Skip to main content

Advertisement

SpringerLink
Log in

Microstructure and Tensile Strength of AA6082 T-joints by Corner Stationary Shoulder Friction Stir Welding: Effect of Tool Rotation Speed

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Tool rotation speed is one of the most important processing parameters that govern the performance of the friction stir welds. In this study, a novel variant of friction stir welding for T-joints, which is termed as corner stationary shoulder friction stir welding (CSSFSW), is investigated regarding the effect of tool rotation speed on the microstructure and tensile strength of the T-joints. T-joints with 5 mm thickness for AA 6082-T6 plates were fabricated via a two-pass welding process by using different tool rotation speeds. The microstructure and tensile strength of the defect-free and defective T-joints were analyzed. It is found that void defects appear on the advancing side when the tool rotation speed was 1200 rpm; defect-free T-joints are obtained in the range of tool rotation speeds from 1500 to 2000 rpm. Generally, high tool rotation speed is favorable for eliminating weld defects. In the case of CSSFSW, the lower limit of the tool rotation speed for defect-free welds is higher than that in the conventional FSW, because the heat input is reduced as the stationary shoulder contributes little to the heat generation. The tensile strength of the defect-free joint made at the tool rotation speed of 1500 rpm reached a maximum in both skin and stiffener direction, while are measured to be 113 MPa in L direction and 170 MPa in T direction. The fracture morphologies of the T-joints welded at different tool rotation speeds in both skin and stiffener directions when subjected to tensile loads are documented. A conceptual model is proposed in order to discuss the weld formation in the CSSFSW configuration.

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

Similar content being viewed by others

References

  1. R.S. Mishra and Z.Y. Ma, Friction Stir Welding and Processing, Mater. Sci. Eng. R, 2005, 50, p 1–78

    Article  Google Scholar 

  2. G.K. Padhy, C.S. Wu, and S. Gao, Friction Stir Based Welding and Processing Technologies: Process, Parameters, Microstructures and Application: A Review, J. Master. Sci. Technol., 2018, 34, p 1–38

    Article  Google Scholar 

  3. P.I. Oliveira, J.M. Costa, and A. Loureiro, Effect of Laser Beam Welding Parameters on Morphology and Strength of Dissimilar AA2024/AA7075 T-joints, Mater. Manuf. Process., 2018, 35, p 16–149

    Article  Google Scholar 

  4. A. Viscusi, C. Leitão, D.M. Rodrigues, F. Scherillo, A. Squillace, and L. Carrino, Laser Beam Welded Joints of Dissimilar Heat Treatable Aluminium Alloys, J. Mater. Process. Technol., 2016, 236, p 48–55

    Article  CAS  Google Scholar 

  5. Q.L. Dai, X.Y. Wang, Z.G. Hou, J.J. Wu, and Q.Y. Shi, Microcavities Accompanying a Zigzag Line in Friction Stir Welded AA6082-T6 Alloy Joint, Sci. Technol. Weld. Join., 2014, 20(1), p 68–74

    Article  Google Scholar 

  6. Q. Dai, Z. Liang, G. Chen, L. Meng, and Q. Shi, Explore the Mechanism of High Fatigue Crack Propagation Rate in Fine Microstructure of Friction Stir Welded Aluminum Alloy, Mater. Sci. Eng. A, 2013, 580, p 184–190

    Article  CAS  Google Scholar 

  7. T. Sun, M.J. Roy, D. Strong, P.J. Withers, and P.B. Prangnell, Comparison of Residual Stress Distributions in Conventional and Stationary Shoulder High-Strength Aluminum Alloy Friction Stir Welds, J. Mater. Process. Technol., 2017, 242, p 92–100

    Article  CAS  Google Scholar 

  8. S. Ji, Z. Li, Z. Zhou, and L. Zhang, Microstructure and Mechanical Property Differences Between Friction Stir Lap Welded Joints Using Rotating and Stationary Shoulders, Int. J. Adv. Manuf. Technol., 2016, 90(9–12), p 3045–3053

    Google Scholar 

  9. L. Fratini, G. Buffa, L. Filice, and F. Gagliardi, Friction Stir Welding of AA6082-T6 T-Joints: Process Engineering And Performance Measurement, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 2006, 220(5), p 669–676

    Article  Google Scholar 

  10. L. Fratini, G. Buffa, F. Micari, and R. Shivpuri, On the Material Flow in FSW of T-Joints: Influence of Geometrical and Tecnological Parameters, Int. J. Adv. Manuf. Technol., 2008, 44(5–6), p 570–578

    Google Scholar 

  11. L. Cui, X. Yang, Y. Xie, X. Hou, and Y. Song, Process Parameter Influence on Defects and Tensile Properties of Friction Stir Welded T-Joints on aa6AA061-T4 Sheets, Mater. Des., 2013, 51, p 161–174

    Article  CAS  Google Scholar 

  12. L. Cui, X. Yang, G. Zhou, X. Xu, and Z. Shen, Characteristics of Defects and Tensile Behaviors on Friction Stir Welded AA6061-T4 T-Joints, Mater. Sci. Eng. A, 2012, 543, p 58–68

    Article  CAS  Google Scholar 

  13. X. Hou, X. Yang, L. Cui, and G. Zhou, Influences of Joint Geometry on Defects and Mechanical Properties of Friction Stir Welded AA6061-T4 T-Joints, Mater. Des., 2014, 53, p 106–117

    Article  CAS  Google Scholar 

  14. M.J. Russell, C. Blignault, N.L. Horrex, and C.S. Wiesner, Recent developments in the friction stir welding of titanium alloys. Weld. World, 2008, 52(9–10), p 12–15

    Article  Google Scholar 

  15. M.M.Z. Ahmed, B.P. Wynne, W.M. Rainforth, and P.L. Threadgill, Through-Thickness Crystallographic Texture of Stationary Shoulder Friction Stir Welded Aluminium, Scr. Mater., 2011, 64(1), p 45–48

    Article  CAS  Google Scholar 

  16. P.S. Davies, B.P. Wynne, W.M. Rainforth, M.J. Thomas, and P.L. Threadgill, Development of Microstructure and Crystallographic Texture During Stationary Shoulder Friction Stir Welding of Ti-6Al-4V, Metall. Mater. Trans. A, 2011, 42(8), p 2278–2289

    Article  CAS  Google Scholar 

  17. J. Martin, Station Shoulder Friction Stir Welding Developments, Electr. Weld. Mach., 2014, 44(4), p 31–38

    Google Scholar 

  18. X.Y. Dongxiao Li, L. Cui, F. He, and X. Zhang, The Local Strength and Toughness for Stationary Shoulder Friction Stir Weld on AA6061-T6 Alloy, J. Mater. Process. Technol., 2016, 111, p 114–121

    Google Scholar 

  19. S.D. Ji, X.C. Meng, Z.W. Li, L. Ma, and S.S. Gao, Experimental Study of Stationary Shoulder Friction Stir Welded 7N01-T4 Aluminum Alloy, J. Mater. Eng. Perform., 2016, 25(3), p 1228–1236

    Article  CAS  Google Scholar 

  20. D. Li, X. Yang, L. Cui, F. He, and H. Shen, Effect of Welding Parameters on Microstructure and Mechanical Properties of AA6061-T6 Butt Welded Joints by Stationary Shoulder Friction STIR Welding, Mater. Des., 2014, 64, p 251–260

    Article  CAS  Google Scholar 

  21. S.D. Ji, X.C. Meng, J.G. Liu, L.G. Zhang, and S.S. Gao, Formation and Mechanical Properties of Stationary Shoulder Friction Stir Welded 6005A-T6 Aluminum Alloy, Mater. Des., 2014, 62, p 113–117

    Article  CAS  Google Scholar 

  22. F. Acerra, G. Buffa, L. Fratini, and G. Troiano, On the FSW of AA2024-t4 and AA7075-T6 T-Joints: an Industrial Case Study, Int. J. Adv. Manuf. Technol., 2009, 48(9–12), p 1149–1157

    Google Scholar 

  23. M.L. Penalva, A. Otaegi, J. Pujana, A. Rivero, V.J. Segui, Development of a new joint geometry for FSW. in Third Manufacturing Engineering Society International Conference, 2009, pp. 1–11

  24. G. Buffa, L. Fratini, B. Arregi, and M. Penalva, A new Friction Stir Welding Based Technique for Corner Fillet Joints: Experimental and Numerical Study, Int. J. Mater. Form., 2010, 3(S1), p 1039–1042

    Article  Google Scholar 

  25. C.A. Maltin, L.J. Nolton, J.L. Scott, A.I. Toumpis, and A.M. Galloway, The Potential Adaptation of Stationary Shoulder Friction Stir Welding Technology to Steel, Mater. Des., 2014, 64, p 614–624

    Article  CAS  Google Scholar 

  26. A.C.F. Silva, D.F.O. Braga, M.A.V.D. Figueiredo, and P.M.G.P. Moreira, Friction Stir Welded T-Joints Optimization, Mater. Des., 2014, 55, p 120–127

    Article  CAS  Google Scholar 

  27. D.X. Li, X. Yang, L. Cui, F. He, and X. Zhang, Fatigue Property of Stationary Shoulder Friction Stir Welded Additive and Non-additive T Joints, Sci. Technol. Weld. Join., 2015, 20(8), p 650–654

    Article  Google Scholar 

  28. H. Wu, Y.-C. Chen, D. Strong, and P. Prangnell, Stationary Shoulder FSW for Joining High Strength Aluminum Alloys, J. Mater. Process. Technol., 2015, 221, p 187–196

    Article  CAS  Google Scholar 

  29. D. Li, X. Yang, L. Cui, F. He, and X. Zhang, Investigation of Stationary Shoulder Friction Stir Welding of Aluminum Alloy 7075-T651, J. Mater. Process. Technol., 2015, 222, p 391–398

    Article  CAS  Google Scholar 

  30. Y.S. Jingqing Zhang, B. Li, H. Xu, X. Yao, B. Kuang, and J. Gao, Numerical Simulation and Experimental Investigation on Friction Stir Welding of 6061-T6 Aluminum Alloy, Mater. Des., 2014, 60(2014), p 94–101

    Article  Google Scholar 

  31. H.-B. Chen, K. Yan, T. Lin, S.-B. Chen, C.-Y. Jiang, and Y. Zhao, The Investigation of Typical Welding Defects for 5456 Aluminum Alloy Friction Stir Welds, Mater. Sci. Eng. A, 2006, 433(1–2), p 64–69

    Article  Google Scholar 

  32. G. Chen, H. Li, G. Wang, Z. Guo, S. Zhang, Q. Dai, X. Wang, G. Zhang, and Q. Shi, Effects of Pin Thread on the In-Process Material Flow Behavior During Friction Stir Welding: A Computational Fluid Dynamics Study, Int. J. Mach. tool Manuf., 2018, 124, p 12–21

    Article  Google Scholar 

  33. K. Kumar and S.V. Kailas, The Role of Friction Stir Welding Tool on Material Flow and Weld Formation, Mater. Sci. Eng., A, 2008, 485(1–2), p 367–374

    Article  Google Scholar 

Download references

Acknowledgments

This study was financially supported by the National Natural Science Foundation of China (Grant No. 51705280 and 51375259) and the State Key Laboratory of Tribology (No. SKLT 2015D07).

Author information

Authors and Affiliations

  1. Tsinghua University, Beijing, China

    Shenbo Zeng, Gaoqiang Chen, Isaac Dinaharan, Qu Liu, Shuai Zhang, Prakash Kumar Sahu, Jianjun Wu, Gong Zhang & Qingyu Shi

Authors
  1. Shenbo Zeng
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Gaoqiang Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Isaac Dinaharan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Qu Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Shuai Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Prakash Kumar Sahu
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Jianjun Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Gong Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Qingyu Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Qingyu Shi.

Additional information

Publisher's Note

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

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zeng, S., Chen, G., Dinaharan, I. et al. Microstructure and Tensile Strength of AA6082 T-joints by Corner Stationary Shoulder Friction Stir Welding: Effect of Tool Rotation Speed. J. of Materi Eng and Perform 29, 7094–7103 (2020). https://doi.org/10.1007/s11665-020-05179-w

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-020-05179-w

Keywords

Search

Navigation