In this study, orbital friction stir lap welding of 360 mm diameter AA5083-H321 tube to 350 mm diameter AA5083-O flange was investigated. The influence of rotational and travel speed of tool with triangular frustum pin on the metallurgical structure and mechanical properties of orbital friction stir lap welded samples were studied. The results indicated that defect free orbital lap joints are successfully obtained using tool rotational speed of 650 and 800 rev min−1 with a constant travel speed of 40 mm min−1. The strengthening mechanism in the stir zone is solid solution strengthening and dislocation looping. The maximum joint strength was achieved at a welding speed of 650 rev min−1 and 40 mm min−1. Failure of tensile shear test samples occurred far from the friction stir welding zone.
KuangB, ShenY, ChenW, The dissimilar friction stir lap welding of 1A99 Al to pure Cu using Zn as filler metal with “pinless” tool configuration. Mater Des. 2015; 68:54–62. doi: 10.1016/j.matdes.2014.12.008
4.
KoilrajM, SundareswaranV, VijayanS. Friction stir welding of dissimilar aluminum alloys AA2219 to AA5083 – optimization of process parameters using taguchi technique. Mater Des. 2012; 42:1–7. doi: 10.1016/j.matdes.2012.02.016
5.
ChenC, KovacevicR. Joining of Al 6061 alloy to AISI 1 018 steel by combined effects of fusion and solid state welding. Int J Machine Tools & Manuf. 2004; 44:1205–1214. doi: 10.1016/j.ijmachtools.2004.03.011
6.
MaZY. Friction stir processing technology: a review. Metall Mater Trans A. 2008; 39:642–658. doi: 10.1007/s11661-007-9459-0
7.
SabooniS, KarimzadehF, EnayatiMH, Friction-stir welding of ultrafine grained austenitic 304L stainless steel produced by martensitic thermomechanical processing. Mater Des. 2015; 76:130–140. doi: 10.1016/j.matdes.2015.03.052
8.
ToumpisA, GallowayA, CaterS, Development of a process envelope for friction stir welding of DH36 steel – a step change. Mater Des. 2014; 62:64–75. doi: 10.1016/j.matdes.2014.04.066
9.
DefalcoJ, SteelR. Friction stir process now welds steel pipe. Weld J. 2009; 88.
10.
PackerS, MatsunagaM. Friction stir welding equipment and method for joining X65 pipe. The 14th International Offshore and Polar Engineering Conference. Toulon, France; 2004. p. 55–60.
11.
DoosQM, WahabBA. Experimental study of fricton stir welding of 6061-T6 aluminium pipe. Int J Mech Eng Robot Res. 2012; 1:143–156.
12.
IsmailA, AwangM, FawadH, Friction stir welding on aluminum alloy 6063 pipe. The 7th Asia Pacific IIW International Congress. Singapore; 2013.
13.
IsmailA, AwangM, RojanMA. An effective jig for friction stir welding of pipe butt joint. Appl Mech Mater. 2015; 752–753:491–495. doi:
10.4028/www.scientific.net/AMM.752-753.491
14.
LammleinDH, GibsonBT, De LappDR, The friction stir welding of small-diameter pipe: an experimental and numerical proof of concept for automation and manufacturing. Proc IMechE Part B: J Eng Manuf. 2011; 225.
15.
D'UrsoG, LongoM, GiardiniC. Microstructure and mechanical properties of friction stir welded AA6060-T6 tubes. Key Eng. Mater. 2009; 554–557:977–984. doi:
10.4028/www.scientific.net/KEM.554-557.977
16.
DubourgL, GholipourJ, JahaziM. Friction stir welding of 2024-T3 aluminum tubes for hydroforming application. Trends in welding research. The 8th International Conference Pine Mountain, GA; 2008. p. 549–556.
17.
MarréM, RuhstorferM, TekkayaAE, Manufacturing of lightweight frame structures by innovative joining by forming processes. Int J Mater Form. 2009; 2:307–310. doi: 10.1007/s12289-009-0524-7
18.
HuZL, YuanSJ, WangXS, Microstructure and mechanical properties of Al–Cu–Mg alloy tube fabricated by friction stir welding and tube spinning. Scr Mater. 2012; 66:427–430. doi: 10.1016/j.scriptamat.2011.12.006
19.
D17.3/D17.3:2016. Specification for friction stir welding of aluminum alloys for aerospace applications. Miami, FL: American Welding Society (AWS); 2016.
20.
FrigaardØ, GrongØ, MidlingOT. A process model for friction stir welding of age hardening aluminum alloys. Metall Mater Trans A. 2001; 32:1189–1200. doi: 10.1007/s11661-001-0128-4
21.
GaaferAM, MahmoudTS, MansourEH. Microstructural and mechanical characteristics of AA7020-O Al plates joined by friction stir welding. Mater Sci Eng: A. 2010; 527:7424–7429. doi: 10.1016/j.msea.2010.08.040
22.
ChenZW, YazdanianS. Friction stir lap welding: material flow, joint structure and strength. J Achiev Mater Manuf Eng. 2012; 55:629–637.
23.
HeX, GubF, BallA. A review of numerical analysis of friction stir welding. Prog Mater Sci. 2014; 65:1–66. doi: 10.1016/j.pmatsci.2014.03.003
24.
Jamshidi AvalH, LoureiroA. Effect of welding parameters on microstructure, mechanical properties and residual stress fields of friction stirwelds on AA5086. Kovove Materialy – Metallic Materials. 2015; 53:51–58. doi: 10.4149/km_2014_1_51
HatchJE. Aluminum: properties and physical metallurgy. Ohio: American Society for Metals (ASM); 1984.
27.
SatoYS, ParkSHC, KokawaH. Microstructural factors governing hardness in friction-stir welds of solid-solution-hardened Al alloys. Metall Mater Trans A: Phys Metall Mater Sci. 2001; 32:3033–3042. doi: 10.1007/s11661-001-0178-7
