study friction stir welding regions of similar (aa6061 …€¦ · welding (fsw) method using three...

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 7, July 2018, pp. 1535–1546, Article ID: IJMET_09_07_163

Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=9&IType=7

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

STUDY FRICTION STIR WELDING REGIONS

OF SIMILAR (AA6061-T6) ALUMINUM ALLOYS

Hatem A. Hassan

Baquba Technical Institute- Middle Technical University, Baghdad, Iraq.

ABSTRACT

Similar AA6061-T6 and AA6061-T6(AA2024-T4 filler) were welded by friction stir

welding (FSW) method using three different values of linear (V) and rotating speed(N)

, V= 40, 75 and 90 mm/min, N= 450, 720 and 920 rpm. Tensile test was used to

determine the efficiency of welded samples. The microstructure, hardness, and fatigue

were studied for the welded sample which gave the highest tensile strength. The fatigue

test was studied in the welding at the both weld region (WM1and (WM) compared with

the base. The welding speed used has an effect on the efficiency of the welded samples

(WM1and (WM) where the maxi welding efficiency (87%, 79.6%) were obtained at N=

450 and V= 75 mm/min. The welding efficiency (WM1) higher than (WM) the reason

may be that the chemical composition of the weld metal (WM1) does change as

compared with the weld metal (WM) does not change, this is leading to change in the

chemical composition of the weld metal (WM1) relative to the base metal. The

microstructural analysis indicated that there is a significant elongation and bending in

the grains of the thermo-mechanical affected zone (TMAZ). The maximum value of

hardness at the both weld region (WM1and (WM) were at the weld line and started to

decrease away from it. Fatigue strength of the welded samples was less than the

wrought alloys. The fatigue efficiency of welded samples was lower than that of parent

alloy. It was observed that the fatigue characteristics of the welded sample of AA6061-

T6 approached the parent alloy when used AA2024-T4 a filler. The reduction

percentage in fatigue endurance limit of of both weld region (WM1) and (WM)

decreases compared with the base.

Key words: Frictions stir welding or stir zone (SZ), Thermo-mechanical affected zone

(TMAZ), weld metal (WM1), microstructure and fatigue.

Cite this Article: Hatem A. Hassan, Study Friction Stir Welding Regions of Similar

(Aa6061-T6) Aluminum Alloys, International Journal of Mechanical Engineering and

Technology, 9(7), 2018, pp. 1535–1546.

http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=9&IType=7

Hatem A. Hassan


1. INTRODUCTION

aluminium and aluminium alloys are extensively used for many applications such as household

utensils, railroad cars, autos, buildings, bridges, water gates, aircrafts, space crafts, ships,

chemical equipment, and storage tanks, because of the inherent advantages of high strength-to-

weight ratio, high notch toughness at cryogenic temperatures, ease in extrusion, excellent

corrosion resistance, and good fabricability Aluminium and its alloys are joined with welding,

adhesive bonding, mechanical fastening , soldering, and brazing. Form these joining processes,

welding is most widely used. [1, 2, 3].The aluminium alloys AA5xxx and AA6xxx used in the

ship, aircraft and transport vehicle structure fabrications [4, 5].Welding of these grades of

aluminium alloys by means gas tungsten arc welding or gas metal arc welding processes result

in welding problems due difference in solidification modes for each type of alloy, and therefore,

the FSW process was considered as a good method to weld different aluminium alloys This

process is a solid state welding technique [7, 8]. The fatigue behaviour of friction stir welded

of different series aluminium alloys (1050, 5083, 6061 and 7075) was investigated. They

concluded that the fatigue behaviour was sensitive to the microstructures of the welding zones.

The fatigue strengths of the welded samples generally were equal to or lower than those of the

parent materials [9]. The fatigue behaviour of similar FSW joints of different aluminium alloys

(AA6082 and AA5754) was studied. The fatigue stress ratio was R=0.1. It was observed that

the fatigue strength of the welded joints was less than those of the base material. The

improvement in the fatigue strength was observed for lower applied stress ranges [10]. The

axial fatigue strength of dissimilar joints between AA2124 and AA2024 by means of FSW was

achieved. The analysis of the fracture surfaces were investigated by SEM. Good fatigue

properties were observed in the joints compared to that of the base material AA2024. The

fractured region was located in the thermo-mechanically affected zone (TMAZ) or in the weld

centre. [11]. Dissimilar aluminium alloys type 5083-H111 and 6082-T651 were welded by

FSW and tested by the bending fatigue. The thickness of each plate was 6mm, the welding

machine parameters were: 1250 rpm rotating speed, 64 mm/min travel speed and 2° tool tilt

angle .The results showed that the fatigue strength of joints was close to each other with small

void effect [12]. Fatigue crack propagation of was investigated for the dissimilar aluminium

alloys joints 6061-T6 and 304 stainless steel welded by FSW. The results showed that the rate

of fatigue crack propagation of the welded joints were comparable or slightly faster as

comparing with the base material of aluminium [13]. The effect of FSW process parameters on

the formation of welding defects of dissimilar aluminium alloys: AA5083-H116 and AA6063-

T6 were investigated. The tunnel defects were found in the advanced side. The kissing bound

were formed towards the retreating side [14]. The microstructure of FSW joints of AA6061 and

AA5086 were studied. The microstructure investigation indicates that the hardness of joints

was improved due to brittle intermetallic phase formation and higher fraction of grain boundary

[15]. A lap joint of AA 6082-T6 and AA 5754-H22 was performed using FSW. They concluded

that the hooking defects were the major factor that affect on the tensile strength of the welded

joints [16]. Dissimilar aluminium alloys AA2024-T3 and AA7075-T6 were welded by FSW.

The effect of welding process parameters on the mechanical properties of joints was

investigated. During the welding process no material mixing was observed. The grain size of

each material has two different sizes [17]. Aluminium alloy type AA6181-T4 was welded with

high strength steel. A similar microstructure development was observed in each material. The

tensile strength efficiency depended on input heat and the TMAZ of the aluminium alloys [18].

FSW of different aluminium alloys 2014-T6 and 6061-T6 were perfumed taking into account

the effect of various welding process parameters. It was found that the percentage of each alloy

in the stirred zone (SZ) affect on the metal flow, hardness, temperature distribution and the

welding torque [19]. The mechanical properties and microstructure of the FSW joints of

AA6061 to AA7050 were studied a similar hardness profile distribution was observed about

Study Friction Stir Welding Regions of Similar (Aa6061-T6) Aluminum Alloys


the weld line. This was due to the distinct properties for both alloys. Increasing the rotating

speed resulted in increase the joint strength. The first sets of welded specimens were failed in

the SZ due to the inadequate material intermixing. The other was failed at the HAZ due to the

material softening [20].The present work objective is to study the effect of the linear and

rotational speeds of the welding machine on the tensile strength of friction stir welded

aluminium alloys type AA6061-T6 to AA6061-T6. The metallurgical and fatigue properties of

the welded sample which gave the highest tensile strength were analyzed.

2. EXPERIMENTAL SETUP

2.1. Materials

The materials used in the friction stir welding process are type of aluminum AA6061-T6 and

(AA2024-T4 used filler). The measured chemical compositions of material using Olympus

Alpha 4000 and Delta Professional Handheld XRF, using three test of measured chemical

composition are listed in able (1).

Table 1. Chemical compositions of AA6061-T6 and (AA 2024-T4 filler).

Element

wt. %

Si Fe Cu Mn Mg Cr Ni Zn Ti A1

AA6061-

T62

0.37 0.4 0.07 0.47 3.721 0.11 - 0.065 0.01 Rem

stander 0.4 0.5 0.1 0.45 3.6-4.5 - 0.02-0.26 - Rem

AA2024-

T4

0.38 0.41 4.22 0.52 1.34 0.22 0.017 0.281 Rem

stander 0.54 0.5 4.41 .612 1.51 0.25 - 0.25 Rem

2.2. Welding Parameters

Tool rotation rate ω rpm- and tool traverse speed ν mm/min along the line of joint weld are very

important for Friction stir welding. The rotation of tool results in stirring and mixing of material

around the rotating pin and the translation of tool moves the stirred material from the front to

the back of the pin and finishes welding process. Higher tool rotation rate generate higher

temperature because of higher friction heating and result in more intense stirring and mixing of

material. High heat generated by the friction of the tool with material leads to produce internal

and external defects during the welding process. When the heat generated during the welding

process is not enough to mix the materials, this leads to these defects. Other important parameter

in FSW is the shoulder plunge depth. Plunge depth of the FSW tool can be defined as the

position of the lowest point of the tool shoulder with respect to the surface of the welded plate

as shown in Figure1. The general relationship between max T ◦C and FSW parameters can be

calculated from the equation below [21, 22, 23].

T/Tm = K (ω2 /ν * 104) α - 1

Where α: exponent is reported to range from 0.04 to 0.06, K: constant is between 0.65 and

0.75, Tm ◦C is the melting point of the alloy. Also the shoulder plunge P can be calculated from

the equation:

P = 0.5 D sin θ 2

Where P = shoulder plunge (mm), D = shoulder diameter (mm), θ = tilt angle (degree). FSW

tool is of hardening tool steel -ASTM A681-94 O1 type, has 56 HRC. The tool had a featureless

shoulder of 14 mm diameter and smooth pin of 4 mm diameter, 2.7 mm height and 2.5 cone

angle. Fig (2-a, b) shows the tool that has been used in making all weld trails. In this research

Hatem A. Hassan


three values were used for rotational N, the three different rotational speeds are 450,680 and

920 rpm and the linear speed are 40,75and 90 mm/min was used in FSW.

2.3. Preparation of welding process

The samples needed to weld the material (AA6061-T6) were cut from a plate with thickness

3mm and dimensions 105x205 mm. and 3 x 2 x105 mm dimensions of the metal AA2024-T4

used filler. The network pieces welled by FSW as shown in fig -3-.Fig - 4-the milling machine

(IWASHITA) used for welling process. The tool used in friction stir welding is of type oil

hardening tool steel (ASTM A681-94 O1 type). This tool consists of two cylindrical parts: the

first represents the pin and the second is the shoulder. Before starting the welding process, the

samples were fixed using fixture and backing plate tied to the base of the milling machine as

shown in figure -4-.

2.4. Welding process parameters

The parameters of the welding machine which can be manually controlled include travelling

and rotational speed as well as tilt angle of tool. The best properties of a weld can be obtained

by experimenting with a wide range of variables that possess the most influence (rotational and

linear speed). Increasing the rotational speed and reducing the linear speed leads to increased

heat generated by the friction between the sample and the welding tool depending on the

roughness of the surface. In order to obtain good welding properties, the generated heat must

be sufficient to plasticized the material around the tool, while, the high input heat leads to

produce weld defects [23].

2.5. Tensile testing

The standard (ASTM B557M-02a)and the AWS D17.3/D17.3M:2010 are adopted for the

manufacture of tensile test samples for the purpose of examining the mechanical properties of

base material, and the welding line are located in the middle of the sample respectively as shown



in Figure. -5 .The tensile tests were carried out at room temperature and constant loading rate

(2mm/min) by computerized universal testing machine (test center 600KN) .Figure.-5-show the

Sample of tensile test -a- schematic for base,. -b- schematic for welded.

2.6. Fatigue test

The fatigue test used is the type of alternating bending test. Samples of this test were

manufactured as shown in Fig.6-a, b. The behavior of the highest fatigue bending stress was

studied. The weld conditions 75 mm/min linear speed and 450 rotating speed respectively that

gave the highest ultimate stress value in tensile testing were approved for the manufacture of

fatigue test samples .The fatigue behavior of the sample was studied in different welding line

and the base material.

2.7. Micro structural of the Welded Area

The specimens were sectioned to the required size from the joint comprising the NZ, TMAZ,

HAZ and BM for FSW, The specimens were mounted with polymeric material for easy

preparing, according to ASTM E3, the specimens are prepared through a series of successive

steps starting from grinding with 220, 320, 400, 600, 800, 1000, 1200 and 2000 emery paper,

the specimens were rotated at 90◦ and polished to a mirror finish with different grades of alumina

suspension by universal grinding and polishing machine for metallographic specimen

preparation. Washing the specimens with distilled water between stages was necessary to

prevent carryover of abrasive and contamination of preparing surfaces. Finally the specimens

were etched in special chemical.

2.8. Micro hardness Testing

Micro hardness testing of the welded joints was done by Zwick/Roell micro hardness machine.

Micro hardness measurements were taken in vertical and horizontal axes using diamond

pyramid indenter with a load of 50 g and loading within 15 sec according to ASTM-E384. The

specimen surface was prepared by different grades of emery papers according ASTM- to

provide a suitable flat surface.

3. RESULTS AND DISCUSSION.

Tensile test

The tensile test results showed that welded samples had failed in the welding region for

AA6061-T6 and in HAZ for (AA6061-T6 (AA2024-T4 filler). The pseudo heat index, ultimate

stress σu, yield Stress σy, elongation e%, and welding efficiency which can be calculated from

equation. [24]:

σu =Force fracture/Area = p/Ao (3)

σy =Force/Area= P/A--- Offset method (4)

Hatem A. Hassan


E% = (Lf –Lo / Lo) × 100 (5)

pseudo heat index= ω2/ν*104 (6)

Welding efficiency = σf/ σu % (7)

Table -2- show the tensile properties test with the standard values of the metal used in

present work at room temperature, all results are an average of three readings.

Figure-7- curve A,B,C show the both variable welding efficiency and T/Tm% in the

welding region of AA6061-T6(2024-T4filler) similar welding and AA6061-T6 similar welding

at the different conditions of rotational speed and travel speed. The highest values of tensile

strength for both welding region were 287 MPa and 277 MPa respectively and highest values

of efficiency were 87% and 79.6% respectively, and observed at rotational speed (N= 450 RPM)

and Leaner speed (V=75 mm/min).The lowest values of both welding region were 219 MPa

and 184MPa respectively and lowest values of efficiency were 63% and 52% respectively and

observed at rotational speed (N= 720 RPM) and Leaner speed (V=90 mm/min). Also the curve

C shows the variable of T/Tm% in the welding region at the different conditions of rotational

and travel speed. The higher value of T/Tm% was 79.66% and observed at rotational speed (N=

920 RPM) and Leaner speed (V=90 mm/min) .The lowest values of was 69.6% and observed

at rotational speed N= 920 RPM and leaner speed V=40mm/min. Fig -8- explain the variation

welding efficiency and variable pseudo heat index in the welding region at the different

conditions of rotational and travel speed. The highest values of pseudo heat index was 2.16

r2/min.mm was observed at rotational speed N= 920 RPM and leaner speed V=40mm/min. The

lowest values was 0.225 r2/min.mm and observed at rotational speed N= 450 RPM and leaner

speed V=90mm/min. The welding efficiency at highest and lowest value of pseudo heat index

were 70% and 64% respectively. Fig -9- explains the variation welding efficiency and T/Tm

against elongation in both welding region at the different conditions of rotational and travel

speed.

The highest values of elongation for both welding region were 9% and 7% gave highest

values 87% and 79.6% of efficiency respectively, and observed at rotational speed (N= 450

RPM) and Leaner speed (V=75 mm/min).The lowest values of both welding region were 5%

and 3.5% gave values 62.6% and 56% of efficiency respectively, and observed at rotational

speed (N= 450 RPM) and Leaner speed (V=90 mm/min).

Table -2- Mechanical properties of AA of AA6061-T6 and (AA 2024-T4

Material σu MPa σy MPa E % Hardness HB

AA6061-T6 stander 321 224 8.9 118

measured 348 212 8 119

AA2024-T4 stander 472 361 19 121

measured 498 324 21 120

Hatem A. Hassan


3.2. Micro hardness results

The amount of high heat generated during the friction stir welding process leads to refinement

grain size and the occurrence of thermal changes in the weld zone, which in turn lead to a clear

variation in the hardness as shown in figure 8. It's noticeable from the figure that the highest

value of the hardness was found at the centres of weld region and decreases in the HAZ through

the parent material of weld similar AA6061-T6 and AA6061-T6 used 2024-T4filler. In general

the hardness values of the weldments were higher as compared with the HAZ and base alloy.

Hardness value was increased in the weld metal which was about (118 HV0.05 of weld similar

AA6061-T6 used 2024-T4filler also was increased in the weld metal which was about (116

HV0.05 of weld similar AA6061-T6 and that conforms to the Hardness distribution in two axes

was recorded. Fig (8) shows hardness test results, while hardness value in the HAZ was about

107HV0.05 recorded to be about 114 HV0.05 for weld similar AA6061-T6 used 2024-T4filler,

also hardness value in the HAZ was about 97HV0.05 recorded to be about 111 HV0.05 for weld

similar AA6061-T6, these values were less than in the weld metal, the base alloy which is about

110 HV0.05. Figure 8 shows the hardness distribution along the line weld, the base alloy and

heat affect zone (HAZ) in the y-axis direction. From this figure it can be seen that the largest

reduction in hardness at the affect heat zone about 97 HV0.05 due to heat input and grain growth

in this region. Fig. 8- shows the hardness of welding section of AA6061-T6 used 2024-T4filler

and AA6061-T6 under using the optimal welding conditions at rotational speed of 450 rpm and

travel speed of 75 mm/min.

3.3. Microstructure Results

The microstructure of the welded sample at weld conditions N=450 RPM, V= 75mm/min which

gave the highest tensile strength were illustrated in figure (9).This figure represents the welded

joints of two similar aluminum alloys; AA6061-T6, AA2024-T4-

In general, the friction stir welded section includes fives zones in regions of welded section

were shown in fig. -9-

• fig. 9-A- The microstructure of the base materials -AA6061-T6- Next to the HAZ.

• fig. 9-B- It is seen that the microstructures of Nugget zone-NZ- between TMAZ and BM -

affected by heat and deformation.

• fig. 9-C- It is seen that the microstructures of Thermo-mechanically affected zone –TMAZ- at

both sides of NZ- affected by heat and deformation.

• fig. 9- D- It is seen that the microstructures of heat-affected zone –HAZ- between TMAZ and

BM- affected by heat with no plastic deformation.

• fig. 9-E- It is seen that the microstructures of weldment mixing AA6061-T6 and 2024-T4- in

the center of weld and fully re-crystallized.



3.4. Fatigue results

Fatigue of welded samples was tested at best welding conditions, which gave the highest value

for tensile strength. Therefore, all samples tested by fatigue test were manufactured according

to welding conditions (N=450 RPM, V= 75mm/min). The stress ratio used was R=-1. Figure

(13) represents the fatigue test results for AA6061-T6 and welded samples. Results showed that

the efficiency of welded samples was lower than that of parent alloy. This can be attributed to

the fact that the heat generated during the friction stir welding process led to a change in the

mechanical and metallurgical properties. Also, the developed residual stress and plastic strains

resulted in reduce the fatigue strength of weldments. The weakest fatigue properties were

observed in the welding) which is exposed to the highest temperature during the welding

process.

The fatigue test was study the mechanical and metallurgical properties of weldments

represent. The tow weld conditions (linear and rotating speed) that gave the highest ultimate

stress value in tensile testing were approved for the manufacture of fatigue test samples. The

fatigue behavior of the sample was studied in different regions, such as weld metal 0f AA6061-

T6 (wm), weld metal of AA6061-T6 (2024T4 used filler) (wm1), and the base metal (BS).The

fatigue test is the type of alternating bending test. All fatigue S-N curves of the three regions

can be analyzed based on Basque equation follows:

σb= M.Y/ I 8

σb maximum applied bending stress,

M: the maximum moment calculated from equation below:

M = F * L 9

Where M in N.mm and L is the moment arm = 100 mm, y is the distance from the tip to center

X- axis section of the specimen = h /2 mm,

I: is the second moment of inertia of the specimen calculated from equation below, [25].

I=bh3/12 10

Fatigue curve of material is obtained by many constant amplitude fatigue tests can be presented

by, [26].

σf = A. Nf 11

σf : applied stress at fierier due to applied stress at σf .

Nf : number of cycle,

A and α are material constants that can be evaluated by linearizing the curve by rewriting

equation (11) in logarithmic form as following:

Log�f = log A + α *log Nf. 12

A and α can be determined by using the fitting and the least square method.

Where I is number of test or -i = 1, 2, 3...h, and h is total factor of test. The Fig -12-

endurance limit for (wm),( wm1), and (BS)under higher tensile stress were carried out at

variable cyclic stresses in pure bending tests .Fatigue curve of material is obtained by many

Hatem A. Hassan


constant amplitude, fatigue tests can be presented by the equation-11- [27]. Figure -12-

illustrates the fatigue behavior of (wm) , (wm1), and (BS) and give the S-N curve equations for

them. Table -3- show the endurance limits at 107 cycles at different weld regions for AA6061-

T6.

Table -3- Fatigue endurance limits at 107 cycles

Base

metal

Weld metal

(WM)

Weld metal

(WM1)

56.58 50.43 56.24

Reduction % in endurance limit

- 6.15 0.61

4. CONCLUSIONS

From the results the following conclusions can be summarized:

• The apparent defects that are generated in the FSW in the weld region depend on welding

parameters (linear and rotating speed), also the internal defects due to high temperature

produced by the high speed of the tool.

• Maximum welding efficiency 87% is found at a lower rotational speed (N= 450 rpm and V= 75

mm/min) at the both weld region (WM1) and (WM) respectively.

• Maximum welding efficiency 87% and 79.6% of the both weld region (WM1) and (WM are

found at temperature 457 oC and 0.27 pseudo heat index r2/min* mm.

• The welding efficiency (WM1) higher than (WM) the reason may be that the chemical

composition of the weld metal (WM1) does change as compared with the weld metal (WM)

does not change; this is leading to change in the chemical composition of the weld metal (WM1)

relative to the base metal.

• The highest value of hardness were 118 and116 Hv at the both weld region (WM1) and (WM)

respectively.

• The fatigue endurance limit of both weld region (WM1) and (WM) decreases compared with

the base metal.

• The fatigue efficiency of welded samples was lower than that of parent alloy.

• It was observed that the fatigue characteristics of the welded sample of AA6061-T6 approached

the parent alloy when used AA2024-T4 a filler.

• The reduction percentage in fatigue endurance limit of of both weld region (WM1) and (WM)

decreases compared with the base.



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study friction stir welding regions of similar (aa6061 …€¦ · welding (fsw) method using three...

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