Abstract
In this paper, 5-mm thick 6082-T6 aluminum alloy plates were friction stir welded in a position control mode at rotation rate of 1800 rpm and welding speeds ranging from 200 to 600 mm/min. The metallurgical morphology of root defects was elucidated. As indicated by observation on electropolished samples that contains the root defects, it was found that there are three types of bonding states near the faying surface at the joint root, which are fully bonded state without cracks, incomplete bonding state in the form of non-continuous cracks (the kissing bond), and unbonded state in the form of continuous cracks (the lack-of-penetration defect). The vertical position of welding tool during the welding pocess is recorded, and it is found that, as the welding speed increased, the rebound amount of the welding tool increased during actual welding process because of increasing deformation resistance. It consequently leads to the decrease of insertion depth of the welding tool, which significantly increases formation tendency of the root defect.
Similar content being viewed by others
References
Meng XM, Huang YX, Cao J, Shen JJ, dos Santos JF (2020) Recent progress on control strategies for inherent issues in friction stir welding. Prog Mater Sci 115:100706
Zolghadr P, Akbari M, Asadi P (2019) Formation of thermo-mechanically affected zone in friction stir welding. Mater Res Express 6:086558
Choi JW, Li WH, Ushioda K (2022) Effect of applied pressure on microstructure and mechanical properties of linear friction welded AA1050-H24 and AA5052-H34 joints. Sci Technol Weld Join 27(2):92–102
Akbari M, Asadi P (2020) Dissimilar friction stir lap welding of aluminum to brass: Modeling of material mixing using coupled Eulerian-Lagrangian method with experimental verifications. Proc Inst Mech Eng L J Mater Des Appl 234:1117–1128
Yu P, Wu CS, Shi L (2021) Analysis and characterization of dynamic recrystallization and grain structure evolution in friction stir welding of aluminum plates. Acta Mater 207:116692
Ghiasvand A, Hassanifard S, Jalilian MM, Kheradmandan H (2021) Investigation of tool offset on mechanical properties of dissimilar AA6061-T6 and AA7075-T6 joint in parallel FSW process. Weld World 65:441–450
Akbari M, Asadi P, Abdi Behnagh R (2021) Modeling of material flow in dissimilar friction stir lap welding of aluminum and brass using coupled Eulerian and Lagrangian method. Int J Adv Manuf Technol 113:721–734
Guan W, Li DX, Cui L, Wang DP, Wu SJ, Kang S, Wang JL, Mao L, Zheng XS (2021) Detection of tunnel defects in friction stir welded aluminum alloy joints based on the in-situ force signal. J Manuf Process 71:1–11
Çam G, Mistikoglu S (2014) Recent developments in friction stir welding of Al-alloys. J Materi Eng Perform 23:1936–1953
Ren SR, Ma ZY, Chen LQ (2008) Effect of initial butt surface on tensile properties and fracture behavior of friction stir welded Al-Zn-Mg-Cu alloy. Mater Sci Eng A 479:293–299
Zhu YC, Chen GQ, Chen QL, Zhang G, Shi QY (2016) Simulation of material plastic flow driven by non-uniform friction force during friction stir welding and related defect prediction. Mater Des 108:400–410
Dubourg L, Merati A, Jahazi M (2010) Process optimisation and mechanical properties of friction stir lap welds of 7075–T6 stringers on 2024–T3 skin. Mater Des 31:3324–3330
Zhai M, Wu CS, Shi L (2022) Influence of tool pin length and dissimilar material configuration on friction stir lap welding of Al and Mg alloys. Int J Adv Manuf Technol 122:1567–1582
Jiuesus JS, Costa JM, Loureiro A, Ferreira JM (2018) Assessment of friction stir welding aluminm T-joints. J Mater Process Tech 255:387–399
Oosterkamp A, Oosterkamp LD, Nordeide A (2004) ‘Kissing bond’ phenomena in solid-state welds of aluminum alloys. Weld J 83:225S-331S
Sato YS, Takauchi H, Park SHC, Kokawa H (2005) Characteristics of the kissing-bond in friction stir welded Al alloy 1050. Mater Sci Eng A 405:333–338
Hu YY, Liu HJ, Li S, Du SS, Sekulic DP (2018) Improving mechanical properties of a joint through tilt probe penetrating friction stir welding. Mater Sci Eng A 731:107–118
Zeng XH, Xue P, Wang D, Ni DR, Xiao BL, Ma ZY (2018) Effect of processing parameters on plastic flow and defect formation in friction-stir-welded aluminum alloy. Metall Mater Trans A 49A(7):2673–2683
Kadlec M, Růžek R, Nováková L (2015) Mechanical behavior of AA 7475 friction stir welds with the kissing bond. Int J Fatigue 74:7–19
Le Jolu T, Morgeneyer TF, Denquin A, Sennour M, Laurent A, Besson J, Gourgues-Lorenzon A-F (2014) Microstructural characterization of internal welding defects and their effect on the tensile behavior of FSW joints of AA2198 Al-Cu-Li alloy. Metall Mater Trans A 45(12):5531–5544
Zhang Z, Xiao BL, Ma ZY (2013) Effect of segregation of secondary phase particles and “S” line on tensile fracture behavior of friction stir-welded 2024Al-T351 joints. Metall Mater Trans A 44:4081–4097
Fadaeifard F, Matori KA, Aziz SA, Zolkarnain L, Bin Abdul MAZ (2017) Effect of the welding speed on the macrostructure, microstructure and mechanical properties of AA6061-T6 friction stir butt welds. Metals 7(2):48–63
Tao Y, Zhang Z, Ni DR, Wang D, Xiao BL, Ma ZY (2014) Influence of welding parameter on mechanical properties and fracture behavior of friction stir welded Al-Mg-Sc joints. Mater Sci Eng A 612:236–245
Khalilabad MM, Zedan Y, Texier D, Jahazi M, Bocher P (2018) Effect of tool geometry and welding speed on mechanical properties of dissimilar AA2198-AA2024 FSWed joint. J Manuf Process 34:86–95
Koilraj M, Sundareswaran V, Vijayan S, Rao SRK (2012) Friction stir welding of dissimilar aluminum alloys AA2219 to AA5083 –optimization of process parameters using Taguchi technique. Mater Des 42:1–7
Khodir SA, Shibayanagi T (2008) Friction stir welding of dissimilar AA2024 and AA7075 aluminum alloys. Mater Sci Eng B 148:82–87
Ma XT, Meng XC, Xie YM, Zhao YB, Peng XY, Liang MY, Mao DX, Wan L, Huang YX (2022) Elimination of root kissing bond in friction stir welding of thick plates. Mater Lett 328:133148
Sato YS, Yamashita F, Sugiura Y (2004) FIB-assisted TEM study of an oxide Array in the root of a friction sir welded aluminium alloy. Scr Mater 50:365–369
Okamura H, Aota K, Sakamoto M, Ezumi M, lkeuchi K (2002) Behaviour of oxides during friction stir welding of aluminium alloy and their effect on its mechanical properties. Weld Int 16:266-275
Wang J, Fu BL, Bergmann L, Liu F, Klusemann B (2023) Effect of welding on friction stir welds of PM2000 alloy. J Materi Eng Perform 32(2):577–586
Dai QL, Wang XY, Hou ZG, Wu JJ, Shi QY (2015) Microcavities accompanying a zigzag line in a friction stir welded A6082–T6 alloy joint. Sci Technol Weld Join 20(1):68–74
Akbari M, Aliha MRM, Berto F (2023) Investigating the role of different components of friction stir welding tools on the generated heat and strain. Forces Mech 10:100166
Akbari M, Asiabaraki HR (2023) Modeling and optimization of tool parameters in friction stir lap joining of aluminum using RSM and NSGA II. Weld Int 37(1):21–33
Chen GQ, Li H, Wang GQ, Guo ZQ, Zhang S, Dai QL, Wang XB, Zhang G, Shi QY (2018) Effects of pin thread on the in-process material flow behavior during friction stir welding: A computational fluid dynamics study. Int J Mach Tool Manu 124:12–21
Yan DY, Shi QY, Wu AP (2009) Numerical analysis on the functions of stir tool’s mechanical loads during friction stir welding. Acta Metar Sin 45(8):994–999
Kumar R, Singh K, Pandey S (2012) Process forces and heat input as function of process parameters in AA5083 friction stir welds. Trans Nonferrous Met Soc China 22:288–298
Jia HP, Wu K, Sun Y, Hu F, Chen G (2022) Evaluation of axial force, tool torque and weld quality of friction stir welded dissimilar 6061/5083 aluminum alloys. CIRP J Manuf Sci Tec 37:267–277
Teng L, Lu XH, Luan YH, Sun SX (2023) Predicting axial force in friction stir welding thick 2219 aluminum alloy plate. Int J Adv Manuf Technol 126:1025–1034
Funding
The research was supported by the National Natural Science Foundation of China (grant no. 52175334 and grant no. 52035005) and State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology.
Author information
Authors and Affiliations
Contributions
Qilei Dai: Investigation, Methodology, Writing-original draft, Review & editing; Lei Jin: Methodology, Writing-review & editing; Kairen Meng: Methodology, Writing-review & editing; Huijie Liu: Investigation, Methodology, Review & editing. Qingyu Shi: Investigation, Methodology, Review & editing. Gaoqiang Chen: Investigation, Supervision, Review & editing, Funding acquisition.
Corresponding author
Ethics declarations
Competing interests
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Dai, Q., Jin, L., Meng, K. et al. Influence of welding speed on the root defects formation and mechanical properties of FSWed 6082-T6 Al alloy joint. Int J Adv Manuf Technol 131, 1097–1106 (2024). https://doi.org/10.1007/s00170-024-13107-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-024-13107-8