Free accessResearch articleFirst published online 2010-3
Mechanical,micro-,and macrostructural analysis of AA7075–T6 fabricated by friction stir butt welding with different rotational speeds and tool pin profiles
Friction stir welding (FSW) is a solid state welding process for joining aluminium alloys, has been employed in different industries, and is a new and promising welding process that can produce low-cost and high-quality joints of heat-treatable aluminium alloys because this process uses a non-consumable tool to generate frictional heat in the abutting surfaces and can eliminate some welding defects such as crack and porosity. The various parameters such as rotational speed, welding speed, axial force, and attack angle play vital roles in the FSW process in order to analyse the weld quality. In this research, the impact of processing parameters such as different rotational speed and tool pin profiles on the mechanical, micro-, and macrostructural properties during the FSW process involving the butt jointing of AA7075 T6 is investigated. It is important to note that four-flute and taper threaded pin profiles are utilized and the mechanical characteristics are determined by comparing the ultimate strength, percentage of elongation, and microhardness profiles for different rotational speeds and tool pin profiles.
RhodesC. G.MahoneyM. W.BingelW. H., Effects of friction stir welding on microstructure of 7075 aluminium. Scripta Mater., 1997, 36, 69–75.
3.
LiuH. J.FujiiH.MaedaM.NogiK., Tensile properties and fracture locations of friction-stir-welded joints of 2017-T351 aluminum alloy. J. Mater. Processing Technol., 2003, 142, 692–696.
4.
RhodesC. G.MahoneyM. W.BingelW. H.SpurlingR. A.BamptonC. C., Effects of friction stir welding on microstructure of 7075 aluminum. Scripta Mater., 1987, 36, 69–75.
5.
ShigematsuI.KwonY. J.SuzukiK.ImaiT.SaitoN., Joining of 5083 and 6061 aluminum alloys by FSW. J. Mater. Sci. Lett., 2003, 22, 343–356.
6.
LeeW. B.YeonY. M.JungS. B., The improvement of mechanical properties of friction-stir-welded A356 Al alloy. Mater. Sci. Engng, Part A., 2003, 355, 154–159.
7.
LiuG.MurrL. E.NiouC. S.McClureJ. C.VegaF. R., Micro structural aspects of the friction-stir welding of 6061-T6 aluminum alloy. Scripta Mater., 1997, 37, 355–361.
8.
BarcallonaA.BuffaG.FratiniL., Process parameters analysis in friction stir welding of AA6082-T6 sheets. Keynote paper of the VII ESAFORM Conference, Trondheim, 2004, 371–374.
9.
ThomasW. M.JohnsonK. I.WiesnerC. S., Friction stir welding — recent developments in tool and process technologies. Advd Engng Mater., 2003, 485–490.
10.
ChenC. M.KovacevicR., Finite element modeling of friction stir welding — thermal and thermomechanical analysis. Int. J. Mach. Tool Mf., 2003, 43, 1319–1326.
11.
SongM.KovacevicR., Thermal modeling of friction stir welding in a moving coordinate system and its validation. Int. J. Mach. Tool Mf., 2003, 43, 605–615.
12.
CavaliereP.SquillaceA., High temperature deformation of friction stir processed 7075 aluminium alloy. Mater. Characterization., 2005, 55, 136–142.
13.
CavaliereP.NobileR.PanellaF. W.SquillaceA., Mechanical and microstructural behaviour of 2024-7075 aluminium alloy sheets joined by friction stir welding. Int. J. Mach. Tool Mf., 2006, 46, 588–594.
14.
FujiiH.CuiL.MaedaM.NogiK., Effect of tool shape on mechanical properties and microstructure of friction stir welded aluminum alloys. Mater. Sci. Engng, Part A, 2006, 419, 25–31.
15.
BuffaG.FratiniL.ShivpuriR., CDRX modelling in friction stir welding of AA7075-T6 aluminum alloy: Analytical approaches. J. Mater. Processing Technol., 2007, 191, 356–359.
16.
BalasubramanianV., Relationship between base metal properties and friction stir welding process parameters. Mater. Sci. Engng, Part A, 2007, 480, 397–403.
17.
KumarK.SatishV.KailasT.SrivatsanS., Influence of tool geometry in friction stir welding. Mater. Mf. Processing., 2008, 23, 188–194.
18.
KhodirS. A.ShibayanagiT., Friction stir welding of dissimilar AA2024 and AA7075 aluminum alloys. Mater. Sci. Engng, Part B, 2008, 148, 82–87.
19.
ZadpoorA. A.SinkeJ.BenedictusR.PietersR., Mechanical properties and microstructure of friction stir welded tailor-made blanks. Mater. Sci. Engng, Part A, 2008, 494, 281–290.
20.
CavaliereP.PanellaF., Effect of tool position on the fatigue properties of dissimilar 2024-7075 sheets joined by friction stir welding. J. Mater. Processing Technol., 2008, 206, 249–255.
21.
BahemmatP.RahbariA.HaghpanahiM.BesharatiM. K., Experimental study on the effect of rotational speed and tool pin profile on AA2024 aluminium friction stir welded butt joints. ASME Early Career Tech. J., 2008, 7(1), 104(ECTC).
22.
LiuH. J.ChenY. C.FengJ. C., Effect of zigzag line on the mechanical properties of friction stir welded joints of an Al-Cu alloy. Scripta Mater., 2006, 55, 231–234.
23.
ChenY.LiuH.FengJ., Friction stir welding characteristics of different heat-treated-state 2219 aluminum alloy plates. Mater. Sci. Engng, Part A, 2006, 420, 21–25.
24.
ArbegastW. J.HartleyP. J., Proceedings of the Fifth International Conference on Trends in welding research, Pine Mountain, GA, 1–5 June 1998, p. 541.
25.
DavisJ. R., Aluminum and aluminum alloys, ASM specialty hand book, May 1994 (ASM International).
26.
MahoneyM. W.RhodesC. G.FlintoffJ. G.BingelW. H.SpurlingR. A., Properties of friction stir welded 7075 T651 aluminum. Metall. Mater. Trans., Part A, 1998, 29, 1955–1964.
27.
MurrL. E.LiuG.McClureJ., Dynamic recrystallization in friction-stir welding of aluminium alloy 1100. J. Mater. Sci. Lett., 1997, 16(22), 1801–1803.
28.
MishraR. S.MaZ. Y., Friction stir welding and processing. Mater. Sci. Engng, Part A, 2005, 50, 1–78.
29.
AydinH.BayramA.UguzA.AkayK. S., Tensile properties of friction stir welded joints of 2024 aluminum alloys in different heat-treated-state. Mater. Design, 2008 (in press).
30.
RenR.MaZ. Y.ChenL. Q., Effect of welding parameters on tensile properties and fracture behavior of friction stir welded Al-Mg-Si alloy. Scripta Mater., 2007, 56, 69–72.
31.
CampbellJ. E., Application of fracture mechanics or selection of metallic structural materials, 1982 (American Society for Metals, Metals Park, Ohio, USA) pp. 169–180.
32.
PrangnellP. B.HeasonC. P., Grain structure formation during friction stir welding observed by stop action technique. Acta Mater., 2005, 53, 3179–3192.
33.
ElangovanK.BalasubramanianV., Influences of tool pin profile and welding speed on the formation of friction stir processing zone in AA2219 aluminium alloy. J. Mater. Processing Technol., 2008, 200, 163–175.
