Friction Stir Welding of Dissimilar Materials: An Overview

Authors: Mukuna P. Mubiayi, Esther T. Akinlabi

Abstract:

Friction Stir Welding is a solid state welding technique which can be used to produce sound welds between similar and dissimilar materials. Dissimilar welds which include welds between the different series of aluminium alloys, aluminium to magnesium, steel and titanium has been successfully produced by many researchers. This review covers the work conducted in the above mentioned materials and further concludes by showing the need to fully understand the FSW process in order to expand the latter industrially.

Keywords: aluminium, dissimilar materials, FSW, hardness, magnesium, microstructure, steel, tensile test, titanium

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1083067

References:

[1] W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Temple- Smith, C.J. Dawes, "Friction stir Butt Welding". International Patent No. PCT/GB92/02203, 1991, GB patent application No. 9125978.8.
[2] A. Scialpi, M. De Giorgi, L.A.C. De Filippis, R. Nobile, F.W. Panella, "Mechanical analysis of ultra-thin friction stir welding joined sheets with dissimilar and similar materials", Materials and Design 29 (2008), pp. 928-936.
[3] Rajiv S. Mishra and Murray W. Mahoney, "Friction Stir Welding and Processing", 2007, ASM international, the materials information society.
[4] T. DebRoy and H. K. D. H. Bhadeshia, "Friction stir welding of dissimilar alloys - a Perspective", Science and Technology of Welding and Joining 2010, Vol 15 No 4, pp. 266- 270.
[5] R. Rai, A. De, H. K. D. H. Bhadeshia and T. DebRoy, "Review: friction stir welding tools", Science and Technology of Welding and Joining, 2011, Vol 16 No 4, pp. 325- 342.
[6] M. Sivashanmugam, S. Ravikumar, T. Kumar, V. Seshagiri Rao, D. Muruganandam, "A Review on Friction Stir Welding for Aluminum Alloys", 978-1-4244-9082-0/10/$26.00 ┬®2010 IEEE, pp. 216 - 221.
[7] Z.Y. MA "Friction Stir Processing Technology: A Review" Metallurgical and Materials Transactions A, 2008, Vol. 39A, pp. 642 - 658.
[8] V. Soundararajan, M. Valant and R. Kovacevic, "An Overview of R&D Work in FrictionStir Welding at SMU"Association of Metallurgical Engineers of Serbia (AMES), pp. 276 - 295.
[9] Bo Li, Yifu Shen, "A feasibility research on friction stir welding of a new-typed lap-butt joint of dissimilar Al alloys" Materials and Design 34 (2012) , pp. 725-731.
[10] C. Leitão, R. Louro, D.M. Rodrigues, " Analysis of high temperature plastic behaviour and its relation with weldability in friction stir welding for aluminum alloys AA5083-H111 and AA6082-T6 Materials and Design 37 (2012), pp. 402-409.
[11] J. Guo, P. Gougeon, X.-G. Chen, "Microstructure evolution and mechanical properties of dissimilar friction stir welded joints between AA1100-B4C MMC and AA6063 alloy", Materials Science and Engineering A 553 (2012) 149- 156.
[12] M. Koilraj, V. Sundareswaran, S. Vijayan, S.R. Koteswara Rao, "Friction stir welding of dissimilar aluminum alloys AA2219 to AA5083 - Optimization of process parameters using Taguchi technique" Materials and Design 42 (2012), pp. 1-7.
[13] R. Palanivel, P. Koshy Mathews, N. Murugan, I. Dinaharan, "Effect of tool rotational speed and pin profile on microstructure and tensile strength of dissimilar friction stir welded AA5083-H111 and AA6351- T6 aluminum alloys", Materials and Design 40 (2012) , pp. 7-16.
[14] R. PalaniveI, P. Koshy Mathews, "Mechanical and microstructural behaviour of friction stir welded dissimilar aluminum alloy", IEEEInternational Conference On Advances In Engineering, Science And Management (ICAESM -2012) March 30, 31, 2012, pp. 7- 11.
[15] A.A.M. da Silva, E. Arruti, G. Janeiro, E. Aldanondo, P. Alvarez, A. Echeverria, "Material flow and mechanical behaviour of dissimilar AA2024-T3 and AA7075-T6 aluminum alloys friction stir welds", Materials and Design 32 (2011) , pp. 2021-2027.
[16] H. Jamshidi Aval, S. Serajzadeh, A.H. Kokabi, "Evolution of microstructures and mechanical properties in similar and dissimilar friction stir welding of AA5086 and AA6061", Materials Science and Engineering A 528 (2011), pp. 8071- 80853.
[17] Changbin Shen, Jiayan Zhang, Jiping Ge, "Microstructures and electrochemical behaviors of the friction stir welding dissimilar weld", Journal of Environmental Sciences, 2011, 23(Supplement) S32-S35.
[18] V.-X. Tran, J. Pan, T. Pan, "Fatigue behavior of spot friction welds in lap-shear and cross-tension specimens of dissimilar aluminum sheets", International Journal of Fatigue 32 (2010), pp. 1022-1041.
[19] T-S. Jun, K. Dragnevski, A.M. Korsunsky, "Microstructure, residual strain, and eigenstrain analysis of dissimilar friction stir welds", Materials and Design 31 (2010) , pp. S121-S125.
[20] M. Ghosh, K. Kumar, S.V. Kailas, A.K. Ray, "Optimization of friction stir welding parameters for dissimilar aluminum alloys" Materials and Design 31 (2010) , pp. 3033-3037.
[21] N. Shanmuga Sundaram, N. Murugan, "Tensile behavior of dissimilar friction stir welded joints of aluminum alloys" Materials and Design 31 (2010) , pp. 4184-4193.
[22] D. Muruganandam, S. Ravikumar, Sushil Lal Das "Mechanical and Micro Structural Behavior of 2024-7075 Aluminum Alloy Plates joined by Friction Stir Welding", 978-1-4244-9082-0/10/$26.00 ┬®2010 IEEE , pp. 247- 251.
[23] P.M.G.P. Moreira, T. Santos, S.M.O. Tavares, V. Richter-Trummer, P. Vilaça, P.M.S.T. de Castro, "Mechanical and metallurgical characterization of friction stir welding joints of AA6061-T6 with AA6082-T6" Materials and Design 30 (2009), pp. 180-187.
[24] C. Leitao, R.M. Leal, D.M. Rodrigues , A. Loureiro, P. Vilaca, "Mechanical behaviour of similar and dissimilar AA5182-H111 and AA6016-T4 thin friction stir welds" Materials and Design 30 (2009) , pp. 101-108.
[25] P. Cavaliere, A. De Santis, F. Panella, A. Squillace, "Effect of welding parameters on mechanical and microstructural properties of dissimilar AA6082-AA2024 joints produced by friction stir welding" Materials and Design 30 (2009), pp. 609-616.
[26] C. Leitão, B. Emílio, B.M. Chaparro, D.M. Rodrigues, "Formability of similar and dissimilar friction stir welded AA 5182-H111 and AA 6016- T4 tailored blanks" Materials and Design 30 (2009) , pp. 3235-3242.
[27] Omar Hatamleh, Adrian DeWald, "An investigation of the peening effects on the residual stresses in friction stir welded 2195 and 7075 aluminum alloy joints", Journal of Materials Processing Technology 209 (2009), pp. 4822-4829.
[28] M.A. Mofid, A. Abdollah-zadeh, F. Malek Ghaini, "The effect of water cooling during dissimilar friction stir welding of Al alloy to Mg alloy" , Materials and Design 36 (2012), pp. 161-167.
[29] S. Malarvizhi , V. Balasubramanian, "Influences of tool shoulder diameter to plate thickness ratio (D/T) on stir zone formation and tensile properties of friction stir welded dissimilar joints of AA6061 aluminum- AZ31B magnesium alloys", Materials and Design 40 (2012) , pp. 453- 460.
[30] M. Simoncini, A. Forcellese, Effect of the welding parameters and tool configuration on micro- and macro-mechanical properties of similar and dissimilar FSWed joints in AA5754 and AZ31 thin sheets, Materials and Design 41 (2012), pp. 50-60.
[31] P. Venkateswaran, A.P. Reynolds, "Factors affecting the properties of Friction Stir Welds between aluminum and magnesium alloys" Materials Science and Engineering A 545 (2012), pp.26- 37.
[32] S.H. Chowdhury, D.L.Chen, S.D.Bhole, X.Cao, P.Wanjara, "Lap shear strength and fatigue life of friction stir spot welded AZ31 magnesium and 5754 aluminum alloys", Materials Science & Engineering A 556 (2012) , pp. 500-509.
[33] M. Sharifitabar, H. Nami, "Microstructures of dissimilar friction stir welded joints between 2024-T4 aluminum alloy and Al/Mg2Si metal matrix cast composite , Composites: Part B 42 (2011), pp. 2004-2012.
[34] YAN Yong, ZHANG Da-tong, QIU Cheng, ZHANG Wen, "Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy", Trans. Nonferrous Met. Soc. China 20 (2010), pp. s619¶Çâ¡s623.
[35] C. Liu, D.L. Chen, S. Bhole, X. Cao, M. Jahazi, "Polishing-assisted galvanic corrosion in the dissimilar friction stir welded joint of AZ31 magnesium alloy to 2024 aluminum alloy" , Materials Characterization 60 ( 2009) , pp. 3 7 0 - 3 7 6.
[36] A. Kostka, R.S. Coelho, J. dos Santos, A.R. Pyzalla, "Microstructure of friction stir welding of aluminum alloy to magnesium alloy", Scripta Materialia 60 (2009), pp. 953-956.
[37] Y.C. Chen, A. Gholinia, P.B. Prangnell, "Interface structure and bonding in abrasion circle friction stir spot welding: A novel approach for rapid welding aluminum alloy to steel automotive sheet" Materials Chemistry and Physics 134 (2012), pp. 459- 463.
[38] Tomo Ogura,Yuichi Saito, Taichi Nishida, Hidehito Nishida, Takumi Yoshida, Noriko Omichi, Mitsuo Fujimoto, Akio Hirose, "Partitioning evaluation of mechanical properties and the interfacial microstructure in a friction stir welded aluminum alloy/stainless steel lap joint", Scripta Materialia 66 (2012) , pp. 531-534.
[39] R.S. Coelho, A. Kostka, J.F. dos Santos, A. Kaysser-Pyzalla , "Frictionstir dissimilar welding of aluminum alloy to high strength steels: Mechanical properties and their relation to microstructure", Materials Science & Engineering A 556 (2012) , pp. 175-183. ¶ÇÇâ ¶ÇÇâ
[40] HanSur Bang, HeeSeon Bang, GeunHong Jeon, IkHyun Oh, ChanSeung Ro, "Gas tungsten arc welding assisted hybrid friction stir welding of dissimilar materials Al6061-T6 aluminum alloy and STS304 stainless steel" Materials and Design 37 (2012), pp. 48-55.
[41] Y. Mashiko, Y. Hatsukade, T. Yasui, H. Takenaka, Y. Todaka, M. Fukumoto, S. Tanaka,"Evaluation of joint interface of friction stir welding between dissimilar metals using HTS-SQUID gradiometer", Physica C 470 (2010), pp. 1524-1528.
[42] Tsutomu Tanaka, Taiki Morishige and Tomotake Hirata, "Comprehensive analysis of joint strength for dissimilar friction stir welds of mild steel to aluminum alloys" Scripta Materialia 61 (2009), pp. 756-759.
[43] Yoshihiko Uematsu, Keiro Tokaji, Yasunari Tozaki, Yasuhito. Nakashima, "Fatigue behaviour of dissimilar friction stir spot weld between A6061 and SPCC welded by a scrolled groove shoulder tool" , Procedia Engineering 2 (2010), pp. 193-201.
[44] CHEN Yu-hua, NI Quan, KE Li-ming, "Interface characteristic of friction stir welding lap joints of Ti/Al dissimilar alloys", Trans. Nonferrous Met. Soc. China 22(2012), pp. 299-304.
[45] Yanni Wei, Jinglong Li, Jiangtao Xiong, Fu Huang, Fusheng Zhang, Syed Hamid Raza Joining aluminum to titanium alloy by friction stir lap welding with cutting pin" , Materials Characterization 71, (2012), pp. 1- 5.
[46] Masayuki Aonuma, Kazuhiro Nakata, "Effect of calcium on intermetallic compound layer at interface of calcium added magnesium- aluminum alloy and titanium joint by friction stir welding, Materials Science and Engineering B 173 (2010), pp. 135-138.
[47] Y.C. Chen, K. Nakata, "Microstructural characterization and mechanical properties in friction stir welding of aluminum and titanium dissimilar alloys", Materials and Design 30 (2009), pp. 469-474.
[48] Ulrike Dressler, Gerhard Biallas, Ulises Alfaro Mercado, "Friction stir welding of titanium alloy TiAl6V4 to aluminum alloy AA2024-T3" , Materials Science and Engineering A 526 (2009) , pp. 113-117.