Manufacturing Technology Today

Open Access Open Access  Restricted Access Subscription Access
Open Access Open Access Open Access  Restricted Access Restricted Access Subscription Access

Effect of Tool Offset on Weld Characteristics During Dissimilar Micro-Friction Stir Welding of AA 6061-T6 and Alclad 2024-T3


Affiliations
1 Indian Institute of Technology Patna, Bihta, Patna, Bihar, India
     

   Subscribe/Renew Journal


A sound dissimilar welded thin sheet joint is required in various engineering applications to meet the demand for miniaturized products. The major concern is rapid heat dissipation which causes improper material intermixing and poor weld performance. Tool offset can resolve this issue. So, in the present work, 0.5 mm thick AA 6061-T6 and ALCLAD 2024-T3 were welded. The tool was offset on the 2024 (high-strength) side to ensure appropriate heat distribution and maximize the involvement of 2024 in weld zone. The degree of material intermixing is defined based on the number of intercalated layers and thickness of the layer of 2024 in stir zone (SZ). The highest weld efficiency of 77.97% was obtained at a tool offset distance of 0.6 mm due to mechanical interlocking produced by more intercalated layers. Moreover, the weld fractures from the heat-affected zone of 6061, unlike other cases where it fractures from the SZ.

Keywords

Dissimilar Micro-Friction Stir Welding (μFSW), Tool Offset, Material Intermixing, Ultra-Thin Sheets, Fractography.
User
Subscription Login to verify subscription
Notifications
Font Size

  • Ahmed, S., & Saha, P. (2018). Development and testing of fixtures for friction stir welding of thin aluminium sheets. Journal of Materials Processing Technology, 252, 242-248. https://doi.org/10.1016/j.jmatprotec.2017.09.034

  • Ahmed, S., & Saha, P. (2020). Selection of optimal process parameters and assessment of its effect in micro-friction stir welding of AA6061-T6 sheets. International Journal of Advanced Manufacturing Technology, 106(7-8), 3045-3061. https://doi.org/10.1007/s00170-019-04840-6

  • Cavaliere, P., & Panella, F. (2008). Effect of tool position on the fatigue properties of dissimilar 2024-7075 sheets joined by friction stir welding. Journal of Materials Processing Technology, 206, 249-255. https://doi.org/10.1016/j.jmatprotec.2007.12.036

  • Cole, E. G., Fehrenbacher, A., Duffie, N. A., & Zinn, M. R. (2014). Weld temperature effects during friction stir welding of dissimilar aluminum alloys 6061-t6 and 7075-t6. International Journal of Advanced Manufacturing Technology, 71, 643-652. https://doi.org/10.10 07/s00170-013-5485-9

  • Guo, J. F., Chen, H. C., Sun, C. N., Bi, G., Sun, Z., & Wei, J. (2014). Friction stir welding of dissimilar materials between AA6061 and AA7075 Al alloys effects of process parameters. Materials and Design, 56, 185-192. https://doi.org/10.1016/j.matdes.2013.10.082

  • Hohenwarter, A., & Pippan, R. (2012). A comprehensive study on the damage tolerance of ultrafine-grained copper. Materials Science and Engineering A, 540, 89-96. https://doi.org/10.1016/j.msea.2012.01.089

  • Jonckheere, C., De Meester, B., Denquin, A., & Simar, A. (2012). Dissimilar friction stir welding of 2014 to 6061 aluminum alloys. Advanced Materials Research, 409, 269-274. https://doi.org/10.4028/www.scientific.net/AMR.409.269

  • Kumar, K., & Kailas, S. V. (2010). Positional dependence of material flow in friction stir welding: Analysis of joint line remnant and its relevance to dissimilar metal welding. Science and Technology of Welding and Joining, 15(4), 305-311. https://doi.org/10.1179/136217109X12568132624280

  • Mao, Y., Ni, Y., Xiao, X., Qin, D., & Fu, L. (2020). Microstructural characterization and mechanical properties of micro friction stir welded dissimilar Al/Cu ultra-thin sheets. Journal of Manufacturing Processes, 60 (October), 356-365. https://doi.org/10.1016/j.jmapro.2020.10.064

  • Reynolds, A. P. (2008). Flow visualization and simulation in FSW. Scripta Materialia, 58, 338-342. https://doi.org/10.1016/j.scriptamat. 2007.10.048

  • Scialpi, A., De Filippis, L. A. C., Cuomo, P., & Di Summa, P. (2008). Micro friction stir welding of 2024-6082 aluminium alloys. Welding International, 22(1), 16-22. https://doi.org/10.1080/09507110801936069

  • Teh, N. J., Goddin, H., & Whitaker, A. (2011). Developments in micro applications of friction stir welding. Cambridge UK TWI Dense. https://www.twi-global.com/technical-knowledge/published-papers/developments-in-micro-applications-of-friction-stir- welding/.

  • Threadgilll, P. L., Leonard, A. J., Shercliff, H. R., & Withers, P. J. (2009). Friction stir welding of aluminium alloys. International Materials Reviews, 54(2), 49-93. https://doi.org/10.1179/ 174328009X411136

  • Vendra, S. S. L., Goel, S., Kumar, N., & Jayaganthan, R. (2017). A study on fracture toughness and strain rate sensitivity of severely deformed Al 6063 alloys processed by multiaxial forging and rolling at cryogenic temperature. Materials Science and Engineering A, 686(January), 82-92. https://doi.org/10.1016/j.msea.2017.01.035

  • Venkateswaran, P., & Reynolds, A. P. (2012). Factors affecting the properties of Friction Stir Welds between aluminum and magnesium alloys. Materials Science and Engineering A, 545, 26-37. https://doi.org/10.1016/j.msea.2012.02.069

  • Verma, M., Ahmed, S., & Saha, P. (2021). Challenges, process requisites / inputs , mechanics and weld performance of dissimilar micro-friction stir welding (dissimilar μ FSW): A comprehensive review. Journal of Manufacturing Processes, 68(PA), 249-276. https://doi.org/10.1016/j.jmapro.2021.05.045


Abstract Views: 108

PDF Views: 0




  • Effect of Tool Offset on Weld Characteristics During Dissimilar Micro-Friction Stir Welding of AA 6061-T6 and Alclad 2024-T3

Abstract Views: 108  |  PDF Views: 0

Authors

Mayank Verma
Indian Institute of Technology Patna, Bihta, Patna, Bihar, India
Probir Saha
Indian Institute of Technology Patna, Bihta, Patna, Bihar, India

Abstract


A sound dissimilar welded thin sheet joint is required in various engineering applications to meet the demand for miniaturized products. The major concern is rapid heat dissipation which causes improper material intermixing and poor weld performance. Tool offset can resolve this issue. So, in the present work, 0.5 mm thick AA 6061-T6 and ALCLAD 2024-T3 were welded. The tool was offset on the 2024 (high-strength) side to ensure appropriate heat distribution and maximize the involvement of 2024 in weld zone. The degree of material intermixing is defined based on the number of intercalated layers and thickness of the layer of 2024 in stir zone (SZ). The highest weld efficiency of 77.97% was obtained at a tool offset distance of 0.6 mm due to mechanical interlocking produced by more intercalated layers. Moreover, the weld fractures from the heat-affected zone of 6061, unlike other cases where it fractures from the SZ.

Keywords


Dissimilar Micro-Friction Stir Welding (μFSW), Tool Offset, Material Intermixing, Ultra-Thin Sheets, Fractography.

References