Thermal Modeling of Tool-Work Interface during Friction Stir Welding Process

Russian Journal of Non-Ferrous Metals - Adequate heat input provided by the proper combination of friction stir welding (FSW) parameters is critical to sound welding. Optimum parameter setting...     

Investigation on material mixing during FSW of AA7475 to AISI304

AA7xxx and AISI304 stainless steel (SS) are employed in promising applications. Al alloy-to-SS dissimilar joining is difficult and challenging. Major challenge in the joining of these alloys is the difficulty in mixing of these materials which possess exotic and widely distant properties. AA7475-T761 is a high strength aluminum alloy which is used in key aircraft components. Maiden AA7475-T761 and AISI304 dissimilar joints were fabricated using friction stir welding. Welding was performed with tool having pin diameter of 4 mm and offset of 1.25 mm on Aluminum side. Tool rotational speed, traverse speed and shoulder diameter were varied in the range of 450–560 rpm, 50–63 mm/min, and 12–14 mm, respectively. Mechanical tests showed that joint formed with 14 mm diameter, 560 rpm and 50 mm/min gave the best joint efficiency of 71% of Al-alloy at 7.31% elongation. The materials mixing issues during processing were analyzed with SEM mircrostructure and fractography. Metallography also revealed that offset is critical to the success of joint as it controlled effective mixing of SS and Al in 15 and 85 vol.%, respectively. SS fragments from thermo-mechanically affected zone of SS were found to be partially sheared forming layer of thickness equal to tool traverse/revolution ratio.     

Multipass FSP on AA6063-T6 Al: Strategy to fabricate surface composites

Surface composites were fabricated on AA6063-T6 base metal using silicon carbide (SiC) reinforcement particles by friction stir processing (FSP). Influence of multiple FSP passes was investigated on the SiC particle distribution, processed zone dimensions, and microhardness of fabricated composites. The rotational speed, traverse speed, and tool tilt were kept constant and the numbers of passes were varied at 2, 4, 6, and 8. The particle distribution in processed zone was analyzed using OM and SEM, while microhardness were evaluated by Vickers indentation test. The results reveal that with increase in FSP passes there is increase in processed zone dimensions and elimination of defects such as agglomeration of particles and void. The microhardness of reinforced region was increased uniformly with increasing passes which is attributed to homogeneous distribution of reinforcement particles. The peak microhardness value of 81.9 Hv was obtained in sample which is processed with eight numbers of FSP passes. Processed zone indicates good bonding with the substrate and grain refinement.