Investigations on the effects of friction stir welding parameters on intermetallic and defect formation in joining aluminum alloy to mild steel |
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| Affiliation: | 1. Université catholique de Louvain, Institute of Mechanics, Materials and Civil Engineering, IMAP, 1348 Louvain-la-Neuve, Belgium;2. Electron Microscopy for Materials Science (EMAT), Department of Physics, University of Antwerp, Groenenborgerlaan 171, B-2020 Antwerp, Belgium;1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, 800 Dong Chuan Rd., Shanghai, 200240, China;2. S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, 2350 Hayward Rd., Ann Arbor, MI, 48109, USA;3. China Academy of Launch Vehicle Technology, 1 S. Dahongmen Rd., Beijing, 100076, China;4. Capital Aerospace Machinery Company, E. Ji8ingbei Rd., Beijing, 100076, China;5. Department of Materials Science and Engineering, the Ohio State University, 2041 N. College Rd., Columbus, OH, 43210, USA;1. Department of Mechanical Engineering, Government Engineering College, Thrissur 680009, Kerala, India;2. Department of Mechanical Engineering, Coimbatore Institute of Technology, Coimbatore 641014, Tamil Nadu, India;1. High Temperature Energy Materials Research Center, Korea Institute of Science and Technology, Seoul, 136-791, Republic of Korea;2. School of Metallurgy and Materials Engineering, University of Tehran, Tehran, Iran;3. Science and Research Branch, Azad University, P.O. Box: 14515/775, Tehran, Iran;4. Nano-Bio Electron Microscopy Research Team, Korea Basic Science Institute, Daejeon, 305-333, Republic of Korea |
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| Abstract: | Joints of Al 5186 to mild steel were performed by using friction stir welding (FSW) technique. The effects of various FSW parameters such as tool traverse speed, plunge depth, tilt angle and tool pin geometry on the formation of intermetallic compounds (IMCs), tunnel formation and tensile strength of joints were investigated. At low welding speeds due to the formation of thick IMCs (which was characterized as Al6Fe and Al5Fe2) in the weld zone the tensile strength of joints was very poor. Even at low welding speeds the tunnel defect was formed. As the welding speed increased, the IMCs decreased and the joint exhibited higher tensile strength. The tunnel defect could not be avoided by using cylindrical 4 mm and 3 mm pin diameter. By using a standard threaded M3 tool pin the tunnel was avoided and a bell shape nugget formed. Therefore tensile strength of the joint increased to 90% of aluminum base alloy strength. At higher welding speed and lower tool plunge depth, the joint strength decreased due to lack of bonding between aluminum and steel. Based on the findings, a FSW window has been developed and presented. |
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