A Review on Enhancement of Friction Stir Welding (FSW) Settings for Microstructural Assessment and Mechanical Characteristics on Aluminium 6082 and Copper Joints

Authors

  • B. Lalit Kumar RSR Rungta College of Engineering and Technology Bhilai, C.G., India Author
  • Dr. Vikash Gadpale RSR Rungta College of Engineering and Technology Bhilai, C.G., India Author

DOI:

https://doi.org/10.32628/IJSRMME

Keywords:

Al 6082, Dissimilar Materials, Friction Stir Welding, Taguchi Technique, ANOVA

Abstract

Aluminium and its alloys are the major material that is used in today’s world. Aluminium alloys are alloys in which Aluminium (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon and zinc. Among the various available Al alloys Al6082 exhibits the properties like low weight, High strength to mass ratio, Weldability etc. Copper and its alloys are widely used in industrial applications due to their excellent electrical and thermal conductivities, good strength, and corrosion and fatigue resistances. The joints of dissimilar materials are widely used in industrial applications due to their technical and beneficial advantages. Aluminium and copper are two common metals in the electric power industry due to unique performances such as higher electrical conductivity, heat conductivity, corrosion resistance and mechanical properties. Friction Stir Welding (FSW) is a relatively new solid-state joining process. It was initially applied to aluminium alloys. In this study, the effect of different process parameters in dissimilar FSW of Al6082 alloy and copper and mechanical behaviour of the same are studied by conducting hardness, bending and tensile tests. Process optimization was done using Taguchi technique along with ANOVA analysis

References

Mishra R.S., Ma Z.Y., Friction stir welding and processing. Mater. Sci. Eng. R, Volume 50, 1-78, 2005.

A.K.Lakshminarayanan, V. Balasubramanian, Process parameters optimization for friction stir welding of RDE-40 aluminium alloy using Taguchi technique, Trans. Nonferrous Met. Soc. China, 18, 548-554, 2008.

S. Vijayan, R. Raju, K. Subbaiah, N. Sridhar, S.R.K. Rao, Friction stir welding of Al–Mg alloy optimization of process parameters using taguchi method, Experimental Techniques, 34, 37-44, 2010.

M. Koilraj, V. Sundareswaran, S. Vijayan, S.R. Koteswara Rao, Friction stir welding of dissimilar aluminum alloys AA2219 to AA5083 – Optimization of process parameters using Taguchi technique, Materials and Design, 42, 1–7, 2012.

L. Xia-wei, Z. Da-tong, Q. Cheng, Z. Wen, Microstructure and mechanical properties of dissimilar pure copper/1350 aluminum alloy butt joints by friction stir welding, Trans. Nonferrous Met. Soc. China, 22, 1298-1306, 2012.

M.H. Shojaeefard, Abolfazl Khalkhali, Mostafa Akbari, Mojtaba Tahani, Application of Taguchi optimization technique in determining aluminum to brass friction stir welding parameters, Materials and Design, 52, 587–592, 2013.

Bisadi H, Tavakoli A, Sangsaraki M T, Sangsaraki K T. The influences of rotational and welding speeds on microstructures and mechanical properties of friction stir welded Al5083 and commercially pure copper sheets lap joints. Materials & Design, 80−88, 2013.

Yahya Bozkurt, Mustafa Kemal Bilici, Application of Taguchi approach to optimize of FSSW parameters on joint properties of dissimilar AA2024-T3 and AA5754-H22 aluminum alloys, Materials and Design, 51, 513–521, 2013.

Mumin Tutar, Hakan Aydin, Celalettin Yuce, Nurettin Yavuz, Ali Bayram, The optimization of process parameters for friction stir spot-welded AA3003-H12 aluminium alloy using a Taguchi orthogonal array, Materials & Design, Volume 63, 789-797, November 2014.

P. Motalleb-nejad, T. Saeid, A. Heidarzadeh, Kh. Darzi, M. Ashjari, Effect of tool pin profile on microstructure and mechanical properties of friction stir welded AZ31B magnesium alloy, Materials and Design, 59, 221–226, 2014.

Bradford W. Baker, et al., Processing-Microstructure Relationships in Friction Stir Welding of MA956 Oxide Dispersion Strengthened Steel, Metallurgical and Materials Transactions, E volume 1, 318–330, 2014.

Nilesh Kumar, Wei Yuan, Rajiv S. Mishra, Friction Stir Welding of Dissimilar Alloys and Materials, Butterworth-Heinemann, Oxford, 1-13, 2015.

Sadiq Aziz Hussein, Abd Salam Md Tahir and R. Izamshah, Generated forces and heat during the critical stages of friction stir welding and processing, Journal of Mechanical Science and Technology, 29 (10), 4319-4328, 2015.

Hamed Jamshidi Aval, Influences of pin profile on the mechanical and microstructural behaviors in dissimilar friction stir welded AA6082–AA7075 butt Joint, Materials and Design, 67, 413–421, 2015.

K.K. Ramachandran, N. Murugan, S. Shashi Kumar, Effect of tool axis offset and geometry of tool pin profile on the characteristics of friction stir welded dissimilar joints of aluminum alloy AA5052 and HSLA steel, Materials Science & Engineering 639, 219–233, 2015.

Heena K Sharma, Kamlesh Bhatt, Krunal Shah, Unnati Joshi, Experimental Analysis of Friction Stir Welding of Dissimilar Alloys AA6061 and Mg AZ31 Using Circular Butt Joint Geometry, Procedia Technology, 23, 566 – 572, 2016.

M.F.X. Muthu, V. Jayabalan, Effect of pin profile and process parameters on microstructure and mechanical properties of friction stir welded Al−Cu joints, Trans. Nonferrous Met. Soc. China, 26, 984−993, 2016.

S.A. Khodir, M. M. Z. Ahmed, Essam Ahmed, S.M.R. Mohamed, H. Abdel-Aleem, Effect of Intermetallic Compound Phases on the Mechanical Properties of the Dissimilar Al/Cu Friction Stir Welded Joints, Journal of Materials Engineering and Performance, volume 25, 4637–4648, 2016.

Gonçalo Sorger, Hao Wang, Pedro Vilaça, Telmo G. Santos, FSW of aluminum AA5754 to steel DX54 with innovative overlap joint, Weld World, 61, 257–268, 2017.

R.Rafiei, A.Ostovari Moghaddam, M.R. Hatami, F. Khodabakhshi, A. Abdolahzadeh, A. Shokuhfar, Microstructural characteristics and mechanical properties of the dissimilar friction-stir butt welds between an Al–Mg alloy and A316L stainless steel, The International Journal of Advanced Manufacturing Technology, volume 90, 2785–2801, 2017.

N. Babu, N. Karunakaran, V. Balasubramanian, A study to estimate the tensile strength of friction stir welded AA 5059 aluminium alloy joints, The International Journal of Advanced Manufacturing Technology, volume 93, 1–9, 2017.

M. Almoussawi, A. J. Smith, M. Faraji, Wear of Polycrystalline Boron Nitride Tool During the Friction Stir Welding of Steel, Metallography, Microstructure, and Analysis, 7, 252–267, 2018.

Jeong-Won Choi, Huihong Liu, Hidetoshi Fujii, Dissimilar friction stir welding of pure Ti and pure Al, Materials Science & Engineering, 730, 168–176, 2018.

Arun Kumar Kadian, Pankaj Biswas, The study of material flow behaviour in dissimilar material FSW of AA6061 and Cu-B370 alloys plates, Journal of Manufacturing Processes, 34, 96–105, 2018.

Z. Sun, C.S. Wu, S. Kumar, Determination of heat generation by correlating the interfacial friction stress with temperature in friction stir welding, Journal of Manufacturing Processes, 31, 801–811, 2018.

S. Rasaee, A. H. Mirzaei, D. Almasi & S. Hayati, A Comprehensive Study of Parameters Effect on Mechanical Properties of Butt Friction Stir Welding in Aluminium 5083 and Copper, Transactions of the Indian Institute of Metals volume 71, 1553–1561, 2018.

L.H. Shah, N.H. Othman, A. Gerlich, Review of research progress on Aluminium magnesium dissimilar friction stir welding, Sci. Technol. Weld. Join., 23, 256-270, 2018.

N. Gangil, S. Maheshwari, A.N. Siddiquee, M.H. Abidi, M.A. El-Meligyd, J.A. Mohammed, Investigation on friction stir welding of hybrid composites fabricated on Al–Zn–Mg–Cu alloy through friction stir processing, Journal of Materials Research and Technology Volume 8, 3733-3740, 2019.

Zhongwei Ma, Qinghua Li, Lin Ma, Wei Hu, Bo Xu, Process Parameters Optimization of Friction Stir Welding of 6005A-T6 Aluminum Alloy Using Taguchi Technique, Transactions of the Indian Institute of Metals, volume 72, 1721–1731, 2019.

P. Geng, G. Qin, J. Zhou, C. Li, Parametric optimization and microstructural characterization of friction welded aeronautic aluminum alloy 2024, Trans. Nonferrous Met. Soc. China, 29, 2483−2495, 2019.

Wei Hu, Zhongwei Ma, Shude Ji, Song Qi, Wenhui Jiang, Improving the mechanical property of dissimilar Al/Mg hybrid friction stir welding joint by PIO-ANN, Journal of Materials Science & Technology, Volume 53, 41-52, September 2020.

Santosh Kumar Sahu, Nimai Haldar, Saurav Datta, Rajneesh Kumar, Experimental studies on AA6063-Cu dissimilar friction stir welding using Inconel 601 tool, Materials Today: Proceedings, 26, 180–188, 2020.

K.E. Ahmed, B.M. Nagesh, B.S. Raju, D.N. Drakshayani, A.S.C. Holla, Studies on the effect of welding parameters for friction stir welded AA6082 reinforced with Aluminium Oxide, Materials Today: Proceedings,20, 108–119, 2020.

Wentao Hou, L.H. Ahmad Shah, Guoqiang Huang, Yifu Shen, Adrian Gerlich, The role of tool offset on the microstructure and mechanical properties of Al/Cu friction stir welded joints, Journal of Alloys and Compounds, 825, 154-165, 2020.

Downloads

Published

16-03-2025

Issue

Section

Research Articles

Similar Articles

1-10 of 38

You may also start an advanced similarity search for this article.