New method for investigating material flow during friction stir spot welding

Abstract

In this paper, an examination of dissimilar wrought and heat treated AZ31 spot welds (AZ31/AZ31_HT) was conducted to allow visualisation of material flow based on their differing etching characteristics. The results indicated that dissimilar AZ31/AZ31_HT welds could successfully mirror the material flow in friction stir spot welding. The upper sheet material moved downwards towards the rotational pin, whereas the lower sheet material displaced upwards and outwards during the penetrate stage, and then moved inwards towards the keyhole after reached the base of the shoulder.     

Process forces during friction stir welding of aluminium alloys

Abstract

Flow and consolidation of the material under the tool shoulder and subsequent nugget formation are among the least understood aspects of friction stir welding and processing (FSW/P). Welding parameters and tool profile impact the process forces acting on the tool. This work is an observational study of the process forces associated with bead on plate runs on two aluminium alloys, 6061 and F357. Polar plots of the resultant forces acting on the tool spindle are analysed and correlated to the process parameters. The dependence of the nugget's width with various heat indices is evaluated.     

Joint formation in dissimilar Al alloy/steel and Mg alloy/steel friction stir spot welds

Abstract

The microstructural features and overlap shear strength properties of friction stir spot welds made between Al 6111 and low carbon steel, and between Mg alloy AM60 and DP600 dual phase steel, are investigated. When Al 6111 is the upper sheet in the dissimilar sandwich, completed spot welds show evidence of intermetallic layer formation and cracking. Increasing tool pin penetration into the lower sheet provided increased mechanical interlocking of the sheets due to clinching. However, increasing penetration also promoted intermetallic formation and cracking in completed welds. However, dissimilar AM60/DP600 steel friction stir spot welds produced with AM60 as the upper sheet in the dissimilar sandwich do not show evidence of intermetallic formation and cracking may be avoided by removing the zinc coating on the DP600 steel before the friction stir spot welding operation.     

Modelling microstructural evolution during multiple pass friction stir welding

Abstract

The effect of multiple weld passes on the microstructure and properties of friction stir welds in aerospace aluminium alloy AA 7050 has been investigated with the aid of a microstructure model. Each weld pass leads to a reduction in minimum strength in the heat affected zone, the decrease being greatest after the first pass. The model predicts that this is due to partial dissolution and coarsening of the strengthening precipitatates, which up to weld pass 3 is dominated by dissolution, and beyond weld pass 3 by coarsening. Microstructural evolution in the nugget is predicted to involve complete precipitate dissolution during each pass, followed by reprecipitation on the refined grain boundaries. A post-weld aging treatment after multiple passes is predicted not to be effective in improving minimum strength since precipitation occurs via growth and coarsening of existing particles, not nucleation of new precipitates.     

Modelling of 7050 aluminium alloy friction stir welding

Abstract

A thermal model combined with a microstructural and yield strength model has been developed to give a prediction of precipitate evolution and strength in the as welded and post-weld heat treated condition for friction stir welding of 7xxx aerospace aluminium alloys. This fully coupled model is applied to an overaged high strength 7050 aluminium alloy friction stir welded using a range of welding rotation and translation speeds. The evolution of the microstructure has been predicted as a function of the process parameters. The resulting microstructural evolution is shown to be a complex function of both peak temperature observed during the weld cycle and heating/cooling rates. Yield strength has been calculated from the microstructural predictions and a comparison between predicted yield strength and measured hardness has been used to test the modelling approach. Reasonably good agreement between model and experiment is found over the wide range of process parameters investigated.     

Resistance and friction stir spot welding of DP600: a comparative study

Abstract

Efforts to reduce vehicle weight and improve crash performance have resulted in increased application of advanced high strength steels (AHSS) and a recent focus on the weldability of these alloys. Resistance spot welding (RSW) is the primary sheet metal welding process in the manufacture of automotive assemblies. Friction stir spot welding (FSSW) was invented as a novel method to spot welding sheet metal and has proven to be a potential candidate for spot welding AHSS. A comparative study of RSW and FSSW on spot welding AHSS has been completed. The objective of this work is to compare the microstructure and mechanical properties of Zn coated DP600 AHSS (1·2 mm thick) spot welds conducted using both processes. This was accomplished by examining the metallurgical cross-sections and local hardnesses of various spot weld regions. High speed data acquisition was also used to monitor process parameters and attain energy outputs for each process. Results show a correlation found among microstructure, failure loads, energy requirements and bonded area for both spot welding processes.     

Peak temperatures and microstructures in aluminium and magnesium alloy friction stir spot welds

Abstract

The peak temperatures during friction stir spot welding of similar and dissimilar aluminium and magnesium alloys are investigated. The peak temperatures attained during friction stir spot welding of Al 6111, Al 2024, and AZ91 are within 6% of their solidus temperatures. In dissimilar AZ91/Al 6111 spot welds the peak temperature corresponds with the α-Mg solid solution and Mg₁₇Al₁₂ eutectic temperature of 437°C. An a-Mg plus Mg₁₇Al₁₂ eutectic microstructure is produced in dissimilar friction stir spot welds when material displaced during pin penetration into the lower sheet material contacts the upper sheet material at the eutectic temperature.     

Microstructural characterisation of stir zone containing residual ferrite in friction stir welded 304 austenitic stainless steel

Abstract

Friction stir welding was applied to a 2 mm thick 304 austenitic stainless steel plate. The microstructural evolution and hardness distribution in the weld were investigated. The stir zone (SZ) and thermomechanically affected zone (TMAZ) showed dynamically recrystallised and recovered microstructures, respectively, which are typically observed in friction stir welds in aluminium alloys. The hardness of the SZ was higher than that of the base material and the maximum hardness was observed at the TMAZ. The higher hardness at the TMAZ was attributed to high densities of dislocations and subboundaries. Microstructural observations revealed that the ferrite was formed along grain boundaries of the austenite matrix in the advancing side of the SZ. It is suggested that the frictional heat due to stirring resulted in the phase transformation of austenite to ferrite and that upon rapid cooling the ferrite was retained in the SZ.     

CFD modelling of friction stir welding of thick plate 7449 aluminium alloy

Abstract

CFD modelling of friction stir welding has been conducted to understand and optimise the welding of thick, 7449 aluminium alloy for aerospace applications. The aim is to produce high strength, defect free welds that do not break the tool. The models compared different pin profiles and rotation speeds and were undertaken in two stages. The first stage involved creating a thermal model to better understand the generation and flow of heat. The second stage involved analysing the flow near the tool with a two-dimensional model. The traversing force results from the two-dimensional planar models compared favourably with experimental findings. The pressure distribution and deformation region size were compared for the different models. Novel maps of the deformation conditions experienced in each weld were produced. The analysis suggested reasons why some pin profiles and rotation speeds are preferable to others and explained the difference in the traversing force measurements.     

Microstructural modification of cast Mg alloys by friction stir processing

Abstract

Cast Mg alloys were processed using friction stir processing (FSP) to acquire a fine grained structure and high strength. Actually, FSP is a novel grain refinement method for light metal alloys. Using FSP, a cast microstructure with coarse grain size was refined to equiaxial fine grain through dynamic recrystallisation; second phase particles were finely dispersed by FSP. Moreover, FSP is effective to eliminate cast defects such as microshrinkages or porosities. Commercial die cast Mg alloy (AZ91D) and high strength Mg–Y–Zn alloy plates were prepared for FSP. Heat input using a rotational tool during FSP closely affected the microstructure in the stirred zone. Actually, FSP with lower heat input produced a finer grain size and higher hardness. Changes in the friction stir processed microstructures affecting mechanical properties were not only grain refinement, but also second phase particle distributions. Results show that alloys with high hardness by FSP have finely dispersed second phase particles without dissolution during FSP.     

Fracture toughness of structural aluminium alloy thick plate joints by friction stir welding

Abstract

The fracture toughness in a friction stir welded joint of thick plates of structural aluminium alloy type A5083-O is investigated. A joint between two 25 mm thick plates is fabricated by one sided, one pass friction stir welding. The Charpy impact energy and critical crack tip opening displacement (CTOD) in the friction stir weld are much higher than those in the base metal or heat affected zone, whereas mechanical properties such as stress–strain curve and Vickers hardness are not conspicuously different. The effects of the microstructure on crack initiation and propagation are studied in order to clarify the difference in fracture toughness between the stir zone and base metal. The analyses of the fracture resistance curves and the diameters of dimples in the fracture surface after both tensile and bending tests show that the fine grained microstructure in the stir zone helps to increase ductile crack initiation and propagation resistance. It is found that the high fracture toughness value in the stir zone is affected by the fine grained microstructure in friction stir welds.     

Modelling heat flow around tool probe in friction stir welding

Abstract

The objective of the present paper is to investigate the effect of including the tool probe in the numerical modelling of three-dimensional heat flow in friction stir welding (FSW). The heat flow close to the probe/matrix interface is investigated. In the models presented, the heat is forced to flow around the 'probe hole'. In this manner, the material flow through the probe region, which often characterises other thermal models of FSW, is avoided. This necessitates controlling the convective heat flow by prescribing the velocity field in the narrow shear layer at the tool/matrix interface. As a consequence the sliding, sticking, or partial sliding/sticking condition can be modelled. Six cases are established, which are represented by three stages of refinement of the heat source model, combined with two different contact conditions, i.e. full sliding and full sticking.     

Two modes of metal flow phenomenon in friction stir welding process

Abstract

It has been widely recognised that the fundamental mechanism of weld formation in friction stir welding (FSW) is too complex, a phenomenon to be understood completely. In the present study two modes of metal transfer phenomenon in FSW have been discussed with the help of three FSW techniques. In the first technique a strip is welded to the plate by the process, in the second one the brass sheet is inserted perpendicular to the welding direction and in the third one the process is performed with tools having different pin lengths. The results suggest a strategy to model the process particularly for predicting welding tool performance.     

Friction stir welding of aluminium 7136-T76511 extrusions

Abstract

This research programme evaluates the as welded properties of Al 7136-T76511 extrusions joined through friction stir welding (FSW). Microstructural characterisation and mechanical testing were performed on the baseline material and on panels friction stir welded at 250 and 350 rev min^–1 (all other weld parameters held constant). Transmission electron microscopy revealed the microstructural features in each of the unique weld regions and demonstrated that the precipitate density and morphology in these regions correlates with the temperature profile produced by the FSW process. A thermal model of FSW is developed that utilises an energy based scaling factor to account for tool slip. The slip factor is derived from an empirical relationship between the ratio of the maximum welding temperature to the solidus temperature and energy per unit length of weld. The thermal model successfully predicts the maximum welding temperatures and profiles over a range of energy levels. The mechanical behaviour after welding is correlated to the temperature distribution predicted by the model and to the observed microstructural characteristics. As welded mechanical properties of the alloy trended positively with the energy per unit length of weld, i.e. the highest joint efficiency was achieved at the highest welding temperature.     

Friction stir welding of dissimilar A319 and A356 aluminium cast alloys

Abstract

In the present investigation, the microstructure and mechanical characteristics of dissimilar A319 and A356 cast Al alloys plates joined by friction stir welding (FSW) were evaluated. The effect of tool rotational and welding speeds as well as the post-weld heat treatment (PWHT) on such properties was investigated. Post-weld heat treatment was carried out at a solutionising temperature of 540°C for 12 h followed by aging at 155°C for 6 h. For the as welded specimens, the welded zone (WZ) exhibited higher hardness values when compared with the A319 and A356 parent alloys. The peak hardness at the WZ was found to increase by increasing the tool rotational speed and/or reducing the welding speed. In contrast, the post-weld heat treated (PWHTed) specimens exhibited lower hardness values at the WZ than the parent alloys. For PWHTed specimens, the peak hardness at the WZ was found to decrease by increasing the tool rotational speed and/or reducing the welding speed. Tensile tests results demonstrate that, for the as welded specimens, the tensile fracture took place on A356 side where the hardness was minimal. While for PWHTed specimens, the fracture took place at the WZ. Increasing the tool rotational speed reducing both tensile and yield strengths, but increases the ductility of the joint.     

Experimental study on distortion of Al-6013 plate after friction stir welding

Abstract

Friction stir welding (FSW) experiments with different panel dimensions and welding parameters have been designed to study the distortion of FSW. The FSW experiments were carried out with a load control facility to make the welding parameters reliable. The distortion of FSW is much smaller than that of arc welding, but it is still very significant. Three-dimensional distortion measuring system was applied to further study distortion trends. The results show that the distortion after FSW is in saddle shape, with convex bending in longitudinal direction and concave bending in transverse direction. This distortion pattern is in contrary with that of traditional arc welding. It is also found that increasing the panel length increases the longitudinal distortion but almost do not influence the transverse distortion. Increasing the rotation speed increases both longitudinal distortion and transverse distortion. The influence of welding speed on distortion is not very clear.     

Microstructural analysis of the stir zone of Al alloy produced by friction stir spot welding

The present study applied friction spot joining (FSJ), which was recently developed as a lap joining technique of Al alloys, to two sheets of Al alloy 6061, 1 mm in thickness, and then examined the microstructural feature in the weld. The weld had the nugget-shaped stir zone around the exit hole of the probe, and the stir zone exhibited the equiaxed grain structure having finer grain size than that of the base material. The crystallographic texture analysis using electron backscattered diffraction method suggested that the material movement occurred along the rotating direction of the welding tool in the wide region including the stir zone. In the periphery of the nugget-shaped stir zone, which was characterized as the region having the finer grain size than that of the stir zone interior, any inclusions and precipitates were not found in the SEM scale. The weld was softened around the weld centre. The softening could be explained by dissolution and/or growth of the strengthening precipitates due to thermal cycle of FSJ.     

Tool design and stir zone grain size in AZ31 friction stir spot welds

Abstract

The influence of tool design and tool rotational speed variations on the torque, energy output, stir zone temperature and average grain size in the stir zones of AZ31 friction stir spot welds was investigated. The average stir zone grain size decreased by ～1 μm in AZ31 friction stir spot welds made using a three-flat/threaded tool design and tool rotational speeds of 2250 and 3000 rev min^?1. However, there was no statistically significant influence of tool design on the average grain sizes in friction stir spot welds made using tool rotational speeds of 1500 and 1000 rev min^?1. There was no evidence of grain growth in the stir zones of AZ31 friction stir spot welds. Similar torque, calculated energy output and stir zone temperature values were found in AZ31 friction stir spot welds made using threaded and three-flat threaded tool designs and tool rotational speeds from 1000 to 3000 rev min^?1.     

The effect of cryogenic CO2 cooling on corrosion behaviour of friction stir welded AA2024-T351

Abstract

Cryogenic cooling with CO₂ was applied during friction stir welding of AA2024-T351 in order to reduce the temperature increase during welding, and thus improve the corrosion resistance of the weld. The effect of cryogenic cooling on corrosion susceptibility was investigated with gel visualisation, immersion tests and local electrochemical measurements. The most susceptible area for both uncooled and cooled welds was in the heat-affected zone (HAZ) region, which showed intergranular attack. Cryogenic cooling had no detectable influence on the degree of anodic reactivity in the weld region. However, it did decrease the width of the reactive HAZ.     

Investigation of microstructure,surface and subsurface characteristics in titanium alloy friction stir welds of varied thicknesses

Abstract

Friction stir welding of titanium alloy (Ti–6Al–4V) was demonstrated on 3, 6, 9 and 12 mm thickness square groove butt joints. Complete microstructural and microhardness evaluations were conducted in addition to surface and subsurface examinations for each case. The 3 mm welds exhibited an extremely fine grained microstructure with evidence of processing temperatures below the beta transus temperature of the alloy. The 6, 9 and 12 mm samples possessed larger grains formed by a slower cooling rate from above the beta transus temperatures. The thick section weld exhibited a nearly uniform microhardness, while the thinner welds showed a slight, 6%, increase in hardness compared with the parent material.