The effect of single-pass (SP) and double-pass (DP) friction stir welding (FSW) on metallographic and mechanical properties of joints was investigated in this study. Uniform temperature distribution across the weld cross-section was obtained during double-pass FSW (DP-FSW). SEM and EDS analyses showed an increase in the fraction of second phase particles (SPPs) and the formation of new SPPs by DP-FSW. An increase in hardness values by 13.3% and a severe decrease in joint efficiency by 46.7% were observed by DP-FSW. Fractography examination of fractured surfaces of welded specimens showed a quasi-cleavage and ductile mode of failure in SP and DP joints, respectively. The potentiodynamic polarisation test of base metal and welded specimens indicated the high corrosion resistance of welded specimens.
MajeedTMehtaYSiddiqueeAN.Challenges in joining of unequal thickness materials for aerospace applications: a review. Proc Inst Mech Eng, Part L J Mater Design Appl. 2021; 235(4):934–945.
2.
BirolYKasmanS.Effect of welding parameters on microstructure and mechanical properties of friction stir welded ENAW5083 H111 plates. Mater Sci Technol. 2013; 29:1354–1362.
3.
GoelPKhanNZKhanZAInvestigation on material mixing during FSW of AA7475 to AISI304. Mater Manuf Processes. 2019; 34(2):192–200.
4.
TavaresSMOdos SantosJFde CastroPMST.Friction stir welded joints of Al–Li alloys for aeronautical applications: butt-joints and tailor welded blanks. Theor Appl Fract Mech. 2013; 65:8–13.
5.
SinkeJIaconoCZadpoorA.Tailor made blanks for the aerospace industry. IntJ Mater Form. 2010; 3:849–852.
6.
VilacaPSantosJPGoisAJoining aluminum alloys dissimilar in thickness by friction stir welding and fusion processes. Weld World. 2005; 49:56–62.
7.
SheikhiSSantosJFD.Effect of process parameter on mechanical properties of friction stir welded tailored blanks from aluminium alloy 6181-T4. Sci Technol Weld Join. 2207; 12:370–375.
8.
TavaresSMOSantosJFCastroPM.Friction stir welded joints of Al–Li alloys for aeronautical applications: butt-joints and tailor welded blanks. Theor Appl Fract Mech. 2013; 65:8–13.
9.
BrownRTangWReynoldsAP.Multi-pass friction stir welding in alloy 7050-T7451: effects on weld response variables and on weld properties. Mater Sci Eng A. 2009; 513:115–121.
10.
RohillaPKumarN.Experimental investigation of tool geometry on mechanical properties of friction stir welding of AA6061. Int J Innov Technol Explor Eng. 2013; 3(3):56–61.
11.
SathariNAAShahLHRazaliAR.Investigation of single-pass/double-pass techniques on friction stir welding of aluminium. J Mech Eng Sci (JMES). 2014; 7:1053–1061. DOI:10.15282/jmes.7.2014.4.0102.
12.
MehraSDhandaPKhannaREffect of tool on tensile strength in single and double sided friction stir welding. Int J Sci Eng Res. 2012; 3(11):1–6.
13.
HeDYangKLiMComparison of single and double pass friction stir welding of skin-stringer aviation aluminium alloy. Sci Technol Weld Join. 2013; 18:610–615.
14.
KarASuwasSKailasSV.Two-pass friction stir welding of aluminum alloy to titanium alloy: a simultaneous improvement in mechanical properties. Mater Sci Eng A. 2018; 733:199–210. DOI:10.1016/j.msea.2018.07.057.
15.
YangCWangBBYuBHHigh-cycle fatigue and fracture behavior of double-side friction stir welded6082Al ultra-thick plates. Eng Fract Mech. 2020; 226:106887. DOI:10.1016/j.engfracmech.2020.106887.
16.
DuCWangXPanQCorrelation between microstructure and mechanical properties of 6061-T6 double-side FSW joint. J Manuf Process. 2019; 38(2019):122–134. DOI:10.1016/j.jmapro.2019.01.010.
17.
DarmadiDBTaliceM.Improving the strength of friction stir welded joint by double side friction welding and varying pin geometry. Eng Sci Technol Int J. 2021; 24:637–647.
18.
SahuPKPalS.Mechanical properties of dissimilar thickness aluminium alloy weld by single/double pass FSW. J Mater Process Technol. 2017; 243:442–455.
19.
BuffaGFratiniLShivpuriR.Finite element studies on friction stir welding processes of tailored blanks. Comput Struct. 2008; 86:181–189.
20.
Richter-TrummerVSuzanoEBeltraoMInfluence of the FSW clamping force on the final distortion and residual stress field. Mater Sci Eng A. 2012; 538:81–88.
21.
SalihOSNeateNOuHInfluence of process parameters on the microstructural evolution and mechanical characterizations of friction stir welded Al-Mg-Si alloy. J Mater Process Tech. 2020; 275:116366.
22.
ZadpoorAASinkeJBenedictusRMechanical properties and microstructure of friction stir welded tailor-made blanks. Mater Sci Eng A. 2008; 494:281–290.
23.
MadhuHCAjay KumarPPeruguCSMicrostructure and mechanical properties of friction stir process derived Al-TiO2 nanocomposite. J Mater Eng Perform. 2018; 27(3):1318–1326.
24.
SatoYKokawaHEnomotoMMicrostructural evolution of 6063 aluminum during friction-stir welding. Metall Mater Trans A. 1999; 30:2429–2437.
25.
FirouzdorVKouS.Al-to-Cu friction stir lap welding. Metall Mater Trans A. 2012; 43:303–314.
26.
MishraRSMaZY.Friction stir welding and processing. Mater Sci Eng R. 2005; 50:1–78.
27.
MilagreMXMogiliNVDonatusUOn the microstructure characterization of the AA2098-T351 alloy welded by FSW. Mater Charact. 2018; 140:233–246. DOI:10.1016/j.matchar.2018.04.015.
28.
MajeedTAnsariNMehtaYAl alloy tailor-welded blanks fabrication via friction stir welding: effect of shoulder size. J Manuf Sci Eng. 2022; 144:041009-1.
29.
Xia-weiLDa-tongZChengQMicrostructure and mechanical properties of dissimilar pure copper/1350 aluminum alloy butt joints by friction stir welding. Trans Nonfer Metals Soc China. 2012; 22:1298–1306.
30.
SahuPKPalS. Fatigue life behaviour of single and double pass friction stir welded different thickness AA1050 joint). 6th international & 27th All India Manufacturing technology, design and research conference (AIMTDR–2016), college of engineering. Pune, Maharashtra, India; 2018, p. 1141–1145, ISBN: 978-93-86256-27-0. DOI:10.13140/RG.2.2.26496.53768
31.
LiuHJFujiiHMaedaMTensile properties and fracture locations of friction-stir-welded joints of 2017-T351 aluminum alloy. J Mater Process Technol. 2003; 142:692–696.
32.
GargABhattacharyaA.Influence of Cu powder on strength, failure and metallurgical characterization of single, double pass friction stir welded AA6061-AA7075 joints. Mater Sci Eng A. 2019; 759:661–679.
33.
GavrasAGChenelleBFLadosDA.Effects of microstructure on the fatigue crack growth behavior of light metals and design considerations. Rev Matér. 2010; 15:319–329.
34.
BalasubramanianNMishraRSKrishnamurthyK.Process forces during friction stir channeling in an aluminum alloy. J Mater Process Technol. 2011; 211:305–331.
MajeedTMehtaYSiddiqueeAN.Precipitation-dependent corrosion analysis of heat treatable aluminum alloys via friction stir welding, a review. Proc IMechE Part C J Mech Eng Sci. 2021; 235(24):7600–7626. DOI:10.1177/09544062211003609.
37.
ProtonVAlexisJAndrieuECharacterisation and understanding of the corrosion behaviour of the nugget in a 2050 aluminium alloy friction stir welding joint. Corros Sci. 2013; 73:130–142.
38.
RalstonKDFabijanicDBirbilisN.Effect of grain size on corrosion of high purity aluminium. Electrochim Acta. 2011; 56:1729–1736.
