Friction Stir Welding of AA6082 Thin Aluminium Alloy Reinforced with Al2O3 Nanoparticles

A review on nanomaterials reinforcement in friction stir welding

Abstract: Nanomaterial reinforced friction stir welding (FSW) is an emerging domain, as it delivers a promising method for enhancing joint properties by making composite joints. Composite joints can enhance surface properties like hardness, strength, corrosion resistance, wear resistance, fatigue life, electrical conductance. Over few years many publications have been reported on the application of nanoparticles reinforcement in FSW joints. The present review critically analyses the current status of nanoparticle reinforcement FSW process. Firstly need, type, behaviour, intrinsic properties of nanoparticles used in FSW are discussed. Then, the microstructural examinations of reinforced joints are analysed. Followed by, various properties associated with reinforced joints are presented with the mechanism of the relationship between microstructure and properties. Finally, various methods of deposition of nanoparticle in FSW is discussed. At last prospects of reinforced FSW are explored followed by concluding remarks.

Selection of friction stir welding tool rotational speed for joining dual phase DP600 steel sheets – an experimental approach

Abstract: In the present work, mechanical and microstructural properties of friction stir welded similar DP600 steel were investigated. The sheets were butt welded with a single pass and three different rota...

Exit-hole repairing in friction stir welding of AA5456 pipe using consumable pin

Abstract: Filling Friction Stir Welding (FFSW) is an FSW completing process, in which the exit-holes at the end of friction stir welded lines are filled by a rotational semi-consumable pin. In the present st...

Interfacial and Cross-sectional Studies of Thermally Cycled Alumina-Monel Brazed Joint

Abstract: Alumina and monel superalloy was successfully joined by active metal brazing technique using Ticusil (68.8Ag-26.7Cu-4.5Ti in wt%) filler alloy in a vacuum furnace at 910°C for 10 min under a vacuum...

Biochar-assisted copper-steel dissimilar friction stir welding: mechanical, fatigue, and microstructure properties

Abstract: This present work investigates the effect of adding novel biochar microparticle into the welding zone of dissimilar friction stir welding of AISI-SAE 1010 (steel)–CDA 101 (copper) alloys. The primary aim of this work was to produce efficient weld joints in AISI-SAE 1010–CDA 101 alloys using biochar as solid lubricant via friction stir welding process. The biochar particles were prepared from rice husk biomass via carbonization process. The welding was performed using tapered pin profiled tool with rotational speed of 900 rpm, traverse speed of 30 mm/min, axial load of 5 KN, dwell time of 5s, plunging depth of 0.2mm, and biochar additions of 0.5, 1, 2, and 4wt%. The highest tensile strength of 205 MPa, elongation of 44%, yield strength of 177MPa, strain value of 36, and Vickers hardness of 121 were observed for FSW joints made using 2wt% of biochar content. Large addition of biochar up to 4wt% marginally affects the properties. Similarly, the fatigue strength of 157MPa was observed for weld made using 2wt% of biochar. The microstructure of biochar-assisted weld nugget shows highly refined less thermally affected grains. The grains were in equiaxial with distortion-free. The EDAX report confirms the presence of copper, iron, and carbon on the weld nugget, which indicates fine mixing of parent metals with solid lubricant. These mechanical properties improved environmental friendly dissimilar welding method could be used in industrial applications such as automobile, aerospace, construction, defense, medical, energy where high strength with high durable weld joints are required to meet the current technology demand, and process economy.

Investigating effects of process parameters on microstructural and mechanical properties of Al5052/SiC metal matrix composite fabricated via friction stir processing

Abstract: Friction stir processing (FSP) is a novel process for refinement of microstructure, improvement of material’s mechanical properties and production of surface layer composites. In this investigation via friction stir processing, metal matrix composite (MMC) was fabricated on surface of 5052 aluminum sheets by means of 5 μm and 50 nm SiC particles. Influence of tool rotational speed, traverse speed, number of FSP passes, shift of rotational direction between passes and particle size was studied on distribution of SiC particles in metal matrix, microstructure, microhardness and wear properties of specimens. Optimum of tool rotational and traverse speed for achieving desired powder dispersion in MMC was found. Results show that change of tool rotational direction between FSP passes, increase in number of passes and decrease of SiC particles size enhance hardness and wear properties.

Effect of welding parameters on mechanical and microstructural properties of dissimilar AA6082–AA2024 joints produced by friction stir welding

Abstract: The effect of processing parameters on the mechanical and microstructural properties of dissimilar AA6082–AA2024 joints produced by friction stir welding was analysed in this study. Different samples were produced by varying the advancing speeds of the tool as 80 and 115 mm/min and by varying the alloy positioned on the advancing side of the tool. In all the experiments the rotating speed is fixed at 1600 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. The mechanical tests were performed on the joints previously subjected to annealing at 250 °C for 1 h. For the fatigue tests, a resonant electromechanical testing machine was employed under constant loading control up to 250 Hz sine wave loading. The fatigue tests were conducted in the axial total stress–amplitude control mode, with R = σmin/σmax = 0.1. In order to analyse the microstructural evolution of the material, the welds’ cross-sections were observed optically and SEM observations were made of the fracture surfaces.

Effect of welding parameters on microstructure and mechanical properties of friction stir spot welded 5052 aluminum alloy

Abstract: Friction stir spot welding (FSSW) is a newly-developed solid state joining technology. In this study, two types of FSSW, normal FSSW and walking FSSW, are applied to join the 5052-H112 aluminum alloy sheets with 1 mm thickness and then the effect of the rotational speed and dwell time on microstructure and mechanical properties is discussed. The lower sheet material underneath the hook didn’t flow into the upper sheet due to the concave surface in the shoulder and groove in the anvil. The hardness profile of the welds exhibited a W-shaped appearance and the minimum hardness was measured in the HAZ. The results of tensile/shear tests and cross-tension tests indicate that the joint strength decreases with increasing rotational speed, while it’s not affected significantly by dwell time. At the rotational speed of 1541 rpm, the tensile/shear strength and cross-tension strength reached the maximum of 2847.7 N and 902.1 N corresponding to the dwell time of 5 s and 15 s. Two different fracture modes were observed under both tensile/shear and cross-tension loadings: shear fracture and tensile/shear mixed fracture under tensile/shear loadings, and nugget debonding and pull-out under cross-tension loadings. The performance of the welds plays a predominant role in determining the type of fracture modes. In addition, the adoption of walking FSSW brings unremarkable improvements in weld strength.

Investigation of mechanical properties of Cu/SiC composite fabricated by FSP: Effect of SiC particles’ size and volume fraction

Abstract: In this experiment, copper-base composites reinforced with 30 nm and 5 μm SiC particles are fabricated on the surface of a purecopper sheetvia friction stir processing (FSP). Microstructure, mechanical properties and wear resistance of friction stir processed (FSPed) materials are investigated as a function of volume fraction of SiC particles. Results show that, applying FSP, without SiC particles, increases the percent elongation significantly (more than 2.5 times) and decreases copper's strength. Adding micro- and nano-sized SiC particles decreases the tensile strength and percent elongation. Increasing the volume fraction or decreasing the reinforcing particle size enhances the tensile strength and wear resistance and lowers the percent elongation.