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Dissimilar Friction Stir Welding between Aluminum Alloy and Magnesium Alloy
, M.Sc. Thesis Sharif University of Technology ; Kokabi, Amir Hossein (Supervisor) ; Seyed Reihani, Morteza (Supervisor)
Abstract
In this project, Dissimilar Friction Stir Welding (FSW) between aluminum alloys (1100-H12 and 5083-O) and Magnesium alloy (AZ31B-O) with 3mm thickness were butt joined. Fusion welding of aluminum/magnesium alloys has failed because of forming much more intermetallic compounds. By using friction stir welded samples, effect of welding parameters such as tool travel speed, tool rotation rate, tool position respect to weld centerline, and sheet position respect to tool direction on mechanical (tensile strength, yield strength and elongation) and microstructural properties of the welds were investigated. After several tests, range of optimum parameters were obtained. In both 1100 and 5083 alloys,...
Influence of hard inclusions on microstructural characteristics and textural components during dissimilar friction-stir welding of an PM Al–Al2O3–SiC hybrid nanocomposite with AA1050 alloy
, Article Science and Technology of Welding and Joining ; Volume 22, Issue 5 , 2017 , Pages 412-427 ; 13621718 (ISSN) ; Simchi, A ; Kokabi, A. H ; Gerlich, A. P ; Nosko, M ; Švec, P ; Sharif University of Technology
Taylor and Francis Ltd
2017
Abstract
Owing to the advantages of nanocomposites for structural applications, we present microstructural evolutions and texture development during dissimilar friction stir welding (DFSW) of an Al-matrix hybrid nanocomposite (Al-2 vol.-% Al2O3-2 vol.-% SiC) with AA1050. It is shown that DFSW can successfully be performed at a rotating speed of 1200 rev min−1 and a transverse speed of 50 mm min−1 while locating the nanocomposite at retreating side. Formation of macro-, micro-, and nano-mechanical interlocks between dissimilar base materials (BMs) as a result of FSW tool stirring action possessed an impact influence on the mechanical performance of dissimilar welds. Electron microscopy revealed...
Influence of hard inclusions on microstructural characteristics and textural components during dissimilar friction-stir welding of an PM Al–Al2O3–SiC hybrid nanocomposite with AA1050 alloy
, Article Science and Technology of Welding and Joining ; 2016 , Pages 1-16 ; 13621718 (ISSN) ; Simchi, A ; Kokabi, A. H ; Gerlich, A. P ; Nosko, M ; Švec, P ; Sharif University of Technology
Taylor and Francis Ltd
2016
Abstract
Owing to the advantages of nanocomposites for structural applications, we present microstructural evolutions and texture development during dissimilar friction stir welding (DFSW) of an Al-matrix hybrid nanocomposite (Al-2 vol.-% Al2O3-2 vol.-% SiC) with AA1050. It is shown that DFSW can successfully be performed at a rotating speed of 1200 rev min−1 and a transverse speed of 50 mm min−1 while locating the nanocomposite at retreating side. Formation of macro-, micro-, and nano-mechanical interlocks between dissimilar base materials (BMs) as a result of FSW tool stirring action possessed an impact influence on the mechanical performance of dissimilar welds. Electron microscopy revealed...
The role of metal-matrix composite development during friction stir welding of aluminum to brass in weld characteristics
, Article Journal of Materials Engineering and Performance ; Volume 21, Issue 11 , 2012 , Pages 2429-2437 ; 10599495 (ISSN) ; Esmaeili, A ; Mohammadi, M ; Sharbati, M ; Givi, M. K. B ; Sharif Unviersity of Technology
2012
Abstract
The present research aims to investigate the development of brass reinforced aluminum composites during dissimilar friction stir welding of brass and aluminum. Moreover, to probe the effect of such a metal matrix composite on its bed, the cross-sectional properties of joint area are studied in two aspects of corrosion behavior and hardness distribution. Microstructural investigations through optical and electron microscopy show development of lamellar composites within the top site of the stir zone and aluminum surface. The measured iso-hardness contours indicate that evolved composite structures increase the cross-sectional hardness of aluminum locally. Also, the electrochemical assessment...
Effect of tool geometry on mechanical and microstructural behaviours in dissimilar friction stir welding of AA 5086-AA 6061
, Article Science and Technology of Welding and Joining ; Volume 16, Issue 7 , 2011 , Pages 597-604 ; 13621718 (ISSN) ; Serajzadeh, S ; Kokabi, A. H ; Loureiro, A ; Sharif University of Technology
Abstract
The aim of this investigation is to study the effect of geometric tool parameters on mechanical and microstructural behaviours during dissimilar friction stir welding of 5 mm thick plates of AA 5086- O and AA 6061-T6. Three tool geometries were used, including a tool with a concave shoulder and a conical probe with three grooves, flat shoulder and threadless cylindrical probe, and a tool with a flat shoulder and a threaded cylindrical probe. It was found that the tool with a concave shoulder and a conical probe with three grooves produces higher heat input and temperatures that provides more homogeneous stir zones than the other tools. In addition, the grain sizes of the stir zone in the AA...
Similar and dissimilar friction-stir welding of an PM aluminum-matrix hybrid nanocomposite and commercial pure aluminum: Microstructure and mechanical properties
, Article Materials Science and Engineering A ; Volume 666 , 2016 , Pages 225-237 ; 09215093 (ISSN) ; Simchi, A ; Kokabi, A. H ; Gerlich, A. P ; Sharif University of Technology
Elsevier Ltd
Abstract
Friction stir welding (FSW) of dissimilar joints has recently attracted great interest for the fabrication of bimetallic and layered composite structures. In this paper, dissimilar joining of an aluminum-matrix hybrid nanocomposite to commercial pure aluminum is reported for the first time. An aluminum hybrid nanocomposite reinforced with Al2O3 (2 vol%; 15 nm) and SiC (2 vol%; 50 nm) nanoparticles was prepared by powder metallurgy routes including mechanical milling and hot powder consolidation techniques. Different joint designs at various ranges of rotational (w) and traverse velocities (v) were evaluated to determine process window for the dissimilar solid-state welding. Macro- and...
Effect of intermetallic compounds on the fracture behavior of dissimilar friction stir welding joints of Mg and Al alloys
, Article International Journal of Minerals, Metallurgy and Materials ; Volume 26, Issue 10 , 2019 , Pages 1285-1298 ; 16744799 (ISSN) ; Sajuri, Z ; Selamat, N. F. M ; Omar, M. Z ; Miyashita, Y ; Kokabi, A. H ; Sharif University of Technology
University of Science and Technology Beijing
2019
Abstract
Joining Mg to Al is challenging because of the deterioration of mechanical properties caused by the formation of intermetallic compounds (IMCs) at the Mg/Al interface. This study aims to improve the mechanical properties of welded samples by preventing the fracture location at the Mg/Al interface. Friction stir welding was performed to join Mg to Al at different rotational and travel speeds. The micro structure of the welded samples showed the IMCs layers containing Al12Mg17 (γ) and Al3Mg2 (β) at the welding zone with a thickness (> 3.5
An investigation on the dissimilar friction stir welding of T-joints between AA5754 aluminum alloy and poly(methyl methacrylate)
, Article Thin-Walled Structures ; Volume 135 , 2019 , Pages 376-384 ; 02638231 (ISSN) ; Simchi, A ; Sharif University of Technology
Elsevier Ltd
2019
Abstract
Process optimization to prepare T-joints of poly methyl methacrylate (PMMA) and AA5754 alloy by friction stir welding (FSW) was performed. Effects of processing parameters including tool rotational velocity, traverse speed, tilt angle and plunge depth (TP) were studied. The material flow and formation of interaction layer upon FSW were evaluated and the tensile strength and hardness of the joints were examined. It is shown that by controlling the heat input into stir zone through increasing the rotational velocity or decreasing travelling speed, less defects are formed while the thickness of the interaction layer increases. The optimum condition is attained at 1600 rpm/30 mm min−1 with a...
Experimental and theoretical evaluations of thermal histories and residual stresses in dissimilar friction stir welding of AA5086-AA6061
, Article International Journal of Advanced Manufacturing Technology ; Volume 61, Issue 1-4 , 2012 , Pages 149-160 ; 02683768 (ISSN) ; Serajzadeh, S ; Kokabi, A. H ; Sharif University of Technology
2012
Abstract
In this work, the thermomechanical responses during the dissimilar friction stir welding of aluminum alloys have been evaluated employing a three-dimensional model and the finite element software ABAQUS. Furthermore, welding experiments have been conducted under different working conditions and the temperature variations during and after welding as well as the produced residual stresses in various positions of the welded samples were measured using hole-drilling technique. The model results were then examined by experimental data, and a reasonable agreement was observed. It is found that tool rotational speed significantly affects the amount of maximum tensile residual stress while traverse...