Influence of a Stationary Shoulder Friction Stir Welding Tool on the Mechanical and Corrosion Properties of AA2024 Aluminum Alloy Joints at Different Parameter Values
Source abstract
Abstract
Sound weld joints of similar AA2024 aluminum alloy plates of 6 mm were achieved unprecedentedly at different rotational (386-1216 rpm) and traverse speeds (13-90 mm/min) using an indigenously developed stationary shoulder friction stir welding (SSFSW) tool. Results indicate a smooth and bowl-shaped symmetrical nugget zone (NZ) with fine equiaxed grains. The grains as well as the nugget zone width vary with the speed variation. A change of 16% in the width of NZ is observed with an increase in traverse speed from 13 to 90 mm/min. The SSFSW tool reduces the width of the weakest region of the weld joint, known as the heat-affected zone, by almost 50%. The SSFSW joint produced at 931-90 mm/min shows the highest value (101 HV) of the minimum hardness region as compared to other parameters. The SSFSW tool shifts the weakest region toward the NZ, as substantiated by the fracture location of the tensile samples. In addition, SSFSW joints show higher corrosion resistance in NZ due to recrystallized fine grains as compared to HAZ. The SSFSW tool reduces the width of the most severely corrosion-affected region and, hence, improves the corrosion resistance of the joint.
Source: expertdata · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Advanced Welding Techniques Analysis · Metal Forming Simulation Techniques · Aluminum Alloy Microstructure Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (38)
Show source-provided references
1. P. Goel, N.Z. Khan, Z.A. Khan, A. Ahmari, N. Gangil, M.H. Abidi, and A.N. Siddiquee, Investigation on Material Mixing during FSW of AA7475 to AISI304, Mater. Manuf. Processes, 2019, 34(2), p 192–200.10.1080/10426914.2018.1544717 ↗
2. N. MohdSelamat, A. Hossein Baghdadi, Z. Sajuri, A.H. Kokabi, and S. Junaidi, Effect of Rolling on Strength of Friction Stir Welded Joint of Aluminium Alloys, Jurnal Kejuruteraan, 2018, sil(6), p 9–15. https://doi.org/10.17576/jkukm-2018-si1(6)-0210.17576/jkukm-2018-si1(6)-02 ↗
3. N.F.M. Selamat, A.H. Baghdadi, Z. Sajuri, S. Junaidi, and A.H. Kokabi, Rolling Effect on Dissimilar Friction Stir Welded AA5083-AA6061 Aluminium Alloy Joints, J. Adv. Manuf. Technol., 2020, 14, p 49–62.
4. N.F.M. Selamat, A.H. Baghdadi, Z. Sajuri, and A.H. Kokabi, Weldability and Mechanical Properties of Dissimilar Al-MgSi to Pure Aluminium and Al-Mg Using Friction Stir Welding Process, J Teknol, 2019, 81(1), p 143–149.
5. K.K. Kumar, A. Kumar, and M.V.N.V. Satyanarayana, Enhancing Corrosion Resistance and Mechanical Properties of Dissimilar Friction Stir Welded 5083–6061 Aluminium Alloys Using External Cooling Environment, Proceed. Instit. Mech. Eng., Part L: J. Mater.: Design Appl., 2021, 235(12), p 2692–2708.
6. X. Meng, Y. Huang, J. Cao, J. Shen, and J.F. dos Santos, Recent Progress on Control Strategies for Inherent Issues in Friction Stir Welding, Prog Mater Sci, 2021, 115, p 100706.10.1016/j.pmatsci.2020.100706 ↗
7. X. Meng, Y. Xie, S. Sun, X. Ma, L. Wan, J. Cao, and Y. Huang, Lightweight Design: Friction-Based Welding between Metal and Polymer, Acta. Metallurgica. Sinica (English Letters), 2023, 36(6), p 881–898.10.1007/s40195-023-01552-5 ↗
8. S. Rajesh and V. Badheka, Influence of Heat Input/Multiple Passes and Post Weld Heat Treatment on Strength/Electrochemical Characteristics of Friction Stir Weld Joint, Mater. Manuf. Processes, 2018, 33(2), p 156–164.10.1080/10426914.2017.1279310 ↗
9. A.H. Baghdadi, Z. Sajuri, A. Keshtgar, N.M. Sharif, and A. Rajabi, Mechanical Property Improvement in Dissimilar Friction Stir Welded Al5083/Al6061 Joints: Effects of Post-Weld Heat Treatment and Abnormal Grain Growth, Materials, 2022, 15(1), p 288.10.3390/ma15010288 ↗
10. J.P. Martin, “Stationary Shoulder Friction Stir Welding,” Proceedings of the 1st International Joint Symposium on Joining and Welding, Woodhead Publishing Limited, 2013, p 477–482, doi:https://doi.org/10.1533/9781782421641.477.10.1533/9781782421641.477 ↗
11. N. Sharma, A.N. Siddiquee, Z.A. Khan, and M.T. Mohammed, Material Stirring during FSW of Al–Cu: Effect of Pin Profile, Mater. Manuf. Processes, 2018, 33(7), p 786–794.10.1080/10426914.2017.1388526 ↗
12. Y. Huang, X. Meng, Y. Xie, L. Wan, Z. Lv, J. Cao, and J. Feng, Friction Stir Welding/Processing of Polymers and Polymer Matrix Composites, Compos Part A Appl Sci Manuf, 2018, 105, p 235–257. https://doi.org/10.1016/j.compositesa.2017.12.00510.1016/j.compositesa.2017.12.005 ↗
13. Y. Huang, X. Meng, Y. Xie, J. Li, and L. Wan, Joining of Carbon Fiber Reinforced Thermoplastic and Metal via Friction Stir Welding with Co-Controlling Shape and Performance, Compos Part A Appl Sci Manuf, 2018, 112, p 328–336.10.1016/j.compositesa.2018.06.027 ↗
14. S. Sinhmar and D.K. Dwivedi, Mechanical Behavior of FSW Joint Welded by a Novel Designed Stationary Shoulder Tool, Journal of Materials Processing Tech., 2020, 277, p 116482. https://doi.org/10.1016/j.jmatprotec.2019.11648210.1016/j.jmatprotec.2019.116482 ↗
15. J.P. Martin, C. Stanhope, and S. Gascoyne, Novel Techniques for Corner Joints Using Friction Stir Welding, Friction Stir Welding and Proceesing VI, 2011 https://doi.org/10.1002/978111806230210.1002/9781118062302 ↗
16. Y. Chen, H. Li, X. Wang, H. Ding, and F. Zhang, A Comparative Investigation on Conventional and Stationary Shoulder Friction Stir Welding of Al-7075 Butt-Lap Structure, Metals (Basel), 2019, 9(12), p 1264.10.3390/met9121264 ↗
17. A. Abdollahzadeh, B. Bagheri, M. Abbasi, F. Sharifi, S.E. Mirsalehi, and A.O. Moghaddam, A Modified Version of Friction Stir Welding Process of Aluminum Alloys: Analyzing the Thermal Treatment and Wear Behavior, Proceed. Institut. Mech. Eng., Part L: J. Mater.: Design App., 2021, 235(10), p 2291–2309.
18. W. He, M. Li, Q. Song, J. Liu, and W. Hu, Efficacy of External Stationary Shoulder for Controlling Residual Stress and Distortion in Friction Stir Welding, Transact. Indian Instit. Metals, 2019, 72(5), p 1349–1359. https://doi.org/10.1007/s12666-019-01630-210.1007/s12666-019-01630-2 ↗
19. W. He, J. Liu, W. Hu, G. Wang, and W. Chen, Controlling Residual Stress and Distortion of Friction Stir Welding Joint by External Stationary Shoulder, High Temp. Mater. Processes (London), 2019, 2019(38), p 662–671.10.1515/htmp-2019-0005 ↗
20. V. Patel, W. Li, and Y. Xu, Stationary Shoulder Tool in Friction Stir Processing: A Novel Low Heat Input Tooling System for Magnesium Alloy, Materials and Manufacturing Processes, 2018, 34(2), p 177–182. https://doi.org/10.1080/10426914.2018.154471610.1080/10426914.2018.1544716 ↗
21. Z. Xu, Z. Li, Z. Lv, and L. Zhang, Effect of Welding Speed on Joint Features and Lap Shear Properties of Stationary Shoulder FSLWed Alclad 2024 Al Alloy, J Mater Eng Perform, 2017, 26(3), p 1358–1364.10.1007/s11665-017-2527-8 ↗
22. Z. Zhou, Y. Yue, S. Ji, Z. Li, and L. Zhang, Effect of Rotating Speed on Joint Morphology and Lap Shear Properties of Stationary Shoulder Friction Stir Lap Welded 6061–T6 Aluminum Alloy, Int. J. Adv. Manuf. Technol., 2017, 88(5–8), p 2135–2141. https://doi.org/10.1007/s00170-016-8924-610.1007/s00170-016-8924-6 ↗
23. H. Yang, H. Zhao, X. Xu, L. Zhou, H. Zhao, and H. Liu, Effect of Stirring Pin Rotation Speed on Microstructure and Mechanical Properties of 2A14-T4 Alloy T-Joints Produced by Stationary Shoulder Friction Stir Welding, Materials, 2021, 14(8), p 1938.10.3390/ma14081938 ↗
24. J. You, Y. Zhao, C. Dong, Y. Yi, and Y. Su, Numerical Modeling of Multiphysics Field in Conventional and Stationary Shoulder Friction Stir Welding of Al-Cu Alloy, J Mater Eng Perform, 2021, 30(4), p 2751–2760. https://doi.org/10.1007/s11665-021-05642-210.1007/s11665-021-05642-2 ↗
25. C. Zhang, Y. Cao, G. Huang, Q. Zeng, and Y. Zhu, Influence of Tool Rotational Speed on Local Microstructure, Mechanical and Corrosion Behavior of Dissimilar AA2024/7075 Joints Fabricated by Friction Stir Welding, J. Manuf. Process., 2019, 2020(49), p 214–226.
26. D. Sejani, W. Li, and V. Patel, Stationary Shoulder Friction Stir Welding-Low Heat Input Joining Technique: A Review in Comparison with Conventional FSW and Bobbin Tool FSW, Critical Rev. Solid State Mater. Sci., 2021 https://doi.org/10.1080/10408436.2021.193572410.1080/10408436.2021.1935724 ↗
27. S. Sinhmar and D.K. Dwivedi, Art of Friction Stir Welding to Produce Weld Joint without Rotation of Shoulder with Narrow Heat- Affected Zone and High Corrosion Resistance, Sci. Technol. Weld. Join, 2020, 25(6), p 490–495. https://doi.org/10.1080/13621718.2020.174651210.1080/13621718.2020.1746512 ↗
28. K.P. Mehta and V.J. Badheka, Effects of Tilt Angle on the Properties of Dissimilar Friction Stir Welding Copper to Aluminum, Mater. Manuf. Process., 2016, 31(3), p 255–263.10.1080/10426914.2014.994754 ↗
29. A. Hossein Baghdadi, N. Fazilah, M. Selamat, Z. Sajuri, and A.H. Kokabi, Effect of Travel Speed on Quality and Welding Efficiency of Friction Stir Welded AZ31B Magnesium Alloy, International Journal of Engineering & Technology, 2018, 7, p 94–99, www.sciencepubco.com/index.php/IJET.10.14419/ijet.v7i3.17.16629 ↗
30. W. Li, P.L. Niu, S.R. Yan, V. Patel, and Q. Wen, Improving Microstructural and Tensile Properties of AZ31B Magnesium Alloy Joints by Stationary Shoulder Friction Stir Welding, J. Manuf. Process., 2019, 37, p 159–167.10.1016/j.jmapro.2018.11.014 ↗
31. H. Wu, Y.C. Chen, D. Strong and P. Prangnell, Stationary Shoulder FSW for Joining High Strength Aluminum Alloys, J. Mater. Process. Technol., 2015, 221, p 187–196.10.1016/j.jmatprotec.2015.02.015 ↗
32. D. Li, X. Yang, L. Cui, F. He, and H. Shen, Effect of Welding Parameters on Microstructure and Mechanical Properties of AA6061-T6 Butt Welded Joints by Stationary Shoulder Friction Stir Welding, Mater. Des., 2014, 64, p 251–260.10.1016/j.matdes.2014.07.046 ↗
33. O.S. Salih, N. Neate, H. Ou, and W. Sun, Influence of Process Parameters on the Microstructural Evolution and Mechanical Characterisations of Friction Stir Welded Al-Mg-Si Alloy, J Mater Process Technol, 2020, 2020(275), p 116366.10.1016/j.jmatprotec.2019.116366 ↗
34. M. Zhang, M. Paidar, O.O. Ojo, S. Mehrez, S. Narayanasamy, A.M. Zain, and V. Mohanavel, Impact of Multiple FSP Passes on Structure, Mechanical, Tribological and Corrosion Behaviors of AA6061/316 Stainless-Steel Reinforced Al Matrix Composites, Surf Coat Technol, 2022, 447, p 128801.10.1016/j.surfcoat.2022.128801 ↗
35. A. Hughes E., N. Birbilis, J. M.C., S. J., X. Zhou, and G. E., High Strength Al-Alloys: Microstructure, Corrosion and Principles of Protection, Recent Trends in Processing and Degradation of Aluminium Alloys, Zaki Ahmad, Ed., InTech, 2011, p 223–262, doi:https://doi.org/10.5772/18766.10.5772/18766 ↗
36. J.R. Davis, “Corrosion of Aluminum and Aluminum Alloys,” Asm International, 1999.10.31399/asm.tb.caaa.9781627082990 ↗
37. T.S. Srivatsan, T.S. Sudarshan, and G.E. Bobeck, Corrosion Behaviour of a Quaternary AI-Li-Cu-Mg Alloy in 3.5% NaCI Solution, Br. Corr. J., 2013, 25(1), p 39–45.10.1179/bcj.1990.25.1.39 ↗
38. S. Liu, M. Paidar, O. OladimejiOjo, M.Š Poková, S. Mehrez, A.M. Zain, Q. Zhao, and J. Wang, Friction Stir Processing of Hybridized AZ31B Magnesium Alloy-Based Composites by Adding CeO2 and ZrO2 powders: Mechanical Wear, and Corrosion Behaviors, J. Mater. Res. Technol., 2023, 24, p 1949–1972.10.1016/j.jmrt.2023.03.028 ↗