In this research, 8-mm-thick plates of 25%SiC/2124Al composite have been joined successfully by using an un-threaded WC–Co tool which showed minimal tool wear. Decreasing the rotational and advancing speeds is a key factor to obtain successful joints. Defect-free welds, and a joint efficiency (100UTSjoint/UTSBaseMaterial) of up to 97%, can be achieved if a high forge force, Fz, (above some 15 kN) is reached. Proportionality between the torque, M, and Fz is observed. High Fz values, and corresponding M, lead to high values of the total energy per unit length of weld, Htot, supplied by the tool to the workpiece. It is proposed that most of this energy is spent in plastic deformation of the high strength composite.
PradoAR, MurrEL, ShindoJD, Tool wear in friction-stir welding of aluminum alloy 6061 + 20% Al2O3: a preliminary study. Scr Mater. 2001; 45:75–80. doi: 10.1016/S1359-6462(01)00994-0
2.
ShindoJD, RiveraRA, MurrEL. Shape optimization for tool wear in the friction-stir welding of cast AI359–20% SiC MMC. J Mater Sci.2002; 37:4999–5005. doi: 10.1023/A:1021023329430
3.
PradoAR, MurrEL, SotoFK, Self-optimization in tool wear for friction-stir welding of Al 6061+20% Al2O3 MMC. Mater Sci Eng A. 2003; 349:156–165. doi: 10.1016/S0921-5093(02)00750-5
4.
CavaliereP, CerriE, MarzoliL, Friction stir welding of ceramic particle reinforced aluminium based metal matrix composites. Appl Compos Mater. 2004; 11:247–258. doi: 10.1023/B:ACMA.0000035478.71092.ec
5.
NakataK, InokiS, NaganoY, Friction stir welding of Al2O3 particulate 6061 Al alloy composite. Mater Sci Forum. 2003; 426–432:2873–2878. doi: 10.4028/www.scientific.net/MSF.426-432.2873
6.
MarzoliML, StrombeckAV, dos SantosFJ, Friction stir welding of an AA6061/Al2O3/20p reinforced alloy. Compos Sci Technol.2006; 66:363–371. doi: 10.1016/j.compscitech.2005.04.048
7.
LiuJH, FujiiH, NogiK. Wear behavior of hard alloy tools in the friction stir welding of AC4A + 30 vol.% SiCp aluminum matrix composite. Proceedings of the 5th International Conference on Friction Stir Welding; Sept 14–16; Metz, France; 2004, Session 3A.
8.
LiuHJ, FengJC, FujiiH, Wear characteristics of a WC–Co tool in friction stir welding of AC4A+30vol.% SiCp composite. Int J Mach Tools Manuf. 2005; 45:1635–1639. doi: 10.1016/j.ijmachtools.2004.11.026
9.
FernandezJG, MurrEL. Characterization of tool wear and weld optimization in the friction-stir welding of cast aluminum 359+20% SiC metal-matrix composite. Mater Charact. 2004; 52:65–75. doi: 10.1016/j.matchar.2004.03.004
10.
AmirizadM, KokabiHA, Abbasi GharachehM, Evaluation of microstructure and mechanical properties stir welded A356+15%SiCp cast composite. Mater Lett. 2006; 60:565–568. doi: 10.1016/j.matlet.2005.09.035
11.
UzunH. Friction stir welding of SiC particulate reinforced AA2124 aluminium alloy matrix composite. Mater Des. 2007; 28:1440–1446. doi: 10.1016/j.matdes.2006.03.023
12.
CeschiniL, BoromeiI, MinakG, Microstructure, tensile and fatigue properties of AA6061/20vol.%Al2O3p friction stir welded joints. Compos A. 2007; 38:1200–1210. doi: 10.1016/j.compositesa.2006.06.009
FengHA, XiaoLB, MaYZ. Effect of microstructural evolution on mechanical properties of friction stir welded AA2009/SiCp composite. Compos Sci Technol. 2008; 68:2141–2148. doi: 10.1016/j.compscitech.2008.03.010
15.
NamiH, AdgiH, SharifitabarM, Microstructure and mechanical properties of friction stir welded Al/Mg2Si metal matrix cast composite. Mater Des. 2011; 32:976–983. doi: 10.1016/j.matdes.2010.07.008
16.
BozkurtY. Weldability of metal matrix composites plates by friction stir welding at low welding parameters. Mater Technol. 2011; 45:407–412.
17.
BozkurtY, UzunH, SalmanS. Microstructure and mechanical properties of friction stir welded particulate reinforced AA2124/SiC/25p–T4 composite. Compos J Mater. 2011; 0:1–9.
18.
BozkurtY, KentliA, UzunH, Experimental investigation and prediction of mechanical properties of friction stir welded aluminium metal matrix composite plates. Mater Sci (Medžiagotyra). 2012; 18:336–340.
19.
PraterT, StraussA, CookG, A comparative evaluation of the wear resistance of various tool materials in friction stir welding. J Mater Eng Perform. 2013; 22:1807–1813. doi: 10.1007/s11665-012-0468-9
20.
CioffiF, FernándezR, GestoD, Friction stir welding of thick plates of aluminum alloy matrix composite with a high volume fraction of ceramic reinforcement. Compos A. 2013; 54:117–123. doi: 10.1016/j.compositesa.2013.07.011
21.
MuruganN, Ashok KumarB. Prediction of tensile strength of friction stir welded stir cast AA6061-T6/AlNp composite. Mater Des. 2013; 51:998–1007. doi: 10.1016/j.matdes.2013.05.012
22.
WangD, XiaoLB, WangZQ, Friction stir welding of SiCp/2009Al composite plate. Mater Des. 2013; 47:243–247. doi: 10.1016/j.matdes.2012.11.052
23.
NiRD, ChenLD, WangD, Influence of microstructural evolution on tensile properties of friction stir welded joint of rolled SiCp/AA2009-T351 sheet. Mater Des. 2013; 51:199–205. doi: 10.1016/j.matdes.2013.04.027
24.
NiRD, ChenLD, WangD, Tensile properties and strain-hardening behaviour of friction stir welded SiCp/AA2009 composite joints. Mater Sci Eng A. 2014; 608:1–10. doi: 10.1016/j.msea.2014.04.060
25.
WangD, XiaoLB, WangZQ, Evolution of the microstructure and strength in the nugget zone of friction stir welded SiCp/Al-Cu-Mg composite. J Mater Sci Technol. 2014; 30:54–60. doi: 10.1016/j.jmst.2013.09.018
26.
WangD, WangZQ, XiaoLB, Achieving friction stir welded SiCp/Al–Cu–Mg composite joint of nearly equal strength to base material at high welding speed. Mater Sci Eng A. 2014; 589:271–274. doi: 10.1016/j.msea.2013.09.096
27.
LiuH, HuY, ZhaoY, Microstructure and mechanical properties of friction stir welded AC4A+30vol.%SiCp composite. Mater Des. 2015; 65:395–400. doi: 10.1016/j.matdes.2014.09.014
28.
SongX, GuoL, FengX, Wear characteristics of a W6Mo5Cr4V2 high speed steel in friction stir welding of AA6061/SiC/55p composite. Proceedings of the International Conference on Materials, Environmental and Biological Engineering (MEBE 2015); Mar 28–30; Guilin, China. Atlantis Press; 2015. p. 915–918.
29.
BistA, SainiSJ, SharmaB. A review of tool wear prediction during friction stir welding of aluminium matrix composite. Trans Nonferrous Met Soc China. 2016; 26:2003–2018. doi: 10.1016/S1003-6326(16)64318-2
30.
Avettand-FènoëlNM, SimarA. A review about friction stir welding of metal matrix composites. Mater Charact. 2016; 120:1–17. doi: 10.1016/j.matchar.2016.07.010
31.
PraterT, StraussMA, CookEG, A phenomenological model for tool wear in friction stir welding of metal matrix composites. Metall Mater Trans A. 2013; 44:3757–3764. doi: 10.1007/s11661-013-1701-3
32.
MishraRS, MaZY. Friction stir welding and processing. Mater Sci Eng R Rep. 2005; 50:1–78. doi: 10.1016/j.mser.2005.07.001
33.
PraterT. Friction stir welding of metal matrix composites for use in aerospace structures. Acta Astronaut. 2014; 93:366–373. doi: 10.1016/j.actaastro.2013.07.023
34.
SalihOS, OuH, SunW, A review of friction stir welding of aluminium matrix composites. Mater Des. 2015; 86:61–71.
PeriyasamyP, MohanB, BalasubramanianV. Effect of heat input on mechanical and metallurgical properties of friction stir welded AA6061–10%SiCp MMCs. J Mater Eng Perform. 2012; 21:2417–2428. doi: 10.1007/s11665-012-0176-5
37.
WangD, XiaoLB, NiDR, Friction stir welding of discontinuously reinforced aluminum matrix composites: a review. Acta Metall Sin (Engl Lett). 2014; 27:816–824. doi: 10.1007/s40195-014-0143-2
38.
NandanR, DebRoyT, BhadeshiaHKDH. Recent advances in friction-stir welding – process, weldment structure and properties. Prog Mater Sci. 2008; 53:980–1023. doi: 10.1016/j.pmatsci.2008.05.001
39.
PeelJM, SteuwerA, WithersJP, Dissimilar friction stir welds in AA5083-AA6082. Part I: process parameter effects on thermal history and weld properties. Metall Mater Trans A. 2006; 37:2183–2193. doi: 10.1007/BF02586138
40.
PewWJ, NelsonWT, SorensenDC. Torque based weld power model for friction stir welding. Sci Technol Weld Join. 2007; 12:341–347. doi: 10.1179/174329307X197601
41.
TrimbleD, O'DonnellGE, MonaghanJ. Force generation during friction stir welding of AA2024-T3. Manuf Technol. 2012; 61:9–12. doi: 10.1016/j.cirp.2012.03.024
42.
SuH, WuSC, PittnerA, Simultaneous measurement of tool torque, traverse force and axial force in friction stir welding. J Manuf Proc. 2013; 15:495–500. doi: 10.1016/j.jmapro.2013.09.001
43.
CioffiF. [PhD Thesis]. Madrid, Spain: Universidad Complutense de Madrid, UCM; 2016.
SchmidtH, HattelJ, WertJ. An analytical model for the heat generation in friction stir welding. Modelling Simul Mater Sci Eng.2004; 12:143–157. doi: 10.1088/0965-0393/12/1/013
46.
HeurtierP, JonesJM, DesrayaudC, Mechanical and thermal modelling of friction stir welding. J Mater Proc Technol. 2006; 171:348–357. doi: 10.1016/j.jmatprotec.2005.07.014
47.
HamiltonC, DymekS, SommersA. A thermal model of friction stir welding in aluminum alloys. Int J Mach Tool Manuf. 2008; 48:1120–1130. doi: 10.1016/j.ijmachtools.2008.02.001
48.
KumarR, SinghK, Sunil PandeyS. Process forces and heat input as function of process parameters in AA5083 friction stir welds. Trans Nonferrous Met Soc China. 2012; 22:288–298. doi: 10.1016/S1003-6326(11)61173-4
49.
ColegroveAP, ShercliffRH. 3-Dimensional CFD modeling of flow round a threaded friction stir welding tool profile. J Mater Proc Technol. 2005; 169:320–327. doi: 10.1016/j.jmatprotec.2005.03.015
50.
FernándezR, González-DoncelG. Threshold stress and load partitioning during creep of metal matrix composites. Acta Mater. 2008; 56:2549–2562. doi: 10.1016/j.actamat.2008.01.037
51.
Cepeda-JiménezMC, RuanoAO, CarsíM, Study of hot deformation of an Al–Cu–Mg alloy using processing maps and microstructural characterization. Mater Sci Eng A.2012; 552:530–539. doi: 10.1016/j.msea.2012.05.082
