Interface characteristic and tensile property of friction stir lap welding of dissimilar aircraft 2060-T8 and 2099-T83 Al–Li alloys (original) (raw)
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Friction Stir Welding of Lap Joints Using New Al–Li Alloys for Stringer-Skin Joints
The minerals, metals & materials series, 2019
The aeronautic industry is continuously looking for new structural concepts with the aim of reducing dangerous gas emissions as well as reducing manufacturing costs and times. The development of advanced lightweight structures is an effective alternative to achieve the mentioned goals. Reinforced panels produced by the third generation aluminum-lithium alloys and Friction Stir Welding (FSW) can bring new solutions for more efficient aircrafts. This work presents the results obtained in the development and characterization of FSW joints directed to reinforced panel manufacturing. FSW lap joints were produced using aluminumlithium alloys AA2099-T83 extrusions and AA2060-T8E30 sheets. Several welding parameter combinations and FSW tool designs were used to produce the joints. Joint properties were investigated by metallographic examination, microhardness tests as well as mechanical strength testing. The appropriate FSW conditions to optimize joint properties were established.
The butt joint with the help of the friction stir welding process is common and easy but when the think about the lap joint then the joining of two overlapping surfaces becomes difficult. Further FSW process traditionally used for joining of similar material, light metals, and alloy. To overcome the above problems this research work is carried out. In this research paper, the lap weld joint of dissimilar materials i.e. Aluminium 6061 and Titanium grade-2 are studied which is joined with help of the FSW process and the joint between them is a lap joint. The rotational tool speed, tool feed, and tool offset are used as process parameters while ultimate tensile strength as a response. The orthogonal array is used to design the experiments that give various combinations of process parameters and according to this workpieces are manufactured. Then Taguchi's analysis and ANOVA are used to optimization of process parameters for the responses. In the end, the metallurgical study of the joint is also conducted to investigate the joint at the microscopic level
Applied Mechanics and Materials, 2012
Friction stir welding (FSW) is a new and promising welding process that can produce low-cost and high-quality joints of Al-Li alloy. In order to demonstrate the friction stir weldability of Al-Li alloy and determine optimum welding parameters, the effect of FSW welding parameters on the tensile properties of the Al-Li alloy butt joints has been studied in this paper. The results showed that, when the heat input increased, the ultimate strength and elongation of butt joints decreased. For the Al-Li alloy butt structure with the thickness of 2mm, the optimum parameters were the rotation speed of 600 rpm, the welding speed of 400mm/min, and the ultimate strength of butt structure was the maximum strength, arrived at 413MPa, equivalent to 83% that of the base material. Furthermore, it was found from the microstructural observation that, the welding parameters had obvious effect on the grain size of welded zone. As the heat input increasing, the grains of weld nugget and heat affected zo...
IRJET, 2021
The butt joint with the help of the friction stir welding process is common and easy but when the think about the lap joint then the joining of two overlapping surfaces becomes difficult. Further FSW process traditionally used for joining of similar material, light metals, and alloy. To overcome the above problems this research work is carried out. In this research paper, the lap weld joint of dissimilar materials i.e. Aluminium 6061 and Titanium grade-2 are studied which is joined with help of the FSW process and the joint between them is a lap joint. The rotational tool speed, tool feed, and tool offset are used as process parameters while ultimate tensile strength as a response. The orthogonal array is used to design the experiments that give various combinations of process parameters and according to this workpieces are manufactured. Then Taguchi's analysis and ANOVA are used to optimization of process parameters for the responses. In the end, the metallurgical study of the joint is also conducted to investigate the joint at the microscopic level
Mechanical and microstructure characterization of al 2029 by friction stir welding
Friction stir welding developed and established by the welding institute (TWI) among the all new welding technologies in 1991, and it is used commonly for welding of high strength aluminium alloy such as Al2029, which are difficult to weld by conventional fusion welding technique. Friction welding (FW) is a collection of a series of Friction-based solid state joining processes which can produce high quality of weld of different component with either similar or dissimilar material and has been attracting increasing attention. This work aim is to weld two plates of Al-2029 and to optimize the different mechanical properties of welded material and base material.
Friction Stir Welding (FSW) is a solid-state joining process; i.e., no melting occurs. The welding process is promoted by the rotation and translation of an axis-symmetric non-consumable tool along the weld centerline. Thus, the FSW process is performed at much lower temperatures than conventional fusion welding, nevertheless it has some disadvantages. Laser Assisted Friction Stir Welding (LAFSW) is a combination in which the FSW is the dominant welding process and the laser pre-heats the weld. In this work FSW and LAFSW tests were conducted on 6 mm thick 5754H111 aluminum alloy plates in butt joint configuration. LAFSW is studied firstly to demonstrate the weldability of aluminum alloy using that technique. Secondly, process parameters, such as laser power and temperature gradient are investigated in order to evaluate changes in microstructure, micro-hardness, residual stress, and tensile properties. Once the possibility to achieve sound weld using LAFSW is demonstrated, it will be possible to explore the benefits for tool wear, higher welding speeds, and lower clamping force.
Advances in Materials Science and Engineering
The study presents the hybrid joining of the third generation AA2198-T8 aluminum lithium alloy to AA2024-T3 aluminum copper alloy, which has been highly demanded recently in the aerospace industry. This investigation aims to reduce the cost of production in the industrial sector. As a result, an affordable alternative is to use hybrid designs using AA2198-T8 alloy in crucial parts and AA2024-T3 alloy in the rest of the structure. A joining method is required to create hybrid structures composed of last-generation and standard aluminum alloys. The joining process was successfully friction stir-welded using five different welding travel speeds—36, 76, 102, 146, and 216 mm/min—with an invariable spindle speed of 960 rev/min. Two reversed steps, double-sided friction stir welding (DS-FSW) and single-sided friction stir welding (SS-FSW) techniques with two appropriate tool designs, were employed to investigate the dissimilar material mechanical properties and their morphological changes....
Friction Stir Welding Process of Aluminum-lithium Alloy 2195
Procedia Engineering, 2016
Friction stir welding is solid state welding and involves heating the metal with a suitable amount of pressure so that homogeneous and complete microstructural welding is possible without melting of the parts to be joined. The process uses a rotating tool with a profiled pin that penetrates the parts to be joined; the tool then starts to travel along the join line. By keeping the tool rotating and moving it along the join line to be welded, the softened material due to the frictional heat is stirred and mixed together by the rotating pin forming a weld in solid state without melting. Frictional heat generated by rotation of the tool due to the high compressive pressure and shearing action of the shoulder along the joint line causes a softened zone of material without melting. Localized severe deformation around the tool results in refinement of the microstructure and the material flow produces coalescence and formation of a weld. FSW provides superior welding over conventional fusion welding and is preferred for joining of Al-Li alloys. The present work is to investigate was to study the effect of friction stir welding parameters on mechanical and microstructural properties of AA2195-T0 and T8. Since FSW is both a deformation and a thermal process, temperature distribution during FSW is measured. The microstructure and mechanical properties of welded joint were investigated for different friction stir welding conditions. This paper describes the results of an experimental study to investigate the mechanical and microstructure evolution of AA2195 friction stir welded joint. The optimum welding condition is also provided for different heat treated AA2195 alloys.
A Study on Friction Stir Welding Process for AA2219/AA2195 Joints
2018
The object of this work was to study mechanical properties of friction stir welded joints of AA2219 and AA2195. AA2219 has been used as an aerospace material for many years primarily due to its high weldability and high specific strength in addition to the excellent cryogenic properties so to be successfully used for manufacturing of cryogenic fuel tanks for space launchers. Relatively new Aluminum-Lithium alloy, AA2195 provides significant saving on weight and manufacturing costs with application of a friction stir welding. Friction stir welding is a solid-state joining process, which use a spinning tool to produce frictional heat in the work piece. To investigate the effect of the rotation direction of the tool, the joining was performed by switching positions of the two dissimilar alloys. The welding parameters include travelling speed, rotation speed and rotation direction of the tool, and the experiment was conducted under the conditions that the travelling speed of the tool was 120-300 mm/min and the rotation speed of the tool was 400-800 rpm. Tensile tests were conducted to study the strength of friction stir welded joints and microhardness were measured with microstructural analysis. The results indicate the failure occurred in the relatively weaker TMAZ/HAZ interface of AA2219. The optimum process condition was obtained at the rotation speed of 600-800 rpm and the travelling speed of 180-240 mm/min.
International Journal of Research in Engineering and Innovation , 2020
The friction stir welding is a newer technique used for refining and homogenizing the grain structure of metal sheet. Friction stir processing is a great potential in the field of super plasticity and metal matrix composites. Many investigators observed that the FSW greatly enhances mechanical properties of welded joints of Al alloys. It is a solid-state welding technique which is specially designed rotating cylindrical tool that comprises of a probe and shoulder. The probe of the tool is inserted into the sheet material while rotating and the shoulder moves over the surface of the sheet, and then traverses in the desired direction. The contact between the rotating probe and the sheet material generate heat due to friction which softens the material and the mechanical stirring caused by the probe, the material within the processed zone undergoes intense plastic deformation yielding a dynamically-recrystallized fine grain microstructure. In this paper, the FSP tool pin rotates on an already welded joint by TIG welding to improve the lower the welding load and weld quality by adjusting the processing parameters of friction stir processing of different aluminum alloy.