Skip to main content
SpringerLink
Log in

Theoretical and experimental investigation into friction stir welding of AA 5086

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This research investigates the relationship between the microstructures of thermomechanically affected zone (TMAZ) and heat input in friction stir welding (FSW) of 5086 aluminum alloy. First, welding heat input has been predicted using a three-dimensional finite element analysis; then, welding experiments have been carried out on annealed and work-hardened conditions to study the developed microstructures and the mechanical properties of the welded metal. The results show that the temperature field in the FSW process is asymmetrically distributed with respect to the welding line. Also, both experimental and predicted data illustrates that peak temperatures are higher on the advancing side than the retreating side. In addition, the microstructures are strongly affected by the heat input, while the grain size within the TMAZ decreases with decreasing heat input per unit length during 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

Similar content being viewed by others

References

  1. Thomas WM, Nicholas ED, Needham JC, Murch MG, Templesmith P, Dawes CJ (1991) Friction stir welding, international patent application No.PCT/GB92102203 and Great Britain patent application No. 9125978.8

  2. Salem HG, Reynolds AP, Lyons JS (2002) Microstructure and retention of superplasticity of friction stir welded superplastic 2095 sheet. Scr Mater 46:337–342

    Article  Google Scholar 

  3. Nicholas ED, Thomas WM (1998) A review of friction processes for aerospace applications. Int J Mater Prod Technol 13:45–55

    Google Scholar 

  4. Tang W, Guo X, McClure J, Murr L (1998) Heat input and temperature distribution in friction stir welding. J Mater Process Manuf Sci 7:163–172

    Article  Google Scholar 

  5. Chao Y, Qi X, Tang W (2003) Heat transfer in friction stir welding-experimental and numerical studies. Transactions of the ASME 125:138–145

    Google Scholar 

  6. Cao G, Kou S (2005) Friction stir welding of 2219 aluminum: behavior of θ(Al2 Cu) particles. Weld J 84(1):1s–8s

    Google Scholar 

  7. Dickerson TL, Przydatek J (2003) Fatigue of friction stir welds in aluminum alloys that contain root flaws. Int J Fatigue 25:1399–1409

    Article  Google Scholar 

  8. Guerra M, Schmidt C, McClure JC, Murr LE, Nunes AC (2003) Flow patterns during friction stir welding. Mater Charact 49:95–101

    Article  Google Scholar 

  9. Li Y, Murr LE, McClure JC (1999) Solid state flow visualization in the friction stir welding of 2024 Al to 6061 Al. Scr Mater 40:1041–1046

    Article  Google Scholar 

  10. Colligan K (1999) Material flow behavior during friction stir welding of aluminum. Suppl Weld J 78:229–237

    Google Scholar 

  11. Sutton MA, Yang B, Reynolds AP, Taylor R (2002) Microstructural studies of friction stir welds in 2024-T3 aluminum. Mater Sci Eng A 323:160–166

    Article  Google Scholar 

  12. Askari A, Silling S, London B, Mahoney M (2001) Modeling and analysis of friction stir welding processes. In: Jata KV, Mahoney MW, Mishra RS, Lienert TJ (eds) Friction stir welding and processing. The Minerals Metals and Materials Society, Warrendale, pp 43–54

    Google Scholar 

  13. Zhao H (2005) Friction stir welding (FSW) simulation using an arbitrary Lagrangian-Eulerian (ALE) moving mesh approach, PhD Dissertation, West Virginia University, West Virginia

  14. Colegrove P, Shercliff H (2003) 2-Dimensional CFD modeling of flow round profiled FSW tooling. In: Jata KV, Mahoney MW, Mishra RS, Lienert TJ (eds) Friction stir welding and processing. The Minerals Metals and Materials Society, Warrendale, pp 13–21

    Google Scholar 

  15. Hyoe T, Colegrove P, Shercliff H (2003) Thermal and microstructure modeling in thick plate aluminum alloy 7075 friction stir welds. In: Jata KV, Mahoney MW, Mishra RS, Lienert TJ (eds) Friction stir welding and processing. The Minerals Metals and Materials Society, Warrendale, pp 33–41

    Google Scholar 

  16. Schmidt H, Hattel J (2005) A local model for the thermo-mechanical conditions in friction stir welding. Model Simul Mater Sci Eng 13:77–93

    Article  Google Scholar 

  17. Nandan R, Roy G, Debroy T (2006) Numerical simulation of three dimensional heat transfer and plastic flow during friction stir welding. Metall Mater Trans A 37:1247–1259

    Article  Google Scholar 

  18. Ulysse P (2002) Three-dimensional modeling of the friction stir welding process. Int J Mach Tools Manuf 42:1549–1557

    Article  Google Scholar 

  19. Song M, Kovacevic R (2003) Thermal modeling of friction stir welding in a moving coordinate system and its validation. Int J Mach Tools Manuf 43:605–615

    Article  Google Scholar 

  20. Chao Y, Qi X (1998) Thermal and thermo-mechanical modeling of friction stir welding of aluminum alloy 6061-T6. J Mater Process Manuf Sci 7:215–233

    Article  Google Scholar 

  21. Xu SW, Deng XM, Reynolds AP, Seidel TU (2001) Finite element simulation of material flow in friction stir welding. Sci Technol Weld Joining 6:191–193

    Article  Google Scholar 

  22. Dunne F, Petrinic N (2007) Introduction to computational plasticity. Oxford University Press, Oxford, pp 89–90

    Google Scholar 

  23. Awang M (2007) Simulation of friction stir spot welding (FSSW) process: study of friction phenomena, PhD Thesis, West Virginia University, West Virginia

  24. Hibbit, Karlsson and Sorensen Inc. (2004) Abaqus/Explicit user's manual, version 6.5. Abaqus Inc., Pawtucket

  25. Prasad YVRK, Sasidhara S (1997) Hot working guide: a compendium of processing maps. ASM International, Materials Park, pp 101–103

    Google Scholar 

  26. Zhang Z, Zhang HW (2009) Numerical studies on controlling of process parameters in friction stir welding. J Mater Process Technol 209(1):241–270

    Article  Google Scholar 

  27. Buffa G, Hua J, Shivpuri R, Fratini L (2006) Design of the friction stir welding tool using the continuum based FEM model. Mater Sci Eng A 419:381–388

    Article  Google Scholar 

  28. Zhang Z, Zhang HW (2009) Numerical studies on the effect of transverse speed in friction stir welding. Mater Des 30(3):900–907

    Article  Google Scholar 

  29. Sato YS, Kurihara Y, Park SHC, Kokawa H, Tsuji N (2004) Friction stir welding of ultrafine grained Al alloy 1100 produced by accumulative roll-bonding. Scr Mater 50:57–60

    Article  Google Scholar 

  30. Cho JH, Boyce DE, Dawson PR (2005) Modeling strain hardening and texture evolution in friction stir welding of stainless steel. Mater Sci Eng A 398:146–163

    Article  Google Scholar 

  31. Dieter GE (1976) Mechanical metallurgy. McGraw-Hill, New York

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Materials Science and Engineering, Sharif University of Technology, Azadi Ave., P.O. Box 11155-9466, Tehran, Iran

    H. Jamshidi Aval, S. Serajzadeh & A. H. Kokabi

Authors
  1. H. Jamshidi Aval
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. S. Serajzadeh
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. H. Kokabi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to S. Serajzadeh.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Aval, H.J., Serajzadeh, S. & Kokabi, A.H. Theoretical and experimental investigation into friction stir welding of AA 5086. Int J Adv Manuf Technol 52, 531–544 (2011). https://doi.org/10.1007/s00170-010-2752-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-010-2752-x

Keywords

Search

Navigation