It was identified that the grain size of the particle and hardness value of the nugget zone varies, purely depending on the welding tool rotational speed and tool traveling speed. However, the effect of the tool plunge speed has not been reported to date. The various effects of the FSW parameters have been discussed, like welding speed, tool revolving speed, axial load, and tool pin profile. This method has more significant potential for joining aluminum alloys since it can reduce welding defects like porosity, welding cracks, and distortions, commonly encountered in other fusion welding techniques. The rotational tool speed was the major influential factor in producing sound weld joints. It has produced defect-free weld joints with more excellent mechanical properties and minimum welding defects. FSW weld joint consists of a heat-affected zone (HAZ) and TMAZ. The FSW process produces an attractive solid- phase bond in the material joining process without melting and recasting the parent materials. This technique was recently developed and is highly important for the material joining of similar and dissimilar materials.
Need for speed 2015 crack free#
This process does not release toxic or nontoxic fumes during material joining and develops welds free from solidification effects. To fabricate weld joints between two metals, a nonconsumable rotating tool was used, which eliminated the need for additional filler materials. FSW is a solid-state material joining technique developed by The Welding Institute (TWI) in 1991. Aluminum alloys find various applications in the wing structure, fuel tanks, railway tanks, vehicle bridges, high-speed ships, aerospace, engine chassis, automotive industries, and military applications due to their lightweight and greater strength and weight ratio.
It has been reported that the tapered pin-profiled tool produced sound (defect-free) weld joints when compared to other pin profiles. The various FSW tool pin profiles are used to make weld joints between two materials. The usage of aluminum alloys is rapidly increasing due to their castability, lightweight structures needing a higher strength ratio, and extraordinary corrosion resistance. FSW tool plays a very important role in the material joining processes. This technique is performed for joining different material combinations, such as aluminum, copper, magnesium, brass, and other material types. FSW has recently been selected as a reliable method for retaining the alloy’s properties when the joining takes place in the solid state. By conventional fusion welding techniques, aluminum alloys are tough to weld, and the joint quality is also unsuitable due to welding defects like distortion, cracks, and porosity. IntroductionĪluminum alloys are lightweight and have more applications in the industrial sector. Additionally, the increment in tool rotational speed significantly improved the tensile strength, weld joint quality, and joint efficiency.
Furthermore, this study revealed that a higher tool plunge speed facilitates the formation of equiaxed grains in the thermomechanically affected zone (TMAZ) on the advancing side (AS). The lowest bending strength of 25.38 N/mm 2 was obtained at 1600 rpm with 60 mm/min due to inappropriate mixing of the base metals and poor joint quality. The weld joints produced at 2300 rpm, tool traveling rate of 40 mm/min, and tool plunge speed of 30 mm/min showed the greatest tensile strength of the 191 MPa hardness of 145 Hv at the weld center and also the maximum bending strength of 114.23 N/mm 2 was achieved. The response of the stir zone microstructure to processing parameters was evaluated using optical microscopy (OM) and fractographic analysis of a tensile specimen shown by scanning electron microscope (SEM). Mechanical properties of microhardness, tensile strength, yield strength, elongation, and bending strength of the joints were analyzed.
A taper pin-profiled tool was utilized to produce the butt welded joints. A constant axial force of 5 kN was maintained throughout the joint fabrication process. The rotational tool speeds of 1600 rpm and 2300 rpm, welding speeds of 40 mm/min and 60 mm/min, and tool plunge speeds of 20 mm/min and 30 mm/min were set as the upper and lower limits. FSW tool rotational speed, welding speed, and tool plunge speed were chosen to make the weld joints. FSW parametric effects have a more significant impact on the mechanical performances and microstructure of produced joints. In this research, microstructural events and mechanical behaviors in dissimilar friction stir welding (FSW) of aluminium (Al) alloy AA6082-AA7075 joints have been evaluated to apply aerospace, defense, and military sectors.
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