A NEW TYPE OF PLUG-IN FRICTION-STIR LAP WELDING BASED ON THE 6061-T6 ALUMINUM ALLOY
Keywords:
Plug-in friction-stir lap welding, mechanical interlocking, microhardness, failure load
Abstract
In this study a new type of plug-in friction-stir lap welding (PFSLW) is proposed to prepare welded joints based on 4-mm-thick 6061-T6 aluminum alloy sheet. The differences in the cross-sectional morphology, microstructure, cross-sectional hardness and shear properties between the PFSLW joint and the normal friction-stir lap-welding (FSLW) joint are discussed. The results show that the cross-sectional morphology of the PFSLW joint has undergone changes. The PFSLW joint has a mechanical interlocking structure on the advancing side that is beneficial to the connection strength of the joint. The grain structure differs at the boundary between the thermo-mechanically affected zone (TMAZ) and the heat-affected zone (HAZ), and the PFSLW joints show a more pronounced bending deformation of the grain organization near the boundary. The microhardness of PFSLW joints was increased in the TMAZ and HAZ areas, and the lowest hardness is further away from the center of the weld. The failure load of the PFSLW joint has been improved, the microcracks part of the PFSLW joint has a ridge-like structure. In addition, the actual welding width of PFSLW joints was improved.
References
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15Wang R, Kang H-T, Lei X, Fatigue Performance and Strength Assessment of AA2024 Alloy Friction Stir Lap Welds. J of Materi Eng and Perform., 29 (2020) 6701–6713, Doi: https://doi.org/10.1007/s11665-020-05145-6
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17Salari E, Jahazi M, Khodabandeh A, Nanesa HG, Friction stir lap welding of 5456 aluminum alloy with different sheet thickness: process optimization and microstructure evolution. Int J Adv Manuf Technol., 82 (2016) 39–48, Doi: https://doi.org/10.1007/s00170-015-7342-5
18Rajendran C, Srinivasan K, Balasubramanian V, BALAJI H, SELVARAJ P, Effect of tool tilt angle on strength and microstructural characteristics of friction stir welded lap joints of AA2014-T6 aluminum alloy. Transactions of Nonferrous Metals Society of China., 29 (2019) 1824–1835, Doi: https://doi.org/10.1016/S1003-6326(19)65090-9
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20Wang W, Yuan SN, Qiao K, Wang KS, Zhang SY, Peng P, Zhang T, Peng H, Wu B, Yang J, Microstructure and nanomechanical behavior of friction stir welded joint of 7055 aluminum alloy. Journal of Manufacturing Processes., 61 (2021) 311–321, Doi: https://doi.org/10.1016/j.jmapro.2020.11.016
21Liu HJ, Zhao YQ, Hu YY, Chen SX, Lin Z, Microstructural characteristics and mechanical properties of friction stir lap welding joint of Alclad 7B04-T74 aluminum alloy. Int J Adv Manuf Technol., 78 (2015) 1415–1425, Doi: https://doi.org/10.1007/s00170-014-6718-2
22Liu F, Fu L, Chen HY, Microstructure Evolution and Mechanical Properties of High-Speed Friction Stir Welded Aluminum Alloy Thin Plate Joints. J of Materi Eng and Perform., 27 (2018) 3590–3599, Doi: https://doi.org/10.1007/s11665-018-3441-4
23Zhang YX, Huang YX, Meng XC, Li JC, Xie YM, Fan Q, Friction stir lap welding of AA2024-T4 with drastically different thickness. Int J Adv Manuf Technol., 106 (2020) 3683–3691, Doi: https://doi.org/10.1007/s00170-019-04865-x
2Singh T, Tiwari SK, Shukla DK, Mechanical and microstructural characterization of friction stir welded AA6061-T6 joints reinforced with nano-sized particles. Materials Characterization., 159 (2020) 110047, Doi: https://doi.org/10.1016/j.matchar.2019.110047
3Hassanifard S, Alipour H, Ghiasvand A, Varvani-Farahani A, Fatigue response of friction stir welded joints of Al 6061 in the absence and presence of inserted copper foils in the butt weld. Journal of Manufacturing Processes., 64 (2021) 1–9, Doi: https://doi.org/10.1016/j.jmapro.2021.01.010
4Nayan N, Yadava M, Sarkar R, Murty S.V.S. N, Gurao N.P, Mahesh S, Prasad M.J.N.V, Samajdar I, Microstructure and tensile response of friction stir welded Al–Cu–Li (AA2198-T8) alloy. Materials Characterization., 159(2020) 110002, Doi: https://doi.org/10.1016/j.matchar.2019.110002
5Zeng SB, Chen GQ, Dinaharan I, Liu Q, Zhang S, Sahu PK, Wu JJ, Zhang G, Shi QY, Microstructure and Tensile Strength of AA6082 T-joints by Corner Stationary Shoulder Friction Stir Welding: Effect of Tool Rotation Speed. J of Materi Eng and Perform., 29 (2020) 7094–7103, Doi: https://doi.org/10.1007/s11665-020-05179-w
6Aghajani Derazkola H, Kordani N, Aghajani Derazkola H, Effects of friction stir welding tool tilt angle on properties of Al-Mg-Si alloy T-joint. CIRP Journal of Manufacturing Science and Technology., 33 (2021) 264–276, Doi: https://doi.org/10.1016/j.cirpj.2021.03.015
7Kalinenko A, Vysotskii I, Malopheyev S, Mironov S, Kaibyshev R, Relationship between welding conditions, abnormal grain growth and mechanical performance in friction-stir welded 6061-T6 aluminum alloy. Materials Science and Engineering: A., 817 (2021) 141409, Doi: https://doi.org/10.1016/j.msea.2021.141409
8Mertinger V, Varbai B, Adonyi Y, DeBacker J, Nagy E, Leskó M, Kárpáti V, Microstructure evaluation of dissimilar AA2024 and AA7050 aluminum joints made by corner stationary-shoulder friction stir welding. Weld World., 66 (2022) 1623–1635, Doi: https://doi.org/10.1007/s40194-022-01321-5
9Ge Z, Gao S, Ji S, Yan D, Effect of pin length and welding speed on lap joint quality of friction stir welded dissimilar aluminum alloys. Int J Adv Manuf Technol., 98 (2018) 1461–1469, Doi: https://doi.org/10.1007/s00170-018-2329-7
10Sharma A, Sharma VM, Gugaliya A, Rai P, Pal SK, Paul J, Friction stir lap welding of AA6061 aluminium alloy with a graphene interlayer. Materials and Manufacturing Processes., 35 (2020) 1532-2475, Doi: https://doi.org/10.1080/10426914.2020.1718694
11Paranthaman V, Sundaram KS, Natrayan L, Influence of SiC Particles on Mechanical and Microstructural Properties of Modified Interlock Friction Stir Weld Lap Joint for Automotive Grade Aluminium Alloy. Silicon., 14 (2022) 1617–1627, Doi: https://doi.org/10.1007/s12633-021-00944-5
12Kesharwani R, Jha KK, Imam M, Sarkar C, The Optimization of Gap Width Size During Friction Stir Welding of AA 6061-T6 with Al2O3 Particle Reinforcement. J of Materi Eng and Perform., (2022) Doi: https://doi.org/10.1007/s11665-022-07525-6
13Dialami N, Cervera M, Chiumenti M, Effect of the Tool Tilt Angle on the Heat Generation and the Material Flow in Friction Stir Welding. Metals., 9 (2018) 28, Doi: https://doi.org/10.3390/met9010028
14Fadaeifard F, Matori KA, Toozandehjani M, DAUD AR, ARIFFIN MKAM, OTHMAN NK, GHARAVI F, RAMZANI AH, OSTOVAN F (2014) Influence of rotational speed on mechanical properties of friction stir lap welded 6061-T6 Al alloy. Trans Nonferrous Met Soc China., 24 (2014) 4, 1004-1011, Doi: https://doi.org/10.1016/S1003-6326(14)63155-1
15Wang R, Kang H-T, Lei X, Fatigue Performance and Strength Assessment of AA2024 Alloy Friction Stir Lap Welds. J of Materi Eng and Perform., 29 (2020) 6701–6713, Doi: https://doi.org/10.1007/s11665-020-05145-6
16Huang YX, Meng XC, Zhou L, FUNDAMENTAL AND APPLICATION OF FRIETION STIR WELDING, HARBIN INSTITUTE OF TECHNOLOGY PRESS, HARBIN 2021, 242
17Salari E, Jahazi M, Khodabandeh A, Nanesa HG, Friction stir lap welding of 5456 aluminum alloy with different sheet thickness: process optimization and microstructure evolution. Int J Adv Manuf Technol., 82 (2016) 39–48, Doi: https://doi.org/10.1007/s00170-015-7342-5
18Rajendran C, Srinivasan K, Balasubramanian V, BALAJI H, SELVARAJ P, Effect of tool tilt angle on strength and microstructural characteristics of friction stir welded lap joints of AA2014-T6 aluminum alloy. Transactions of Nonferrous Metals Society of China., 29 (2019) 1824–1835, Doi: https://doi.org/10.1016/S1003-6326(19)65090-9
19Yang M, Bao R, Liu X, Song C, Thermo-mechanical interaction between aluminum alloy and tools with different profiles during friction stir welding. Transactions of Nonferrous Metals Society of China., 29 (2019) 495–506, Doi: https://doi.org/10.1016/S1003-6326(19)64958-7
20Wang W, Yuan SN, Qiao K, Wang KS, Zhang SY, Peng P, Zhang T, Peng H, Wu B, Yang J, Microstructure and nanomechanical behavior of friction stir welded joint of 7055 aluminum alloy. Journal of Manufacturing Processes., 61 (2021) 311–321, Doi: https://doi.org/10.1016/j.jmapro.2020.11.016
21Liu HJ, Zhao YQ, Hu YY, Chen SX, Lin Z, Microstructural characteristics and mechanical properties of friction stir lap welding joint of Alclad 7B04-T74 aluminum alloy. Int J Adv Manuf Technol., 78 (2015) 1415–1425, Doi: https://doi.org/10.1007/s00170-014-6718-2
22Liu F, Fu L, Chen HY, Microstructure Evolution and Mechanical Properties of High-Speed Friction Stir Welded Aluminum Alloy Thin Plate Joints. J of Materi Eng and Perform., 27 (2018) 3590–3599, Doi: https://doi.org/10.1007/s11665-018-3441-4
23Zhang YX, Huang YX, Meng XC, Li JC, Xie YM, Fan Q, Friction stir lap welding of AA2024-T4 with drastically different thickness. Int J Adv Manuf Technol., 106 (2020) 3683–3691, Doi: https://doi.org/10.1007/s00170-019-04865-x
Published
2024-02-06
How to Cite
1.
Cao G, Wang J, Gao B, Mu K, Zhang H, Li B. A NEW TYPE OF PLUG-IN FRICTION-STIR LAP WELDING BASED ON THE 6061-T6 ALUMINUM ALLOY. MatTech [Internet]. 2024Feb.6 [cited 2025Jan.19];58(1):103–110. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/839
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