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


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

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

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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