Mechanical, fatigue and microstructural properties of friction stir welded 5083-H111 and 6082-T651 aluminum alloys (original) (raw)
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International Journal of Materials Science and Engineering, 2014
The aim of the present work is to investigate the fatigue behavior of friction stir welded joints for dissimilar aluminum alloys 5052-H34 and 7075-T6. Friction stir welding (FSW) has been done on 4.826mm (0.19) in thick plate by using MTS-5 axis friction stir welder. FSW were carried out under optimum welding parameters with travel speed of 187mm/min (7in/min), rotational speed of 400rpm and forge load of 9KN (2000lbf). Mechanical tests and inspection were performed to characterize the welded joints and determine it to be defect-free. Tension-tension fatigue tests have been done at a frequency of 7Hz with stress ratio R=0.1. Also topography analysis was done using scanning electron microscopy combined with energy dispersive spectroscopy. The fatigue failure has been analyzed. Index Terms-friction stir welding, fatigue behavior, dissimilar joints, aluminum alloys Prof. Dr. Ali H Ataiwi, I have born in Iraq, Baghdad at 1953. I work as a Professor in Material Engineering Dep., University of Technology in Baghdad, Iraq. I have PhD in Metallurgical Engineering 1985 from University of Pierre and Marie Curie, France. I have many papers published in national and international journal, first; "Effect of Different Coating Tec with hniques Al on the Corrosion
Kovové materiály, 2021
In this study, AISI 7075/AISI 6061 aluminum alloy plates were welded in butt position by friction stir welding (FSW). The welding process was performed using different process parameters, also investigating their effect on mechanical and fatigue behavior of FSW joints. The microstructural evolution of the material was analyzed by optical observations and SEM analysis of the weld cross sections. Tension tests were applied to welded parts to obtain the strength of the joints. Fatigue crack growth behavior and fatigue life of the welded joints have been evaluated by conducting the test using servo hydraulic controlled fatigue testing machine. According to the results, welding speed and tool profile in the tested range have major influence on the mechanical and fatigue properties of the FSW joints.
Low cycle fatigue failure study of friction stir welded AA 6061 alloy similar joints
International Journal of Mechanics of Solids
In this study, Al-Mg-Si alloy plates in 4 mm thickness that are particularly used for aerospace and automotive industries were welded using Friction Stir Welding (FSW) method as similar joints with one side pass with parameters of varying tool rotation, weld speed and 2.3 degree tool tilt angle. Tensile tests results showed high yield stress values for FSW joints. Micro Vickers hardness test gave the required result for FSW welded Al-Mg-Si alloy plates. While fatigue test results showed all similar welded joints have fatigue strength close to each other.
International Journal of Scientific Research in Science, Engineering and Technology, 2019
The effect of processing parameters on the mechanical and microstructural properties of dissimilarAA5083–AA6062 joints produced by friction stir welding was analysed in this study. Different samples were produced by varying the advancing speeds of the tool as 5 mm/min and by varying the alloy positioned on the advancing side of the tool. In all the experiments the rotating speed is fixed at1200 RPM. All the welds were produced perpendicularly to the rolling direction for both the alloys. Microhardness (HV) and tensile tests performed at room temperature were used to evaluate the mechanical properties of the joints. For the mechanical fatigue tests, a resonant electromechanical testing machine was employed under constant loading control up to 10 Hz sine wave loading. The fatigue tests were conducted in the axial total stress–amplitude control mode, with R = rmin/rmax = -1. In order to analyse the microstructural evolution of the material, the welds’ cross-sections a SEM observation was made of the fracture surfaces.
Materials
The fatigue crack initiation and growth characteristics in 7050-T7451 aluminum alloy butt joints subjected to different stress ratios and owing to friction stir welding (FSW) were investigated using fatigue tests for stress ratios of 0.1, 0.3, and 0.5. The difference between the fatigue crack initiation in the base material (BM) and FSW joints, related to coarse secondary phases, was explored using scanning electron microscopy (SEM). Accordingly, Al23CuFe4, Al7Cu2Fe, and Al2Mg3Zn3 were the preferred joint crack initiation locations, whereas Mg2Si was the major fracture initiation point of the parent material, and cracks tended to propagate along dense, coarse secondary phases, becoming more pronounced for larger cracks. In addition, as the stress ratio increased, non-Mg2Si phase fracture initiation points appeared in the BM. Meanwhile, the quantity of non-Mg2Si phases in the joints continued to increase, and the crack initiation sites became increasingly concentrated in the TMAZ-HAZ...
The aim of the present work is to investigate the fatigue behavior of friction stir welded joints for dissimilar aluminum alloys (2024 -T3 and 7020-T6). Friction stir welding (FSW) had been done for 6.6 mm thick plate by using NC milling machine with R18 tool steel of 18mm with shoulder diameter and 6mm pin diameter with different tool designs; threaded cone with double bevel, threaded cylinder with concave shoulder of 4°, and beveled cone with concave shoulder of 4°. FSW were carried out under various welding parameters, travel speed of 40, 50, 75 mm/min, rotation speed range (275-1250) rpm and tilt angle of (Ɵ = 3°) with counterclockwise revolution. Many non-destructive inspections and mechanical tests were performed to evaluate welded joints to determine the best welding parameters. Fatigue test has been done at constant stress amplitude cantilever with stress ratio of (R= -1). The results showed that maximum tensile strength and joint efficiency were 360MPa and 86% respectively ...
Fatigue life of friction stir welded-aluminum alloy-7010 joints
Materials Characterisation VII, 2015
FSW is a solid state welding process which is widely used with high strength Aluminum Alloys (AA) such as AA-7xxx series. This alloy series is typically used in various structural applications such as truck wheels and bodies, heavy duty structures and aerospace. Durability of these structures is perhaps the most significant attribute they can possess manifesting the importance of fatigue life assessment. In this work, FSW was applied on AA-7010 using tool rotational speed of 850 rpm at a welding speed of 56 mm/min. The tool axial load was maintained constant within the whole welding runs. The resulting weldments were divided into two groups namely; as-welded and shot-peened conditions. Tensile and axial fatigue testing with stress-ratio (R=0.1) were used to evaluate and compare tensile properties and S-N curves of the welded and welded + peened conditions. The weldments were also characterized using optical microscopy, fractography, mechanical and fatigue testing as well as microhardness profiles across the weldment.
International Journal of Engineering Research and Technology (IJERT), 2014
https://www.ijert.org/evaluation-of-strength-degradation-and-microstructure-in-friction-stir-welded-aluminium-6063-t6 https://www.ijert.org/research/evaluation-of-strength-degradation-and-microstructure-in-friction-stir-welded-aluminium-6063-t6-IJERTV1IS7458.pdf Friction stir welding (FSW) is a new welding technology, which has been applied widely in aerospace, traffic, marine, industriesetc. because of its unique mechanical properties and metallurgic structure. It is common importance to find strength degradation and microstructure in FSW welded aluminium 6063-T6because of its applications ranging from rail road to aerospace vehicles. For this purpose an experimental investigation has been carried out on strength degradation using tensile and microstructural testing of FSW butt welded joints of 6063 T6 aluminum alloy. SEM technique is used to find out the microstructure at different points .In FSW joint, lower temperatures are involved in the process due to severe plastic deformation induced by the tool motion resulting in lower decay of mechanical properties. In the nugget zone there is a recrystallisation of very fine grain structure. Hence from industrial perspectives, FSW process is very competitive as it saves energy, has higher tensile strength and prevents the joints from fusion related defects.
Fatigue Life Evaluation of Friction Stir Welded 7075-T651 Aluminum Alloy Joints
2013
Aluminium 7075T651 alloys are widely used in the production of light weight structures requiring a high strength to weight ratio and high corrosion resistance. The effect of processing parameters on fatigue life of 7075-T651 aluminium joints produced by friction stir welding was investigated in the present study. Welding samples were made by employing rotating tool speed of 770, 900 and 1200 r.p.m, welding speeds of 70, 75 and 80 mm/min. After welding process, mechanical properties of samples were evaluated by means of fatigue testing machine at room temperature. Results clearly illustrated that as the tool speed decreases, fatigue life decreases. The highest fatigue life was obtained with 80mm/min welding feed and weld speed of 1200 r.p.m.
High-cycle fatigue behavior of friction stir butt welded 6061 aluminium alloy
Transactions of Nonferrous Metals Society of China, 2014
Friction stir welding (FSW) of 6061 aluminium alloy butt joint was carried out at each rotation speed of 600, 800, 1000, 1200 r/min for two different travel speeds, 80 and 100 mm/min, at a constant probe depth of 1.85 mm. The calculated energy input based on the FSW parameters studied shows that the ultimate tensile strength (UTS) of the butt joint is obtained within a certain range of energy input of 297 kJ to 354 kJ out of total range of energy input studied from 196 kJ to 405 kJ. The fatigue behaviors of high-strength and low-strength joints performed at different stress ratios, i.e., 0.5, 0.3, 0.1, −0.3, −0.5, indicate that the fatigue behaviors of both the welds are sensitive to the microstructural features, such as stir zone (SZ), thermo mechanically affected zone (TMAZ) and heat affected zone (HAZ). The observed fatigue strengths were discussed in terms of the microstructure, crack path behavior and fracture surface.