Skip to main content
SpringerLink
Log in

Al Alloy Tailor Welded Blank Fabrication by Friction Stir Welding: Effect of Double-Pass

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Friction stir welding (FSW) in butt joint configuration between 6.35 mm thick plates of AA2024-T3 and 2.5 mm thick plates of AA7475-T7 dissimilar alloys is addressed using T4 tool steel with a tapered cylindrical pin having scrolled shoulder. In this experimental study, the effect of double-pass FSW on joint properties has been investigated in detail. The weld microstructure and mechanical properties of FSWed joints were characterized. Scanning electron microscopy and x-ray energy-dispersive spectroscopy were employed to analyze the distribution and nature of precipitates. The temperature rise and traverse load during the FSW process were evaluated. Experimental results indicated the significant increase in grain size by double-pass FSW. Moreover, the hardness value decreases with the second pass, and the hardness dropped significantly in the heat-affected zone due to grains coarsening and change in precipitate morphology caused by increased heat input by double-pass FSW. The overall reduction in joint strength was found to be 4.8% by second pass FSW.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17

Similar content being viewed by others

References

  1. P.A. Schweitzer, Aluminum and Aluminum Alloys, Met. Mater. Phys. Mech. Corros. Prop., 2003 https://doi.org/10.1201/9780203912423.ch19

    Article  Google Scholar 

  2. A.K. Jha, P.R. Narayanan, V. Diwakar, K.S. Kumar and M.C. Mittal, Metallurgical Analysis of Cracked Aluminum Alloy (AFNOR 7020) Components Used in Satellite Launch Vehicles, Eng. Fail. Anal., 2004, 11, p 463–474. https://doi.org/10.1016/j.engfailanal.2003.05.016

    Article  CAS  Google Scholar 

  3. K.V. Jata, K.K. Sankaran and J.J. Ruschau, Friction-Stir Welding Effects on Microstructure and Fatigue of Aluminum Alloy 7050–T7451Metal, Mater. Trans. A, 2000, 31A, p 2181–2192.

    Article  CAS  Google Scholar 

  4. S.N.J. Reddy, R. Sathiskumar, K.G. Kumar, S. Jerome, A.V. Jebaraj, N. Arivazhagan et al., Friction Based Joining Process for High Strength Aerospace Aluminium Alloy, Mater. Res. Expr., 2019, 6, p 0863–0865.

    Google Scholar 

  5. M. Ubaid, D. Bajaj, A.K. Mukhopadhyay and A.N. Siddiquee, Friction Stir Welding of Thick AA2519 Alloy: Defect Elimination, Mechanical and Microstructural Characterization, Metals Mater. Int., 2020, 26, p 1841–1860.

    Article  CAS  Google Scholar 

  6. E.C. Bonome, C.B. Carletti, N.G.D. Alcantara and J.F.D. Santos, Friction Stir Welding Applied to Tailored Blanks, Weld. Inter, 2007, 21(4), p 279–283.

    Article  Google Scholar 

  7. P. Rohilla and N. Kumar, Experimental Investigation of Tool Geometry on Mechanical Properties of Friction Stir Welding of AA6061, Int. J. Innov. Technol. Expl. Eng. (IJITEE), 2013, 3, p 2278–3075.

    Google Scholar 

  8. N.A.A. Sathari, L.H. Shah and A.R. Razali, Investigation of Single-Pass/Double-Pass Techniques on Friction Stir Welding of Aluminium, J. Mech. Eng. Sci. (JMES), 2014, 7, p 1053–1061. https://doi.org/10.15282/jmes.7.2014.4.0102

    Article  CAS  Google Scholar 

  9. G. Ghangas and S. Singhal, Investigations of Multi-Pass Friction Stir Welding for Al-Zn-Mg alloy, Mater. Today: Proc., 2018, 5, p 17107–17113.

    CAS  Google Scholar 

  10. R. Brown, W. Tang and A.P. Reynolds, Multi-Pass Friction Stir Welding in Alloy 7050–T7451: Effects on Weld Response Variables and on Weld Properties, Mater. Sci. Eng. A, 2009, 513, p 115–121.

    Article  Google Scholar 

  11. S. Gopi and K. Manonmani, Predicting Tensile Strength of Double Side Friction Stir Welded 6082–T6 Aluminium Alloy, Sci. Technol. Weld. Join., 2012, 17(7), p 601.

    Article  CAS  Google Scholar 

  12. S. Mehra, P. Dhanda, R. Khanna, N. Singh Goyat and S. Verma, Effect of tool on tensile strength in single and double sided friction stir welding, Int. J. Sci. Eng. Res., 2012, 3, p 11.

    Google Scholar 

  13. N.H. Othman, L.H. Shah and M. Ishak, Mechanical and microstructural characterization of single and double pass aluminum AA6061 friction stir weld joints, Dec 2015. 3rd international conference of mechanical engineering research, IOP Conference Series: Materials Science and Engineering, 2015. https://doi.org/10.1088/1757-899X/100/1/012016.

  14. M. Muzvidziwa, M. Okazaki, S. Yamagishi and M. Seino, Local Fatigue Crack Propagation Behavior of a Two-Pass Friction Stir Welded Aluminum Alloy, Mech. Eng. J., 2014, 1, p 6.

    Article  Google Scholar 

  15. A. Kar, S. Suwas and S.V. Kailas, Two-Pass Friction Stir Welding of Aluminum Alloy to Titanium Alloy: A Simultaneous Improvement in Mechanical Properties, Mater. Sci. Eng. A, 2018 https://doi.org/10.1016/j.msea.2018.07.057.PII

    Article  Google Scholar 

  16. A. Garg and A. Bhattacharya, Influence of Cu Powder on Strength, Failure and Metallurgical Characterization of Single, Double pass Friction Stir Welded AA6061-AA7075 Joints, Mater. Sci. Eng., A, 2019, 759, p 661–679.

    Article  CAS  Google Scholar 

  17. N. Gangil, S. Maheshwari and A.N. Siddiquee, Novel use of Distribution Facilitators and Time–Temperature Range For Strengthening in Surface Composites on AA7050-T7451, Metallogr., Microstruct. Anal., 2018, 7(5), p 561–577.

    Article  CAS  Google Scholar 

  18. P. Kumar Sahu and S. Pal, Mechanical Properties of Dissimilar Thickness Aluminium Alloy weld by Single/Double pass FSW, J. Mater. Process. Technol., 2017 https://doi.org/10.1016/j.jmatprotec.2017.01.009

    Article  Google Scholar 

  19. T. Majeed and Y. Mehta, Arshad Noor Siddiquee, Proc. IMechE Part L: J Mater.: Design Appl., 2021, 235(4), p 934–945.

    Google Scholar 

  20. N. Birbilis, M.K. Cavanaugh and R.G. Buchheit, Electrochemical Behavior and Localized Corrosion Associated with Al7Cu2Fe Particles in Aluminum Alloy 7075–T651, Corros. Sci., 2006, 48, p 4202–4215. https://doi.org/10.1016/j.corsci.2006.02.007

    Article  CAS  Google Scholar 

  21. D. Bajaj, A.N. Siddiquee, A.K. Mukhopadhyay and N. Ali, The Effect of Tool Design on the Friction Stir Welding of Thick Aluminum Alloy AA6082-T651 Extruded Flats, Metallogr., Microstruct. Anal., 2020, 9, p 841–855.

    Article  CAS  Google Scholar 

  22. W.P. Koster, in Aluminium Alloys, ASM Handbook, 9th edn. Metallography and Microstructure, vol 9 (The ASM Handbook Committee, ASM International, 1992), p 351–388.

  23. M. Starink and X. Li, A model for the Electrical Conductivity of Peak-Aged and Overaged Al-Zn-Mg-Cu alloys Metall, Mater. Trans. A, 2003, 34, p 899–911.

    Article  Google Scholar 

  24. G. Cam, S. Gucluer and A. C, akan and H. Serindag, , ‘Mechanical Properties of Friction Stir Butt-Welded Al-5086 H32 plate’, Materialwiss, Werkstofftech, 2009, 40, p 638–642.

    Article  CAS  Google Scholar 

  25. C. Menzemer and T. Srivatsan, The Effect of Environment on Fatigue Crack Growth Behavior of Aluminum Alloy 5456’, Mater. Sci. Eng. A, 1999, A271, p 188–195.

    Article  CAS  Google Scholar 

  26. W.S. Huang, J.H. Chen, H.G. Yan, W.J. Xia, B. Su and W.J. Zhu, Effects of Ga Content on Dynamic Recrystallization and Mechanical Properties of High Strain Rate Rolled Mg-Ga Alloys, Met. Mater.-Int., 2019, 26(6), p 747–759.

    Article  Google Scholar 

  27. H. Mohanty, M.M. Mahapatra, P. Kumar, P. Biswas and N.R. Mandal, Study on the Effect of Tool Profiles On Temperature Distribution and Material Flow Characteristics In Friction Stir Welding, IMech E Part B: J Eng Manuf, 2012, 226(9), p 1527–1535.

    Article  Google Scholar 

  28. T.J. Lienert, W.L. Stellwag Jr., B.B. Grimmett and R.W. Warke, Friction Stir Welding Studies on Mild Steel, Weld J-New York, 2003, 82(1), p 1–8.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, National Institute of Technology, Hazratbal, Srinagar, 190006, Jammu and Kashmir, India

    Tanveer Majeed & Yashwant Mehta

  2. Department of Mechanical Engineering, Jamia Millia Islamia, New Delhi, 110025, India

    Arshad Noor Siddiquee

Authors
  1. Tanveer Majeed
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yashwant Mehta
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Arshad Noor Siddiquee
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Tanveer Majeed.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Majeed, T., Mehta, Y. & Siddiquee, A.N. Al Alloy Tailor Welded Blank Fabrication by Friction Stir Welding: Effect of Double-Pass. J. of Materi Eng and Perform 31, 410–423 (2022). https://doi.org/10.1007/s11665-021-06161-w

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-021-06161-w

Keywords

Search

Navigation