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Influences of welding parameters on axial force and deformations of micro pinless friction stir welding

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Abstract

0.5-mm-thick 7075-T6 aluminum alloy sheets were butt joined successfully by high-speed micro friction stir welding (μFSW) as well as conventional μFSW using a pinless tool. The influences of welding parameters on the axial force, residual stresses, and deformations were studied through experiments. Good surface morphology and defect-free joints were obtained by high-speed μFSW as well as conventional μFSW in a fixed rotational speed/welding speed of 6.67 rad/mm. The axial force during μFSW increased with the increment in welding speed and decreased with the increment in rotational speed. When the ratio of rotational speed/welding speed was 6.67 rad/mm, compared with conventional μFSW (2000/300), the lower axial force of 1460 N was obtained by using high-speed μFSW (10,000/1500). Longitudinal tensile residual stress and transverse compressive residual stress occurred around the weld zone for all μFSW joints. The residual stresses of joint fabricated by a parameter of 10,000/1500 were slightly less than that fabricated by 2000/300. Both longitudinal maximum bending deformation Zmax and transverse angular deformation α increased with the increment in rotational speed and decreased with the increment in welding speed. As a comparison to 2000/300, the welded sheet with a parameter of 10,000/1500 exhibited slightly lower Zmax and α.

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Acknowledgments

The authors would like to acknowledge the financial support from the National Natural Science Foundation of China (No. 51575450), Aeronautical Science Foundation of China (No. 2016ZE53040), and Natural Science Foundation of Shaanxi Province (No. S2016YFJZ0164).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Y. Ni, D. Q. Qin, Y. Mao, X. Xiao & L. Fu

  2. State Key Laboratory of Solidification, Xi’an, 710072, China

    L. Fu

  3. Shaanxi Key Laboratory of Friction Welding Technologies, Xi’an, 710072, China

    L. Fu

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  1. Y. Ni
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  2. D. Q. Qin
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  3. Y. Mao
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  4. X. Xiao
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  5. L. Fu
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Correspondence to L. Fu.

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Ni, Y., Qin, D.Q., Mao, Y. et al. Influences of welding parameters on axial force and deformations of micro pinless friction stir welding. Int J Adv Manuf Technol 106, 3273–3283 (2020). https://doi.org/10.1007/s00170-019-04739-2

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  • DOI: https://doi.org/10.1007/s00170-019-04739-2

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