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Cu donor material assisted friction stir welding of AA2024 and AA6061 dissimilar alloys: Effect on downward force, temperature profile, and mechanical properties

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A Correction to this article was published on 03 July 2023

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Abstract

This research investigation focuses on copper (Cu) donor material assisted friction stir welding (FSW) of AA2024-T4 and AA6061-T6 plates of 6.35 mm thickness. FSW joints were prepared at optimized process parameters of 1400 rpm and welding speeds of 1, 2, or 3 mm/s. The Cu donor material of 25% and 50% thickness with respect to the workpiece thickness were selected to assist the FSW joining during the plunge stage. The downward force generated in the FSW process was gradually decreased after introducing the Cu donor material because more heat was produced in the donor material and conducted to the base plate. The temperature profiles that the inclusion of the Cu donor material increased the temperature at the beginning of the welding process. The welded joints were characterized in terms of the micro-hardness and tensile properties. Defect-free joints could be obtained when placing high strength AA2024 alloy at the advancing side of the weld with 25% thick donor material. From the hardness profiles, it is observed that the hardness decreases from the base metal of AA 2024 to the center of the weld followed by thermomechanical affected zone (TMAZ) and the heat affected zone (HAZ). The hardness measurements are lower in the TMAZ and HAZ where tensile failure occurs. The maximum tensile strength improved by 130% with 25% Cu donor material as compared to the as welded samples. SEM Fractography images confirmed mixed modes of brittle and ductile fracture surfaces with tearing ridges and finer dimples after the inclusion of donor material in FSW.

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Acknowledgements

The authors would like to acknowledge support from NASA (award number: 80NSSC20M0015). The author ZW also acknowledges support from ONR (award number: N00014-19-1-2728). Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the NASA and ONR. The authors would also like to thank the Commonwealth Center for Advanced Manufacturing (CCAM) and Amsted Rail for providing the facility for sample characterization. The assistance of Mr. Geoff Widman in performing the experiments is also gratefully acknowledged.

Funding

The authors would like to acknowledge support from NASA (award number: 80NSSC20M0015). The author ZW also acknowledges support from ONR (award number: N00014-19–1-2728). Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the NASA and ONR.

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Authors and Affiliations

  1. Department of Engineering, Virginia State University, Petersburg, VA, 23806, USA

    Srinivasa Naik Bhukya & Zhenhua Wu

  2. Department of Mechanical and Aerospace Engineering, Old Dominion University, Norfolk, VA, 23529, USA

    Abdelmageed Elmustafa, Aiman Al-Allaq, Manish Ojha & Yousuf Mohammed

Authors
  1. Srinivasa Naik Bhukya
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  2. Zhenhua Wu
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  3. Abdelmageed Elmustafa
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  4. Aiman Al-Allaq
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  5. Manish Ojha
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  6. Yousuf Mohammed
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Contributions

Dr. S. Bhukya carried out experimentation and data analysis, and wrote/revised the manuscript. Dr. Z. Wu, as the Principal Investigator, secured funding and resources for the research, designed and carried out the experiment, wrote and revised the manuscript. Dr. A. Elmustafa reviewed and revised the manuscript. Mr. A. Al-Allaq, Mr. M. Ojha, and Dr. Y. Mohammed characterized samples.

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Correspondence to Zhenhua Wu.

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The original online version of this article was revised: Figure 2 citation should not be in this sentence “The positions of the points where the temperature was measured on both sides are selected on two different cross sections, respectively.”

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Bhukya, S.N., Wu, Z., Elmustafa, A. et al. Cu donor material assisted friction stir welding of AA2024 and AA6061 dissimilar alloys: Effect on downward force, temperature profile, and mechanical properties. Int J Adv Manuf Technol 127, 3839–3851 (2023). https://doi.org/10.1007/s00170-023-11778-3

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  • DOI: https://doi.org/10.1007/s00170-023-11778-3

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