Skip to main content
SpringerLink
Log in

Process Parametric Dependency of Axial Downward Force and Macro- and Microstructural Morphologies in Ultrasonically Assisted Friction Stir Welding of Al/Mg Alloys

  • Published:
Metallurgical and Materials Transactions A Aims and scope Submit manuscript

Abstract

An elementary analysis is proposed to quantify the effects of ultrasonic vibrations during friction stir welding (FSW) of AA6061-T6 to AZ31B Mg alloy. In the present context, the ultrasonic vibrations are applied in the stirred zone (SZ) via a specially designed welding tool. The influence of ultrasonic vibration has been analyzed for a wide range of welding and rotation speeds. The acoustic addition has proven beneficial to enhance joint strength. Significant diminutions in axial downward force, tool torque, and tool input power equal to ~ 38, 38.7, and 38.75 pct, respectively, have been observed during the ultrasonic addition. Melioration in interfacial bonding, enhanced material mixing, and an improvement in weldment surface quality are observed for ultrasonic joints. For conventional joints, the intermetallic phases βAl3Mg2 and γAl12Mg17 have been found in the SZ and are fragmented under the acoustic influence. The microstructural analysis of the fracture surface shows a ductile fracture mechanism at ultrasonically treated surfaces. A noteworthy grain refinement cum recrystallization is observed in the SZ as well as the immediate deformation zone. The maximum ultrasonic effects are apparent at the weld center and gradually diminish as they move ahead from it.

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. L. Liu, D. Ren, and F. Liu: Materials (Basel), 2014, vol. 7, pp. 3735–57.

    CAS  Google Scholar 

  2. S. Kumar and C.S. Wu: J. Harbin Inst. Technol. (New Ed.), 2017, vol. 24, pp. 1–37.

    Google Scholar 

  3. P. Liu, Y. Li, H. Geng, and J. Wang: Mater. Lett., 2007, vol. 61, pp. 1288–91.

    CAS  Google Scholar 

  4. Y. Zhao, Z. Lu, K. Yan, and L. Huang: Mater. Des., 2015, vol. 65, pp. 675–81.

    CAS  Google Scholar 

  5. J. Wang, J.C. Feng, and Y.X. Wang: Mater. Sci. Technol., 2008, vol. 24, pp. 827–31.

    CAS  Google Scholar 

  6. B. Meyghani, M.B. Awang, S. Emamian, and E.T. Akinlabi: Materwiss. Werksttech., 2018, vol. 49, pp. 427–34.

    Google Scholar 

  7. V. Buchibabu, G.M. Reddy, D. Kulkarni, and A. De: J. Mater. Eng. Perform., 2016, vol. 25, pp. 1163–71.

    CAS  Google Scholar 

  8. S. Kumar, W. Ding, Z. Sun, and C.S. Wu: Int. J. Adv. Manuf. Technol., 2018, vol. 97, pp. 1269–84.

    Google Scholar 

  9. Y.C. Chen and K. Nakata: Scripta Mater., 2008, vol. 58, pp. 433–36.

    CAS  Google Scholar 

  10. X.Q. Lv, C.S. Wu, C.L. Yang, and G.K. Padhy: J. Mater. Process. Technol., 2018, vol. 254, pp. 145–57.

    CAS  Google Scholar 

  11. J. Peng, Z. Zhang, J. Huang, P. Guo, Y. Li, W. Zhou, and Y. Wu: J. Alloys Compd., 2019, vol. 792, pp. 16–24.

    CAS  Google Scholar 

  12. A. Dorbane, B. Mansoor, G. Ayoub, V.C. Shunmugasamy, and A. Imad: Mater. Sci. Eng. A, 2016, vol. 651, pp. 720–33.

    CAS  Google Scholar 

  13. M. Czechowski: J. Mater. Process. Technol., 2005, vol. 164, pp. 1001–06.

    Google Scholar 

  14. V. Firouzdor and S. Kou: Metall. Mater. Trans. A, 2010, vol. 41A, pp. 2914–35.

    CAS  Google Scholar 

  15. M. Simoncini and A. Forcellese: Mater. Des., 2012, vol. 41, pp. 50–60.

    CAS  Google Scholar 

  16. J. Verma, R.V. Taiwade, C. Reddy, and R.K. Khatirkar: Mater. Manuf. Process., 2018, vol. 33, pp. 308–14.

    CAS  Google Scholar 

  17. L. Giraud, H. Robe, C. Claudin, C. Desrayaud, P. Bocher, and E. Feulvarch: J. Mater. Process. Technol., 2016, vol. 235, pp. 220–30.

    CAS  Google Scholar 

  18. A. Kostka, R.S. Coelho, J. dos Santos, and A.R. Pyzalla: Scripta Mater., 2009, vol. 60, pp. 953–56.

    CAS  Google Scholar 

  19. U.F.H. Suhuddin, V. Fischer, and J.F. Dos Santos: Scripta Mater., 2013, vol. 68, pp. 87–90.

    CAS  Google Scholar 

  20. Y.S. Sato, S.H.C. Park, M. Michiuchi, and H. Kokawa: Scripta Mater., 2004, vol. 50, pp. 1233–36.

    CAS  Google Scholar 

  21. M.A. Mofid, A. Abdollah-Zadeh, and C.H. Gür: Int. J. Adv. Manuf. Technol., 2014, vol. 71, pp. 1493–99.

    Google Scholar 

  22. S. Ji, R. Huang, X. Meng, L. Zhang, and Y. Huang: J. Mater. Eng. Perform., 2017, vol. 26, pp. 2359–67.

    CAS  Google Scholar 

  23. S. Benfer, B. Straß, G. Wagner, and W. Fürbeth: Surf. Interface Anal., 2016, vol. 48, pp. 843–52.

    CAS  Google Scholar 

  24. B. Strass, G. Wagner, C. Conrad, B. Wolter, S. Benfer, and W. Fürbeth: Adv. Mater. Res., 2014, vols. 966–967, pp. 521–35.

    Google Scholar 

  25. K. Park: Development and Analysis of Ultrasonic Assisted Friction Stir Welding Process. PhD Dissertation, 2009.

  26. S. Kumar: Arch. Civ. Mech. Eng., 2016, vol. 16, pp. 473–84.

    Google Scholar 

  27. S. Kumar, C.S. Wu, Z. Sun, and W. Ding: Int. J. Adv. Manuf. Technol., 2019, vol. 100, pp. 1787–99.

    Google Scholar 

  28. S. Kumar and C.S. Wu: Mater. Today Proc., 2018, vol. 5, pp. 18142–18151.

    CAS  Google Scholar 

  29. S. Kumar and C. Wu: J. Alloys Compd., 2020. https://doi.org/10.1016/j.jallcom.2020.154343.

    Article  Google Scholar 

  30. F. Ning, H. Wang, W. Cong, and P.K.S.C. Fernando: Ultrasonics, 2017, vol. 76, pp. 44–51.

    Google Scholar 

  31. P.K.S.C. Fernando, M. Zhang, and Z. Pei: Mach. Sci. Technol., 2019, vol. 23, pp. 595–611.

    CAS  Google Scholar 

  32. C. Xu, G. Sheng, X. Cao, and X. Yuan: J. Mater. Sci. Technol., 2016, vol. 32, pp. 1253–59.

    CAS  Google Scholar 

  33. S. Ji, X. Meng, Z. Liu, R. Huang, and Z. Li: Mater. Lett., 2017, vol. 201, pp. 173–76.

    CAS  Google Scholar 

  34. S. Kumar, C.S. Wu, and G.K. Padhy: 7th Int. Conf. on Welding Science and Engineering (WSE 2017) in Conjunction with 3rd International Symposium on Computer-Aided Welding Engineering (CAWE 2017), Shandong University, Jinan, China, 2017, pp. 272–76.

  35. A. Banik, J.D. Barma, and S.C. Saha: Iran J. Sci. Technol. Trans. Mech. Eng., https://doi.org/10.1007/s40997-019-00289-w.

  36. P. Venkateswaran, Z.H. Xu, X. Li, and A.P. Reynolds: J. Mater. Sci., 2009, vol. 44, pp. 4140–47.

    CAS  Google Scholar 

  37. R. Fonda, J. Bingert, and K. Colligan: Scripta Mater., 2004, vol. 51, pp. 243–48.

    CAS  Google Scholar 

  38. T. McNelley, S. Swaminathan, and J. Su: Scripta Mater., 2008, vol. 58, pp. 349–54.

    CAS  Google Scholar 

  39. W. Xunhong and W. Kuaishe: Mater. Sci. Eng. A, 2006, vol. 431, pp. 114–17.

    Google Scholar 

  40. G.K. Padhy, C.S. Wu, and S. Gao: Mater. Des., 2017, vol. 116, pp. 207–18.

    CAS  Google Scholar 

  41. G.K. Padhy, C.S. Wu, S. Gao, and L. Shi: Mater. Des., 2016, vol. 92, pp. 710–23.

    CAS  Google Scholar 

  42. Y.S. Sato, M. Urata, H. Kokawa, and K. Ikeda: Mater. Sci. Eng. A, 2003, vol. 354, pp. 298–305.

    Google Scholar 

  43. M. Ahmadnia, A. Seidanloo, R. Teimouri, Y. Rostamiyan, and K.G. Titrashi: Int. J. Adv. Manuf. Technol., 2015, vol. 78, pp. 2009–24.

    Google Scholar 

  44. X.C. Liu, C.S. Wu, and G.K. Padhy: Sci. Technol. Weld. Join., 2015, vol. 20, pp. 345–52.

    CAS  Google Scholar 

  45. L. Shi, C.S. Wu, and X.C. Liu: J. Mater. Process. Technol., 2015, vol. 222, pp. 91–102.

    CAS  Google Scholar 

  46. V. Firouzdor and S. Kou: Metall. Mater. Trans. A, 2010, vol. 41A, pp. 3238–51.

    Google Scholar 

  47. J. Philibert: Mater. Sci. Forum, 1994, vols. 155–156, pp. 15–30.

    Google Scholar 

  48. Y. Chen and K. Nakata: Mater. Des., 2009, vol. 30, pp. 469–74.

    CAS  Google Scholar 

  49. S. Malarvizhi and V. Balasubramanian: Mater. Des., 2012, vol. 40, pp. 453–60.

    CAS  Google Scholar 

  50. A.C. Somasekharan and L.E. Murr: J. Mater. Sci., 2006, vol. 41, pp. 5365–70.

    CAS  Google Scholar 

  51. S.H. Chowdhury, D.L. Chen, S.D. Bhole, X. Cao, and P. Wanjara: Metall. Mater. Trans. A, 2013, vol. 44A, pp. 323–36.

    Google Scholar 

  52. R. Nandan, G.G. Roy, T. Debroy, and I. Introduction: Metall. Mater. Trans. A, 2006, vol. 37A, pp. 1247–59.

    CAS  Google Scholar 

  53. N.Z. Khan, A.N. Siddiquee, Z.A. Khan, and A.K. Mukhopadhyay: J. Alloys Compd., 2017, vol. 695, pp. 2902–08.

    CAS  Google Scholar 

  54. A. Kouadri-Henni and L. Barrallier: Metall. Mater. Trans. A, 2014, vol. 45A, pp. 4983–96.

    Google Scholar 

  55. S.H. Chowdhury, D.L. Chen, S.D. Bhole, X. Cao, and P. Wanjara: Mater. Sci. Eng. A, 2012, vol. 556, pp. 500–09.

    CAS  Google Scholar 

  56. K.-J. Lee and E.-P. Kwon: Trans. Nonferrous Met. Soc. China, 2014, vol. 24, pp. 2374–79.

    CAS  Google Scholar 

  57. S.H.C. Park, Y.S. Sato, and H. Kokawa: Scripta Mater., 2003, vol. 49, pp. 161–66.

    CAS  Google Scholar 

  58. I. Dinaharan and N. Murugan: Mater. Sci. Eng. A, 2012, vol. 543, pp. 257–66.

    CAS  Google Scholar 

  59. S. Alireza Askariani, H. Pishbin, and M. Moshref-Javadi: J. Alloys Compd., 2017, vol. 724, pp. 859–68.

  60. X.C. Liu and C.S. Wu: J. Mater. Process. Technol., 2015, vol. 225, pp. 32–44.

    CAS  Google Scholar 

  61. S. Kumar, C.S. Wu, G.K. Padhy, and W. Ding: J. Manuf. Process., 2017, vol. 26, pp. 295–322.

    Google Scholar 

  62. X.C. Liu, C.S. Wu, and G.K. Padhy: Scripta Mater., 2015, vol. 102, pp. 95–98.

    Google Scholar 

  63. V. Gaur, M. Enoki, T. Okada, and S. Yomogida: Int. J. Fatigue, 2018, vol. 107, pp. 119–29.

    CAS  Google Scholar 

  64. T. Wen, L. Wei, X. Chen, and C.L. Pei: Int. J. Miner. Metall. Mater., 2011, vol. 18, pp. 70–76.

    CAS  Google Scholar 

  65. S. Kumar and C.S. Wu: 5th Int. Symp. on Visualization in Joining & Welding Science through Advanced Measurements and Simulation and 8th Int. Conf. of Welding Science and Engineering, Osaka, Japan, 2019.

Download references

Acknowledgment

The authors acknowledge the financial support from the Key R&D Program of Shandong Province in China (Grant No. 2018GGX103001).

Author information

Authors and Affiliations

  1. MOE Key Lab for Liquid-Solid Structure Evolution and Materials Processing, Institute of Materials Joining, Shandong University, Jinan, 250061, P.R. China

    Sachin Kumar, Chuansong Wu & Song Gao

Authors
  1. Sachin Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Chuansong Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Song Gao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Chuansong Wu.

Additional information

Publisher's Note

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

Manuscript submitted April 1, 2019.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kumar, S., Wu, C. & Gao, S. Process Parametric Dependency of Axial Downward Force and Macro- and Microstructural Morphologies in Ultrasonically Assisted Friction Stir Welding of Al/Mg Alloys. Metall Mater Trans A 51, 2863–2881 (2020). https://doi.org/10.1007/s11661-020-05716-1

Download citation

  • Received:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11661-020-05716-1

Search

Navigation