Sharif Digital Repository

Weight reduction is one of the most concerning issues of automotive and aircraft industries in reducing fuel consumption. Magnesium (Mg) alloys are the lightest alloys which can be used in the structure due to low density and high strength to weight ratio. Developing a reliable joining process of magnesium alloys is required due to limited ductility and low workability at room temperature. Friction stir welding (FSW) is a solid-state welding process that can be performed to produce sound joints in magnesium alloys. Researchers have performed investigations on the effect of rotation and travel speeds in FSW of AZ31B magnesium alloy. However, there is lack of study on the FSW parameters, i.e.... 

In this study, we explored the growth kinetics of the Al-Fe intermetallic (IM) layer at the joint interface of the St-12/Al-5083 friction stir lap welds during post-weld annealing treatment at 350, 400 and 450 C for 30 to 180 min. Optical microscope (OM), field emission gun scanning electron microscope (FEG-SEM) and transmission electron microscope (TEM) were employed to investigate the structure of the weld zone. The thickness and composition of the IM layers were evaluated using image analysis system and electron back-scatter diffraction (EBSD), respectively. Moreover, kernel average misorientation (KAM) analysis was performed to evaluate the level of stored energy in the as-welded state.... 

Aluminium alloys are lightweight materials relatively used in automotive industries. However, welding using the conventional welding methods is known to be difficult. In this study, the friction stir welding (FSW) known as the solid state joining process was extensively used for joining similar and dissimilar 5 mm aluminium alloy plates. The butt-joint type of similar joints (AA5083-AA5083) and dissimilar joints (AA5083-AA6061) were carried out under the same welding parameters; 1000 rpm (rotational speed) and 100 mm/min (transverse speed). Macro- and microstructural observations were acquired at the cross-section of the weld regions by stereo and optical microscopes. The microstructural... 

5083 aluminium (Al) alloy materials have extensive structural applications in transportation industries because of their high strength-to-weight ratio and corrosion resistance. However, under conventional fusion weldings, these materials are limited by their porosity, hot cracking, and distortion. Herein, friction stir welding (FSW) was performed to join a similar AA5083 alloy. A post-weld cold-rolling (PWCR) process was applied on joint samples at different thickness-reduction percentages (i.e., 10%, 20%, and 40%) to identify the effect of strain hardening on the microstructure and mechanical properties of the friction-stir-welded joint of AA5083 while considering the serration-flow... 

In the present study, the dissimilar aluminum alloys of 5083-H12 and 6061-T6 were joined by friction stir welding (FSW). Then, the design of experiments (DOE), the Box-Benken method, and the response surface methodology (RSM) were used to optimize the effective parameters of the FSW process. The optimized parameters that led to the maximum tensile strength in dissimilar friction stir welded sheets were determined. The predicted results were then compared with those measured experimentally. The results show that there is good agreement between the predicted and measured amounts. By applying the limit dome height (LDH) test, the formability of friction stir welded sheets was studied. During... 

The severely plastic deformed aluminum sheets were joined by friction stir welding (FSW). The technique used for imposing the severe strain to the sheets was constrained groove pressing (CGP) process. The specimens with three different imposed strains by CGP, which lead to different initial microstructures, were joined at various rotation (. ω) and traveling (. V) speeds. The microhardness measurements and microstructure investigations were carried out. It was revealed that after FSW process of the specimens strained by CGP process, grain growth and correspondingly hardness reduction were observed at the stir zone. Also, transverse tensile test was performed at all conditions. For the CGPed... 

In this paper an integrated model has been utilized to predict thermo-mechanical behavior during friction stir welding of an aluminum alloy. A finite element code, ABAQUS, is employed to solve the governing equations of heat conduction and plastic deformation, while a rigid - viscoplastic material behavior is utilized and effects of different thermal and mechanical boundary conditions are considered in the simulation. To assess the accuracy of the model, predicted results have been compared with experimental data and good agreement has been observed  

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... 

Welded sheets with different thicknesses are one of the interesting types of tailor-welded blanks (TWBs) that are widely used in metal-forming industries. In the present work, the formability behavior of different 1100-aluminum TWBs was studied. In this regard, the TWBs were made with different thickness ratios by using friction stir welding (FSW) at different welding rotational speeds (ω). The thickness ratios of 1.0, 1.3, and 1.7 were investigated where the thinner sheets had 1.5 mm thick for all conditions; i.e., the volume of welded material increased when the thickness ratio increased. Macrostructural observations, mechanical investigations, and sheet-forming limit tests were... 

Travel speeds between 25–300 mm/min and tool rotational speeds of 800 and 1250 rpm were employed for this study. The microstructure, mechanical properties and fracture surfaces of the joints were studied. Underwater environment and an increase in travel speed significantly increase the precipitates’ volume fraction, reduce the average grain and precipitate sizes of the weld nugget zones. A critical travel speed of 150 mm/min is attained in underwater welds beyond which the average grain sizes remain relatively the same. Average grain and precipitate sizes have linear relationships with the tool rotational and travel speed ratio. Optimum weld strengths of 396 and 360 MPa were obtained in the... 

In the present work, the feasibility of friction stir welding (FSW) of poly(methyl methacrylate) sheets was studied experimentally and theoretically by employing thermomechanical simulations. The effect of processing parameters including tool plunge depth, tilt angle, tool rotational speed (w), and transverse velocity (v) was investigated to determine suitable conditions to attain sound and defect-free joints. It is shown that a low tool plunge depth of 0.2 mm and a tilt angle of 2° provide suitable material flow to gain sound joints. By controlling the heat input into stir zone by increasing the tool rotational speed and decreasing linear velocity, the formation of defects can be minimised.... 

In this work, similar butt joints of AA6061-T6 alloy prepared by underwater friction stir welding (UWFSW) and friction stir vibration welding (FSVW) processes were examined. The characteristics of joints were compared with the joints obtained by conventional friction stir welding (CFSW). The different kinds of microstructural modifications that occurred during CFSW, FSVW, and UWFSW processes were analyzed. The results are employed to analyze the different behaviors in strength, ductility, weldability, and hardness of the joints in different processes at different traverse speeds, rotational speeds, and vibration frequency. It was found that mechanical vibration decreases the grain size in... 

In this work, similar butt joints of AA6061-T6 alloy prepared by underwater friction stir welding (UWFSW) and friction stir vibration welding (FSVW) processes were examined. The characteristics of joints were compared with the joints obtained by conventional friction stir welding (CFSW). The different kinds of microstructural modifications that occurred during CFSW, FSVW, and UWFSW processes were analyzed. The results are employed to analyze the different behaviors in strength, ductility, weldability, and hardness of the joints in different processes at different traverse speeds, rotational speeds, and vibration frequency. It was found that mechanical vibration decreases the grain size in... 

Friction stir welding (FSW) is a relatively new solid-state joining technique that is widely adopted in manufacturing and industry fields to join different metallic alloys that are hard to weld by conventional fusion welding. Friction stir welding is a very complex process comprising several highly coupled physical phenomena. The complex geometry of some kinds of joints makes it difficult to develop an overall governing equations system for theoretical behavior analyse of the friction stir welded joints. Weld quality is predominantly affected by welding effective parameters, and the experiments are often time consuming and costly. On the other hand, employing artificial intelligence (AI)... 

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... 

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