Technical Brief

A Study on Friction Stir Welding of Dissimilar Thin Sheets of Aluminum Alloys AA 5052–AA 6061

[+] Author and Article Information
Jyoti K. Doley

Mechanical Engineering Department,
Indian Institute of Technology Guwahati,
Guwahati 781039, India
e-mail: j.doley@iitg.ac.in

Sachin D. Kore

Mechanical Engineering Department,
Indian Institute of Technology Guwahati,
Guwahati 781039, India
e-mail: sdk@iitg.ac.in

1Corresponding author.

Manuscript received November 15, 2015; final manuscript received May 19, 2016; published online June 23, 2016. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 138(11), 114502 (Jun 23, 2016) (6 pages) Paper No: MANU-15-1583; doi: 10.1115/1.4033691 History: Received November 15, 2015; Revised May 19, 2016

Friction stir welding (FSW) of AA 5052 H32 to AA 6061 T6 blanks was obtained for each thicknesses of 1 mm and 1.5 mm. Successful welds were obtained at constant tool spindle speed of 1500 rpm and two tool traverse speeds of 63 mm/min and 98 mm/min. For both thicknesses, weld produced at 63 mm/min speed gives more ductility than the weld produced at 98 mm/min. Elongation prior failure of 1.5 mm thick tailor welded blank (TWB) was found to be 47% more than that of 1 mm thickness weld. Microhardness measurement of the dissimilar welds showed lower values at heat-affected zones (HAZ) on both the sides of weld line, whereas lowest hardness value was obtained at HAZ of AA 5052. Optical microscope and energy dispersive spectroscopy (EDS) analyses on the stir zone (SZ) suggest dynamic recrystallization and finer grain size with uniform mixing at the center of SZ. Intermetallic compounds are formed during welding which plays detrimental role in the fracture strength of the joint.

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Fig. 1

FSW tool nomenclature and tools used in the present work

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Fig. 2

Surface appearance of FSWed sample at tool traverse rate: (a) 63 mm/min and (b) 98 mm/min

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Fig. 3

Tensile test specimens showing fracture at weld

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Fig. 4

Tensile test result of (a) 1 mm and (b) 1.5 mm thickness FSWed samples

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Fig. 5

Vickers microhardness graph for friction stir welded samples

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Fig. 6

Optical macrographs of the cross section perpendicular to the tool traverse direction of FSW sample welded at 68 mm/min speed

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Fig. 7

Optical micrograph image of (a) base AA 6061 alloy, (b) TMAZ at AA 6061 side, (c) SZ at AA 6061 side, (d) SZ at AA 5052 side, (e) TMAZ at AA 5052 side, and (f) base AA 5052 alloy

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Fig. 8

SEM image and EDS spectra showing the chemical compositions at the center of the weld

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Fig. 9

FESEM images of the weld SZ at tool rotational speed of 68 mm/min (a) at lower magnification and (b) at higher magnification

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Fig. 10

FSEM images of the fracture surface of weld region of tensile specimen




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