journal article·2016-01

Joining Ti6Al4V and AISI 304 through friction stir welding of lap joints: experimental and numerical analysis

Gianluca Buffa

Publisher page

Abstract

The results of an experimental and numerical analysis on Friction Stir Welding of dissimilar lap joints made out of AISI304 and Ti-6Al-4 V thin sheets are presented. The mixed joints, welded with varying process parameters, have been characterized from a mechanical and metallurgical point of view. A numerical model able to take into account the behaviour of the two different materials has been used. The numerical results have been utilized to explain the joint properties and the occurring material flow. The effect of the heat input, tilt angle and sheets mutual position has been investigated. It is found that both hooking defects and tunnels may occur with incorrect choice of process parameters. Good nugget integrity is obtained when the titanium sheet is used as upper sheet and high heat input is conferred to the joint. Finally, welding speed influences the nugget morphology as low values contribute to minimize the formation of the hooking defect.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Advanced Welding Techniques Analysis · Welding Techniques and Residual Stresses · Aluminum Alloy Microstructure Properties

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (28)

Show source-provided references
1. Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mater Sci Eng R 50(1–2):1–7810.1016/j.mser.2005.07.001 ↗
2. Liu HJ, Fujii H, Maeda M, Nogi K (2003) Tensile properties and fracture locations of friction-stir-welded joints of 2017-T351 aluminum alloy. J Mater Process Technol 142(3):692–696. doi: 10.1016/S0924-0136(03)00806-910.1016/S0924-0136(03)00806-9 ↗
3. Reynolds AP (2000) Visualisation of material flow in autogenous friction stir welds. Sci Technol Weld Join 5(2):120–12410.1179/136217100101538119 ↗
4. Guerra M, Schmidt C, McClure JC, Murr LE, Nunes AC (2002) Flow patterns during friction stir welding. Mater Charact 49(2):95–10110.1016/S1044-5803(02)00362-5 ↗
5. Bilgin MB, Meran C (2012) The effect of tool rotational and traverse speed on friction stir weldability of AISI 430 ferritic stainless steels. Mater Des 33:376–383. doi: 10.1016/j.matdes.2011.04.01310.1016/j.matdes.2011.04.013 ↗
6. Mironov S, Sato YS, Kokawa H (2009) Development of grain structure during friction stir welding of pure titanium. Acta Mater 57(15):4519–4528. doi: 10.1016/j.actamat.2009.06.02010.1016/j.actamat.2009.06.020 ↗
7. P’ng D, Molian P (2008) Q-switch Nd: YAG laser welding of AISI 304 stainless steel foils. Mater Sci Eng A-Struct 486(1–2):680–685. doi: 10.1016/j.msea.2007.08.06310.1016/j.msea.2007.08.063 ↗
8. Bhadeshia HKDH, Debroy T (2009) Critical assessment: friction stir welding of steels. Sci Technol Weld Join 14(3):193–19610.1179/136217109X421300 ↗
9. Kina AY, Souza VM, Tavares SSM, Pardal JM, Souza JA (2008) Microstructure and intergranular corrosion resistance evaluation of AISI 304 steel for high temperature service. Mater Charact 59(5):651–655. doi: 10.1016/j.matchar.2007.04.00410.1016/j.matchar.2007.04.004 ↗
10. Miyazawa T, Iwamoto Y, Maruko T, Fujii H (2012) Friction stir welding of 304 stainless steel using Ir based alloy tool. Sci Technol Weld Join 17(3):207–21210.1179/1362171811Y.0000000096 ↗
11. Reynolds AP, Tang W, Gnaupel-Herold T, Prask H (2003) Structure, properties, and residual stress of 304L stainless steel friction stir welds. Scripta Mater 48(9):1289–129410.1016/S1359-6462(03)00024-1 ↗
12. Sato YS, Nelson TW, Sterling CJ (2005) Recrystallization in type 304L stainless steel during friction stirring. Acta Mater 53(3):637–645. doi: 10.1016/j.actamat.2004.10.01710.1016/j.actamat.2004.10.017 ↗
13. Zhang Y, Sato YS, Kokawa H, Park SHC, Hirano S (2008) Microstructural characteristics and mechanical properties of Ti-6Al-4V friction stir welds. Mater Sci Eng A-Struct 485(1–2):448–455. doi: 10.1016/j.msea.2007.08.05110.1016/j.msea.2007.08.051 ↗
14. Mironov S, Zhang Y, Sato YS, Kokawa H (2008) Development of grain structure in beta-phase field during friction stir welding of Ti-6Al-4V alloy. Scripta Mater 59(1):27–30. doi: 10.1016/j.scriptamat.2008.02.01410.1016/j.scriptamat.2008.02.014 ↗
15. Pasta S, Reynolds AP (2008) Residual stress effects on fatigue crack growth in a Ti-6Al-4V friction stir weld. Fatigue Fract Eng M 31(7):569–580. doi: 10.1111/j.1460-2695.2008.01258.x10.1111/j.1460-2695.2008.01258.x ↗
16. Fazel-Najafabadi M, Kashani-Bozorg SF, Zarei-Hanzaki A (2011) Dissimilar lap joining of 304 stainless steel to CP-Ti employing friction stir welding. Mater Des 32(4):1824–1832. doi: 10.1016/j.matdes.2010.12.02610.1016/j.matdes.2010.12.026 ↗
17. Fazel-Najafabadi M, Kashani-Bozorg SF, Zarei-Hanzaki A (2010) Joining of CP-Ti to 304 stainless steel using friction stir welding technique. Mater Des 31(10):4800–480710.1016/j.matdes.2010.05.003 ↗
18. Buffa G, Hua J, Shivpuri R, Fratini L (2006) A continuum based FEM model for friction stir welding–model development. Mat Sci Eng A-Struct 419(1–2):389–396. doi: 10.1016/j.msea.2005.09.04010.1016/j.msea.2005.09.040 ↗
19. Buffa G, Fratini L (2009) Friction stir welding of steels: process design through continuum based FEM model. Sci Technol Weld Join 14(3):239–246. doi: 10.1179/136217109x42132810.1179/136217109X421328 ↗
20. Buffa G, Ducato A, Fratini L (2013) FEM based prediction of phase transformations during friction stir welding of Ti6Al4V titanium alloy. Mater Sci Eng A 581:56–6510.1016/j.msea.2013.06.009 ↗
21. Fratini L, Buffa G, Lo Monaco L (2010) Improved FE model for simulation of friction stir welding of different materials. Sci Technol Weld Join 15(3):199–207. doi: 10.1179/136217109x1266504820757510.1179/136217110X12665048207575 ↗
22. Buffa G, Ducato A, Fratini L (2013) Dissimilar material lap joints by friction stir welding of steel and titanium sheets: Process modeling. pp 491–49810.1063/1.4806866 ↗
23. Buffa G, Fratini L, Micari F, Settineri L On the choice of tool material in friction stir welding of titanium alloys. In: Transactions of the North American Manufacturing Research Institution of SME 2012. pp 785–794
24. Zhang Y, Sato YS, Kokawa H, Park SHC, Hirano S (2008) Stir zone microstructure of commercial purity titanium friction stir welded using pcBN tool. Mat Sci Eng A-Struct 488(1–2):25–30. doi: 10.1016/j.msea.2007.10.06210.1016/j.msea.2007.10.062 ↗
25. Colegrove PAS, H.R., Hyoe T (2004) Development of the Trivex™ Friction Stir Welding tool for making lap welds. 5th International Symposium on Friction Stir Welding
26. Buffa G, Campanile G, Fratini L, Prisco A (2009) Friction stir welding of lap joints: influence of process parameters on the metallurgical and mechanical properties. Mat Sci Eng A-Struct 519(1–2):19–26. doi: 10.1016/j.msea.2009.04.04610.1016/j.msea.2009.04.046 ↗
27. Dubourg L, Merati A, Jahazi M (2010) Process optimisation and mechanical properties of friction stir lap welds of 7075-T6 stringers on 2024-T3 skin. Mater Des 31(7):3324–333010.1016/j.matdes.2010.02.002 ↗
28. Ericsson M, Jin LZ, Sandström R (2007) Fatigue properties of friction stir overlap welds. Int J Fatigue 29(1):57–6810.1016/j.ijfatigue.2006.02.052 ↗