Tubular components are challenging to weld using friction stir welding (FSW) process due to its curvature. In the present work, a novel strategy involving concave shoulder tool with three different concavities (3°, 6° and 9°) coupled with double pass was devised to fabricate longitudinal FSWed tubes of AA5083-O. An increase in concavity resulted in formation of flash and thinning of weld zone (WZ) due to excessive heat generation caused by enhanced tool contact with tube curvature. The flash generation led to the formation of porosity in the WZ. The tool with 6° concavity resulted in spherical pores whereas long and needle shaped pores were witnessed in case of 9° concave tool. However, negligible pores were observed with 3° concave tool leading to excellent WZ strength. Therefore, it was inferred that concave shoulder tool with small concavity along with double pass was suitable for welding tubes using FSW.
Van Der HoevenJAZhuangLSchepersB, et al. A new 5xxx series alloy developed for automotive applications. SAE Technical Paper Series 2002-01-2128, 2002.
2.
HirschJ.Aluminium in innovative light-weight car design. Mater Trans2011; 52: 818–824.
3.
VermaRPKumar LilaM.A short review on aluminium alloys and welding in structural applications. Mater Today Proc2021; 46: 10687–10691.
4.
SenDPalSKPandaSK.Tubular structures: welding difficulty and potential of friction stir welding. In: DavimJP (ed.) Welding technology. Materials forming, machining and tribology. Cham: Springer International Publishing, 2021, pp. 229–252.
5.
AgrawalAKNarayananRGKailasSV.Experimental evaluation and prediction of end-forming behavior of friction stir processed Al6063T6 tubes at different tool traverse speeds. Int J Adv Manuf Technol2019; 104: 3607–3627.
6.
AgrawalAKNarayananRGKailasSV.End forming behaviour of friction stir processed Al 6063-T6 tubes at different tool rotational speeds. J Strain Anal2017; 52: 434–449.
7.
AgrawalAKGanesh NarayananRKailasSV.End forming behaviour of friction stir processed aluminum tubes at different tool traverse speed. Mater Today Proc2018; 5: 27100–27106.
8.
MeshramSReddyM.Influence of tool tilt angle on material flow and defect generation in friction stir welding of AA2219. Def Sci J2018; 68: 512–518.
9.
WahidMAKhanZASiddiqueeAN, et al. Analysis of process parameters effects on underwater friction stir welding of aluminum alloy 6082-T6. Proc IMechE, Part B: J Engineering Manufacture2019; 233: 1700–1710.
10.
Rajesh Jesudoss HynesNVivek PrabhuMShenbaga VeluP, et al. An experimental insight of friction stir welding of dissimilar AA 6061/Mg AZ 31 B joints. Proc IMechE, Part B: J Engineering Manufacture2022; 236: 787–797.
11.
BhattacharjeeRDattaSBiswasP.Thermomechanical and material flow analysis during friction stir welding of marine grade aluminum alloy 5083. J Sh Prod Des2023; 39: 1–24.
12.
ThakurASharmaVBhadauriaSS.Investigation of metallurgical characterization and mechanical properties of double-sided friction stir welding of aluminum 6061 T6 alloy. Proc IMechE, Part B: J Engineering Manufacture2023; 237: 16–30.
13.
VermaSGuptaMMisraJP.Effect of pin-profiles on thermal cycle, mechanical and metallurgical properties of friction stir–welded aviation-grade aluminum alloy. Proc IMechE, Part B: J Engineering Manufacture2019; 233: 2183–2195.
14.
IqbalMPVishwakarmaRKPalSK, et al. Influence of plunge depth during friction stir welding of aluminum pipes. Proc IMechE, Part B: J Engineering Manufacture. Epub ahead of print 23August2020. DOI: 10.1177/0954405420949754.
15.
ElyasiMDerazkolaHAHosseinzadehM.Investigations of tool tilt angle on properties friction stir welding of A441 AISI to AA1100 aluminium. Proc IMechE, Part B: J Engineering Manufacture2016; 230: 1234–1241.
16.
BajajDSiddiqueeANZaman KhanN, et al. Flow, process forces and strains during friction stir welding: a comprehensive first principle approach. Proc IMechE, Part B: J Engineering Manufacture2021; 235: 912–924.
17.
SimonciniMCabibboMForcelleseA.Development of double-side friction stir welding to improve post-welding formability of joints in AA6082 aluminium alloy. Proc IMechE, Part B: J Engineering Manufacture2016; 230: 807–817.
18.
LonghurstWRStraussAMCookGE, et al. Investigation of force-controlled friction stir welding for manufacturing and automation. Proc IMechE, Part B: J Engineering Manufacture2010; 224: 937–949.
19.
AkbariMAsadiP.Optimization of microstructural and mechanical properties of friction stir welded A356 pipes using taguchi method. Mater Res Express2019; 6: 066545.
20.
SenDPalSKPandaSK.Fabrication of longitudinal welded tube of aluminum alloy for structural application using friction stir welding process and its characterization. Arch Civ Mech Eng2022; 22: 91.
21.
LammleinDHGibsonBTDelappDR, et al. The friction stir welding of small-diameter pipe: an experimental and numerical proof of concept for automation and manufacturing. Proc IMechE, Part B: J Engineering Manufacture2012; 226: 383–398.
22.
MajeedTMehtaYSiddiqueeAN.Analysis of tool wear and deformation in friction stir welding of unequal thickness dissimilar Al alloys. Proc IMechE, Part L: J Materials Design and Applications2021; 235: 501–512.
23.
GadakhVSKumarA.Friction stir welding window for AA6061-T6 aluminium alloy. Proc IMechE, Part B: J Engineering Manufacture2014; 228: 1172–1181.
24.
KumarKKailasSV.The role of friction stir welding tool on material flow and weld formation. Mater Sci Eng A2008; 485: 367–374.
25.
ZhangHJWangMZhuZ, et al. Impact of shoulder concavity on non-tool-tilt friction stir welding of 5052 aluminum alloy. Int J Adv Manuf Technol2018; 96: 1497–1506.
26.
HattinghDGvon WellighLGBernardD, et al. Semiautomatic friction stir welding of 38 mm OD 6082-T6 aluminium tubes. J Mater Process Tech2016; 238: 255–266.
27.
BusuNJaffarullahMSLowCY, et al. A review of force control techniques in friction stir process. Procedia Comput Sci2015; 76: 528–533.
28.
VermaSMisraJP.Effect of process parameters on temperature and force distribution during friction stir welding of armor-marine grade aluminum alloy. Proc IMechE, Part B: J Engineering Manufacture2021; 235: 144–154.
29.
MishraRSMaZY.Friction stir welding and processing. Mater Sci Eng R Reports2005; 50: 1–78.
30.
MahoneyMWRhodesCGFlintoffJG, et al. Properties of friction-stir-welded 7075 T651 aluminum. Metall Mater Trans A Phys Metall Mater Sci1998; 29: 1955–1964.
31.
SchmidtHNBDickersonTLHattelJH.Material flow in butt friction stir welds in AA2024-T3. Acta Mater2006; 54: 1199–1209.
32.
ColliganK.Material flow behavior during friction stir welding of aluminum. Weld J (Miami, Fla)1999; 78: 229-s.
33.
LondonBMahoneyMBingelW, et al. Friction stir welding and processing II. Warrendale, PA: TMS, 2003, pp. 3–12.
34.
MahtoRPKumarRPalSK.Characterizations of weld defects, intermetallic compounds and mechanical properties of friction stir lap welded dissimilar alloys. Mater Charact2020; 160: 110115.
35.
AgrawalAKNarayananRGKailasSV.Formability and instability evaluation of friction stir processed AA6063-T6 tubes during end forming and numerical prediction. J Mater Eng Perform2021; 30: 973–993.
36.
YuanSJHuZLWangXS.Formability and microstructural stability of friction stir welded Al alloy tube during subsequent spinning and post weld heat treatment. Mater Sci Eng A2012; 558: 586–591.
37.
SenDKatiyarBSPandaSK, et al. Numerical simulation on end expansion of tubes fabricated through friction stir welding and validation of fracture behaviour. CIRP J Manuf Sci Technol2023; 43: 227–241.
38.
ChinchanikarSGhardeSGadgeM.Investigation of tool forces, weld bead micro-hardness and surface roughness during friction stir welding of Aluminium 6063 alloy. Adv Mater Process Technol2022; 8: 231–239.
