EFFECT OF TOOL PIN PROFILES OVER SQUARE WAVE TOOL PATH PATTERN ON FRICTION STIR WELDING OF AA6061-CU DISSIMILAR ALLOYS

  • Loganathan Prabhu Department of Mechanical Engineering, SatyabamaInstitute of Science and Technology
  • Satish Shanmugam Department of Mechanical Engineering, Velammal Engineering College
  • Thiagarajan Chandrasekaran Department of Mechanical Engineering, AarupadaiVeeduInstitute of Technology
Keywords: Friction stir welding; Square wave pattern; Pin profile; X-ray; Microstructure.

Abstract

In this present work friction stir welding of Al6061-annealed pure copper dissimilar metals with square wave pattern tool pin movementwas investigated.  The aim of this experiment is to identify the significance square wave tool movement on friction stir welding process along with three different tool pin profiles. Different tool pin profiles of square, round and hexaspiral shapes were selected and their significant outcomes were unveiled. Friction stir welding process parameters of 1500 and 2000rpm & tool pin movement step size of 1.0mm and 2.0mm & weaving rate of 100mm/min and 150mm/min were selected. The advantages of tool movement pattern and tool pin profile shape wereexamined by mechanical testing, microstructure analysis. The mechanical results were showed that process parameter of 1500 rpm, 1.0mm step size, weldingrate of 150mm/min and square tool pin profile combination gives better mechanical properties. Micro structural results unveiled achievement of better grain refinement and uniform dispersion of micro constituents by implementation of square wave tool pin movement pattern along with square tool pin profile.The EDAX report confirms that the weld nugget contains both aluminum and copper as equal percentage, which indicates fine mixing of two parent metals.

References

1. Shens.h, Liu H.J, Effect of welding speed on microstructure and mechanical properties of friction stir welded copper,Materials and design,31 (2010)3937–3942, doi: 10.1016/j.matdes.2010.03.027.
2. Vijayan, S, Raju, R, Rao, S.R.K, Multi objective optimization of friction stir welding process parameters on aluminum alloy AA 5083 using Taguchi-based grey relation analysis, Mater. Manuf. Process. 25 (2010) 1206–1212, doi.org/10.1080/10426910903536782.
3. Khan, Noor Zaman, Khan, Zahid A, Siddiquee, Arshad Noor, Effect of shoulder diameter to pin diameter (D/d) ratio on tensile strength of friction stir welded 6063 aluminium alloy, Materials Today: Proceedings. 2 (4-5) (2015) 1450-1457, doi.org/10.1016/j.matpr.2015.07.068.
4. Rodriguez, RI, Jordon, JB, Allison, PG, Rushing, T, Garcia, L, Microstructure and mechanical properties of dissimilar friction stir welding of 6061-to-7050 aluminum alloys, Mater. Des. 83 (2015) 60-65, doi.org/10.1016/j.matdes.2015.05.074.
5. Mahto, Raju Prasad, Bhoje, Rahul, Pal, Surjya K, Joshi, Harshadeep S, Das, Siddhartha, A study on mechanical properties in friction stir lap welding of AA 6061-T6 and AISI 304, Materials Science and Engineering: A. 652 (2016) 136-144, doi: 10.1016/J.MSEA.2015.11.064.
6. Mohammadi, J, Behnamian, Y, Mostafaei, A, Izadi, H, Saeid, T, Kokabi, AH, Gerlich, AP, Materials Characterization Friction stir welding joint of dissimilar materials between AZ31B magnesium and 6061 aluminum alloys: Microstructure studies and mechanical characterizations, Materials Characterization. 101 (2015) 189-207, doi:
10.1016/j.matchar.2015.01.008.
7. Babu, S, Elangovan, K, Balasubramanian, V, Balasubramanian, M 2009, Optimizing Friction Stir Welding Parameters to Maximize Tensile Strength of AA2219 Aluminum Alloy Joints, Metals and Materials International. 15 (2) (2009) 321-330, doi.org/10.1007/s12540-009-0321-3.
8. Qiu-zhengzhang, Wen-biao GONG and Wei LIU. Microstructure and mechanical properties of dissimilar Al−Cu joints by friction stir welding. Trans. Nonferrous Met. Soc. China 25(2015) 1779−1786, doi.org/10.1016/S1003-6326(15)63783-9.
9. H. Bisadi , A. Tavakoli , M. Tour Sangsaraki and K. Tour Sangsaraki. The influences of rotational and welding speeds on microstructuresand mechanical properties of friction stir welded Al5083 and commerciallypure copper sheets lap joints, Materials and Design 43 (2013) ,80–88, doi: 10.1016/j.matdes.2012.06.029.
10. Ghosh M, Kumar K, Mishra RS. Friction stir lap welded advanced high strengthsteels: microstructure and mechanical properties. Mater SciEngA , (528) 2011, 8111–8119, doi: 10.1016/j.msea.2011.06.087.
11. Saeid T, Abdollah-zadeh A, Sazgari B. Weldability and mechanical properties of dissimilar aluminum–copper lap joints made by friction stir welding. Journal of Alloys Compound (2010) 5, 490:652, doi: 10.1016/j.jallcom.2009.10.127.
12. Mohanty, HK, Mahapatra, MM, Kumar, P, Biswas, P, Mandal, NR, Modeling the effect of tool shoulder and probe profile geometries on friction stirred aluminum welds using RSM, J. Marine Sci. Appl. 11 (2012): 493-503, doi: 10.1007/s11804-012-1160-z
13. Chen YC, Nakata K. Microstructural characterization and mechanicalproperties in friction stir welding of aluminum and titanium dissimilaralloys. Mater Des (2009) 30, 469–474, doi: 10.1016/j.matdes.2008.06.008.
14. Hu, ZL, Wang, XS, Pang, Q, Huang, F, Qin, XP, Hua, L, The effect of post processing on tensile property and microstructure evolution of friction stir welding aluminium alloy joint, Materials Characterization. 99 (2015) 180-187, doi.org/10.1016/j.matchar.2014.11.015.
15. Xue P, Xie GM, Xiao BL, Ma ZY, Geng L. Effect of heat input conditions onmicrostructure and mechanical properties of friction-stir-welded pure copper.Metall Mater Trans A (2010) 41, 2010–2021, doi: 10.1007/s11661-010-0254-y.
16. Luis truebaJr, Georgiana Heredia and Lucie B Johannes. Effect of tool shoulder features on defects and tensile properties of friction stir welded aluminium 6061-T6. Journal of material processing technology, 12 (2015): 455-561, doi: 10.1016/j.jmatprotec.2014.12.027.
17. Shigematsu I, Kwon YJ, Suzuki K, Imai T, Saito N. Joining of 5083 and 6061aluminum alloys by friction stir welding. Journal of material science letter.(2003) 22, 353–356, doi.org/10.1023/A:1022688908885.
18. Karthikeyan L, Senthilkumar VS, Padmanabhan KA. On the role of process variables in the friction stir processing of cast aluminium A319 alloy. Mater Des. 31 (2010): 761–71, doi: 10.1016/j.matdes.2009.08.001
19. Joswik .P, L. Śnieżek, Experimental Analysis of Crack Growth in a Notched Specimen Made of Ni3Al Inter metallic Alloy. Journal of notch effect and fracture, 11 (2001):257-269, doi: 10.1007/978-94-010-0880-8_16.
20. Azari.Z, Casavola. C, characterization and prediction of cracks in coated materials. International scholarly research notice, 594147 (2015): 197-207, doi.org/10.1155/2015/594147
21. Xue P, Xiao B L, Ni DR, Ma ZY. Enhanced mechanical properties of friction stir welded dissimilar Al−Cu joint byinter metallic compounds. Journal of materials science and engineering A, (2010) 527, 5723−5727, doi:10.1016/j.msea.2010.05.061
22. Liu H J, Shen J J, Zhou L, Zhao Y Q, Liu C, Kuang L Y.Microstructural characterization and mechanical properties of frictionstir welded joints of aluminum alloy to copper. Journal ofscience and technology of welding and joining, 2011, 16: 92−99, doi.org/10.1179/1362171810Y.0000000007
Published
2021-09-30
How to Cite
1.
Prabhu L, Shanmugam S, Chandrasekaran T. EFFECT OF TOOL PIN PROFILES OVER SQUARE WAVE TOOL PATH PATTERN ON FRICTION STIR WELDING OF AA6061-CU DISSIMILAR ALLOYS. MatTech [Internet]. 2021Sep.30 [cited 2021Nov.27];55(5):693–700. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/202