vol. 70, No. 1, (2014), 145-156. doi: 10.1007/s00170-013-5256-7.
  4. Tiwan, H., Ilman, M. and Kusmono, K., "Effect of pin geometry and tool rotational speed on microstructure and mechanical properties of friction stir spot welded joints in aa2024-o aluminum alloy", International Journal of Engineering, Transactions B: Applications, Vol. 34, No. 8, (2021), 1949-1960. doi: 10.5829/IJE.2021.34.08B.16.
  5. Mishra, R.S. and Ma, Z., "Friction stir welding and processing", Materials science and engineering: R: reports, Vol. 50, No. 1-2, (2005), 1-78. doi: 10.1016/j.mser.2005.07.001.
  6. Khatami, H., Azdast, T., Mojaver, M., Hasanzadeh, R. and Rafiei, A., "Study of friction stir spot welding of aluminum/copper dissimilar sheets using taguchi approach", International Journal of Engineering, Transections B: Applications,, Vol. 34, No. 5, (2021), 1329-1135. doi: 10.5829/IJE.2021.34.05B.28.
  7. Ethiraj, N., Sivabalan, T., Sivakumar, B., Vignesh Amar, S., Vengadeswaran, N. and Vetrivel, K., "Effect of tool rotational speed on the tensile and microstructural properties of friction stir welded different grades of stainless steel joints", International Journal of Engineering, Transections A: Basics, Vol. 33, No. 1, (2020), 141-147. doi: 10.5829/IJE.2020.33.01A.16.
  8. Gibson, B.T., Lammlein, D., Prater, T., Longhurst, W., Cox, C., Ballun, M., Dharmaraj, K., Cook, G. and Strauss, A., "Friction stir welding: Process, automation, and control", Journal of Manufacturing Processes, Vol. 16, No. 1, (2014), 56-73. doi: 10.1016/j.jmapro.2013.04.002.
  9. Singh, R., Rizvi, S.A. and Tewari, S., "Effect of friction stir welding on the tensile properties of aa6063 under different conditions", International Journal of Engineering, Transections A: Basics, Vol. 30, No. 4, (2017), 597-603. doi: 10.5829/idosi.ije.2017.30.04a.19.
  10. Torres, E., Graciano-Uribe, J. and Santos, T., "Control of steel detachment and metal flow on aluminum-steel friction stir welding of thin joints", International Journal of Engineering, Transections A: Basics, Vol. 34, No. 4, (2021), 1024-1034. doi: 10.5829/IJE.2021.34.04A.29.
  11. Salah, A.N., Mehdi, H., Mehmood, A., Hashmi, A.W., Malla, C. and Kumar, R., "Optimization of process parameters of friction stir welded joints of dissimilar aluminum alloys aa3003 and aa6061 by rsm", Materials Today: Proceedings, Vol. 56, (2022), 1675-1683. doi: 10.1016/j.matpr.2021.10.288.
  12. Cole, E., Fehrenbacher, A., Duffie, N., Zinn, M., Pfefferkorn, F. and Ferrier, N., "Weld temperature effects during friction stir welding of dissimilar aluminum alloys 6061-t6 and 7075-t6", The International Journal of Advanced Manufacturing Technology, Vol. 71, No. 1, (2014), 643-652. doi: 10.1007/s00170-013-5485-9.
  13. Verbiţchi, V., Cojocaru, R., Boțilă, L.N., Ciucă, C. and Perianu, I.A., "Considerations on the ultimate tensile strength of butt welds of the en aw 5754 aluminium alloy, made by friction stir welding (FSW)", in Advanced Materials Research, Trans Tech Publ. Vol. 1157, (2020), 38-46.
  14. Huang, C., Lu, J., Zhu, M., Xu, Y., Li, B., Zhou, Y. and Huang, J., "Oxidation behaviors of the rotary friction welded joints of ht700 superalloy in saturated water steam at 700° c", Corrosion Communications, (2022). doi: 10.1016/j.corcom.2021.11.008.
  15. El-Sayed, M.M., Shash, A., Abd-Rabou, M. and ElSherbiny, M.G., "Welding and processing of metallic materials by using friction stir technique: A review", Journal of Advanced Joining Processes, Vol. 3, (2021), 100059. doi: 10.1016/j.jajp.2021.100059.
  16. Azeez, S. and Akinlabi, E., "Effect of processing parameters on microhardness and microstructure of a double-sided dissimilar friction stir welded aa6082-t6 and aa7075-t6 aluminum alloy", Materials Today: Proceedings, Vol. 5, No. 9, (2018), 18315-18324. doi: 10.1016/j.matpr.2018.06.170.
  17. Avinash, P., Manikandan, M., Arivazhagan, N., Ramkumar, K.D. and Narayanan, S., "Friction stir welded butt joints of aa2024 t3 and aa7075 t6 aluminum alloys", Procedia Engineering, Vol. 75, (2014), 98-102. doi: 10.1016/j.proeng.2013.11.020.
  18. Haribalaji, V., Boopathi, S. and Asif, M.M., "Optimization of friction stir welding process to join dissimilar aa2014 and aa7075 aluminum alloys", Materials Today: Proceedings, Vol. 50, No., (2022), 2227-2234. doi: 10.1016/j.matpr.2021.09.499.
  19. Prasanth, R. and Hans Raj, K., "Determination of optimal process parameters of friction stir welding to join dissimilar aluminum alloys using artificial bee colony algorithm", Transactions of the Indian Institute of Metals, Vol. 71, No. 2, (2018), 453-462. doi: 10.1007/s12666-017-1176-9.
  20. Guo, J., Chen, H., Sun, C., Bi, G., Sun, Z. and Wei, J., "Friction stir welding of dissimilar materials between aa6061 and aa7075 al alloys effects of process parameters", Materials & Design (1980-2015), Vol. 56, (2014), 185-192. doi: 10.1016/j.matdes.2013.10.082.
  21. Kesharwani, R., Panda, S. and Pal, S., "Multi objective optimization of friction stir welding parameters for joining of two dissimilar thin aluminum sheets", Procedia Materials Science, Vol. 6, No., (2014), 178-187. doi: 10.1016/j.mspro.2014.07.022.
  22. Peng, G., Ma, Y., Hu, J., Jiang, W., Huan, Y., Chen, Z. and Zhang, T., "Nanoindentation hardness distribution and strain field and fracture evolution in dissimilar friction stir-welded aa 6061-aa 5a06 aluminum alloy joints", Advances in Materials Science and Engineering, Vol. 2018, (2018). doi: 10.1155/2018/4873571.
  23. RajKumar, V., VenkateshKannan, M., Sadeesh, P., Arivazhagan, N. and Ramkumar, K.D., "Studies on effect of tool design and welding parameters on the friction stir welding of dissimilar aluminium alloys aa 5052–aa 6061", Procedia Engineering, Vol. 75, No., (2014), 93-97. doi: 10.1016/j.proeng.2013.11.019.
  24. Heidarzadeh, A., Javidani, M., Mofarrehi, M., Farzaneh, A. and Chen, X.-G., "Submerged dissimilar friction stir welding of aa6061 and aa7075 aluminum alloys: Microstructure characterization and mechanical property", Metals, Vol. 11, No. 10, (2021), 1592. doi: 10.3390/met11101592.
  25. Azeez, S., Akinlabi, E., Kailas, S. and Brandi, S., "Microstructural properties of a dissimilar friction stir welded thick aluminum aa6082-t6 and aa7075-t6 alloy", Materials Today: Proceedings, Vol. 5, No. 9, (2018), 18297-18306. doi: 10.1016/j.matpr.2018.06.168.
  26. Venkateswarlu, D., Mahapatra, M., Harsha, S.P. and Mandal, N., "Processing and optimization of dissimilar friction stir welding of aa 2219 and aa 7039 alloys", Journal of Materials Engineering and Performance, Vol. 24, No. 12, (2015), 4809-4824. doi: 10.1007/s11665-015-1779-4.
  27. Ahmed, M.M., El-Sayed Seleman, M.M., Zidan, Z.A., Ramadan, R.M., Ataya, S. and Alsaleh, N.A., "Microstructure and mechanical properties of dissimilar friction stir welded aa2024-t4/aa7075-t6 t-butt joints", Metals, Vol. 11, No. 1, (2021), 128. doi: 10.3390/met11010128.
  28. Torzewski, J., Łazińska, M., Grzelak, K., Szachogłuchowicz, I. and Mierzyński, J., "Microstructure and mechanical properties of dissimilar friction stir welded joint aa7020/aa5083 with different joining parameters", Materials, Vol. 15, No. 5, (2022), 1910. doi: 10.3390/ma15051910.
  29. Koilraj, M., Sundareswaran, V., Vijayan, S. and Rao, S.K., "Friction stir welding of dissimilar aluminum alloys aa2219 to aa5083–optimization of process parameters using taguchi technique", Materials & Design, Vol. 42, (2012), 1-7. doi: 10.1016/j.matdes.2012.02.016.
  30. Shojaeefard, M.H., Akbari, M., Khalkhali, A., Asadi, P. and Parivar, A.H., "Optimization of microstructural and mechanical properties of friction stir welding using the cellular automaton and taguchi method", Materials & Design, Vol. 64, (2014), 660-666. doi: 10.1016/j.matdes.2014.08.014.
  31. Kumar, K.K., Kumar, A. and Satyanarayana, M., "Effect of friction stir welding parameters on the material flow, mechanical properties and corrosion behavior of dissimilar aa5083-aa6061 joints", Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, Vol. 236, No. 6, (2022), 2901-2917. doi: 10.1177/09544062211036102.
  32. İpekoğlu, G. and Çam, G., "Effects of initial temper condition and postweld heat treatment on the properties of dissimilar friction-stir-welded joints between aa7075 and aa6061 aluminum alloys", Metallurgical and Materials Transactions A, Vol. 45, No. 7, (2014), 3074-3087. doi: 10.1007/s11661-014-2248-7.
International Journal of Engineering
Volume 36, Issue 1
TRANSACTIONS A: Basics
January 2023
Pages 19-27

Files

Share

How to cite

Statistics