article · Materials
This research assesses the performance of a hemispherical friction stir welding tool for joining dissimilar aluminium alloys, specifically AA5083-H111 and AA7075-T6. Using a constant rotation speed of 500 rpm, the process was tested across welding speeds of 25, 50, and 75 mm/min. alongside an analytical model created to estimate heat generation and temperature distribution. Experimental findings aligned closely with model predictions. Sound dissimilar welds were formed at 25 and 50 mm/min. In contrast, the 75 mm/min speed produced a tunnel-like defect due to insufficient heat input. The lowest welding speed of 25 mm/min yielded the highest tensile strength, achieving a joint efficiency exceeding 97%.
Joining different grades of aluminium is traditionally challenging but valuable for manufacturing lighter structures. Demonstrating that a hemispherical tool combined with specific processing speeds produces strong, defect-free bonds provides a clear method to join distinct aluminium alloys without sacrificing joint strength.
This work is at an applied and tested stage, offering specific operating parameters and an analytical model for manufacturing engineers joining dissimilar aluminium alloys. It could enable more reliable friction stir welding procedures for industrial fabricators, though the abstract does not specify target commercial sectors or formal scale-up plans.
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This study investigated the effect of a hemispherical friction stir welding (FSW) tool on the heat generation and mechanical properties of dissimilar butt welded AA5083 and AA7075 alloys. FSW was performed on the dissimilar aluminum alloys AA5083-H111 and AA7075-T6 using welding speeds of 25, 50, and 75 mm/min. The tool rotation rate was kept constant at 500 rpm. An analytical model was developed to calculate heat generation and temperature distribution during the FSW process utilizing a hemispherical tool. The experimental results were compared to the calculated data. The latter confirms the accuracy of the analytical model, demonstrating a high degree of agreement. Sound FSW dissimilar joints were achieved at welding speeds of 50 and 25 mm/min. Meanwhile, joints created at a welding speed of 75 mm/min exhibited a tunnel-like defect, which can be attributed to the minimal heat generated at this particular welding speed. At a lower welding speed of 25 mm/min, a higher tensile strength of the dissimilar FSWed joints AA5083 and AA7075 was achieved with a joint efficiency of over 97%.
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DOI: 10.3390/ma17020433
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