Evaluation Of Mechanical Corrosion And Tribological Properties Of Normal And Submerged Friction Stir Welded Joints Of Aa6061 And Aa6063
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| Author | : Dr. Laxmanaraju Salavaravu & Dr. Lingaraju Dumpala |
| Publisher | : Laxmi Book Publication |
| Total Pages | : 132 |
| Release | : 2023-09-01 |
| Genre | : Art |
| ISBN | : 1312218789 |
Aluminium is a soft, light metal with a dull silvery-white colour. It is the second most abundant element. Aluminium's lightweight and corrosion resistance made it a vital metal in the 19th century. It is the second most malleable and sixth most ductile element after gold. It is three times lighter than steel and is three times stronger than steel. Tm-660°C and has a lower density (2.7g/cm3). In annealed form, pure aluminium has a tensile strength of 40-50 MPa. It is strengthened by alloying, cold working, and heat treatment. The joining of aluminium alloys presents many challenges due to a tenacious oxide layer, high thermal conductivity, high Coefficient of thermal expansion, and solidification defects [1]. Aluminium is alloyed with many other elements to improve its strength and corrosion resistance. Many difficult-to-weld aluminium alloys can be defect-free and mechanically sound using FSW [2]. Their numerous benefits make aluminium alloys widely used in vehicle and building structural applications. Aluminium and its alloys have various capabilities and applications, making them the material of choice for many products and markets. Their low density, appearance, strength, and fabricability make them appealing. They have wrought alloys or cast alloys. Wrought alloys are designated as 1xxx-pure aluminium, 2xxx-Al-Cu alloys, 3xxx-Al-Mn alloys, 4xxx-Al-Si alloys, 5xxx-Al-Mg alloys, 6xxx-Al-Mg-Si alloys, 7xxx-Al-Zn alloys, and 8xxx-Al-Tin-Li, where the first digit denotes principal alloying. These alloys are classified in to two types-one is heat-treatable(2xxx, 6xxx, 7xxx, and some of the 8xxx alloys) and another one is non-heat treatable (ASTM Handbook 1985) [3]. 6xxx series are wrought aluminium alloys with Si and Mg. They are heat treatable and corrosion-resistant. They naturally weld due to their high strength to weight ratio. The 6xxx series accounts for roughly 80% of global aluminium extrusion [4]. AA6063 is popular for its formability, medium strength, and high corrosion resistance. AA6063 is a heat treatable magnesium silicide. AA6063 is used for extrusions and irrigation pipes [5].
| Author | : Akshansh Mishra |
| Publisher | : GRIN Verlag |
| Total Pages | : 17 |
| Release | : 2017-09-11 |
| Genre | : Technology & Engineering |
| ISBN | : 3668521638 |
Project Report from the year 2017 in the subject Engineering - Mechanical Engineering, grade: 8.9, SRM University, language: English, abstract: This paper deals with the mechanical, microstructural and fatigue analysis of welded joints. In the study, 6061-T6 aluminium alloy plates in 4mm thickness, that are particularly used for aerospace and in automotive industries, were welded using Tungsten Inert Gas (TIG) welding and Friction Stir Welding (FSW) methods as similar joints with one side pass and parameters of varying tool rotation, weld speed and 2.3 degree tool tilt angle. The weld zones cross sections were analysed with light optical microscopy (LOM). During recent years several investigations have been made of fatigue properties of friction stir welded joints. The great majority of available data from the fatigue analysis of friction stir welded joints are concerned with uniaxial loading conditions for a simple geometry. In uniaxial loading nominal stress is normally used as reference stress and it is easy to determine. However, fatigue failure is a highly localized phenomenon in engineering components and determining the nominal stress is not always possible due to the complexity of structures and presence of stress concentrators such as notches and cracks in which many approaches based on local parameters.
| Author | : Rogie Irwin Rodriguez |
| Publisher | : |
| Total Pages | : 148 |
| Release | : 2015 |
| Genre | : Electronic dissertations |
| ISBN | : |
In this work, the relationship between microstructure and mechanical properties of dissimilar friction stir welded AA6061-to-AA7050 aluminum alloys were evaluated. Experimental results from this study revealed that static strength increased with the tool rotational speed and was correlated with the material intermixing. Fully-reversed low cycle fatigue experimental results showed an increase in the strain hardening properties as well as the number of cycles-to-failure as the tool rotational speed was increased. Furthermore, under both static and cyclic loading, fracture of the joint was dominated by the AA6061 alloy side of the weld. In addition, inspection of the fatigue surfaces revealed that cracks initiated from intermetallic particles located near the surface. In order to determine the corrosion resistance of the dissimilar joint, corrosion defects were produced on the crown surface of the weld by static immersion in 3.5% NaCl for various exposure times. Results revealed localized corrosion damage in the thermo-mechanically affected and heat affected zones. Results demonstrated a decrease in the fatigue life, with evidence of crack initiation at the corrosion defects; however, the fatigue life was nearly independent of the exposure time. This can be attributed to total fatigue life dominated by incubation time. Furthermore, two types of failure were observed: fatigue crack initiation in the AA6061 side at high strain amplitudes (>0.3%); and fatigue crack initiation in the AA7050 side at low strain amplitudes (
| Author | : Shanavas Shamsudeen |
| Publisher | : |
| Total Pages | : 16 |
| Release | : 2018 |
| Genre | : Dissertations, Academic |
| ISBN | : |
AA 5052 H32 aluminum alloy is one of the most commonly used materials in the marine environment due to its good formability, good weldability, and better corrosion resistance. Assessment of resistance of welds of the alloy against corrosion is necessary for reliable design. In the present study, pitting and intergranular corrosion behavior of tungsten inert gas (TIG), normal friction stir welding (FSW), and underwater FSW (UFSW) joints of AA 5052 H32 aluminum alloy and parent alloy are investigated. Electrochemical corrosion behavior by Tafel polarization technique and intergranular corrosion susceptibility by mass loss of the specimen in concentrated nitric acid solution are studied as per ASTM standards. The corrosion studies were conducted on welded plates for which welding parameters during TIG welding and FSW were kept optimum for maximum tensile strength. The result shows that corrosion resistance of welded joints is inferior to that of parent metals. Corrosion resistance of the FSW joint and UFSW joint are nearly equal and found to be higher compared with the TIG joint. Density and size of pits formed on the parent metal and welded joints are examined via macro- and microscopic analysis and atomic force microscopic study. Results also show that the specimens welded by FSW and UFSW processes are immune to intergranular corrosion attack.
| Author | : Kenneth Thomas Nathaniel Doering |
| Publisher | : |
| Total Pages | : 0 |
| Release | : 2009 |
| Genre | : Aluminum |
| ISBN | : |
"A lack of understanding of corrosion fatigue in friction stir welded aluminum joints prevents friction stir welding from being implemented in aerospace applications. Fatigue testing reveals a 60-75% reduction in the fatigue life of friction stir welded aluminum lap joints immersed in 3.5% NaCl solution (corrosion fatigue) compared with that of lap joints tested in ambient air. The loss in fatigue life is attributed to accelerated fatigue cracking due to hydrogen environment embrittlement. Two polymer sealant candidates are investigated: silicone rubber and nylon-11. Both sealant candidates can be applied prior to welding and seal the faying surface gaps in lap joints upon welding. The rubber sealant cures at room temperature after welding and can be welded with the same parameters as without the sealant. The 50% sample population corrosion fatigue life is increased by 22% with the use of the rubber sealant, but the effectiveness of the rubber sealant is limited by its cohesive mechanical properties, e.g. elongation to failure. In ambient fatigue, the nylon sealed welds exhibit twice the 50% sample population fatigue life of other welds. Finite element modeling predicts a reduction in the stresses in the weld due the stiffness contribution of the nylon sealant. The effectiveness of the nylon sealant is limited by its adhesive bond strength. When immersed in water, as in corrosion fatigue, the adhesive bond strength is reduced, the sealant bond fails within 500 fatigue cycles, and the mechanical benefits of the nylon sealant are negated. The corrosion fatigue life of nylon sealed welds is 26% less than that of welds without sealant because of the more severe hook defect associated with hotter welding conditions required to melt the nylon. Finite element modeling results indicate an increase in stress intensity factors of about 10% in welds with more severe hook defects--Abstract, leaf iii
| Author | : P. Hema |
| Publisher | : |
| Total Pages | : 0 |
| Release | : 2022 |
| Genre | : Electronic books |
| ISBN | : |
Aluminum and aluminum composites play important role in aerospace, automobile, marine and structural applications. Literature shows that some of the conventional fusion welding processes in joining of aluminum metals result in defects like porosity, distortion owing to elevated thermal conductivity and solidification shrinkage. To overcome such issues, experimental investigations are conducted using Friction Stir Welding (FSW) process in joining of metal plates of aluminum 6061 alloy. Weld joint samples are cut to required sizes and secured them in position by mechanical clamps. The setup is loaded onto Vertical Machining Centre. Nonconsumable tool tips of four different shapes of tungsten carbide and H13 materials are prepared and attached to the spindle. The machine is started and allowed spindle to rotate the tool to plunge onto metal plates along joint line. An axial force is continuously applied until sufficient heat is generated at mating surfaces for joining. Experiments are repeated at different levels by varying welding parameters. Joints are tested for their mechanical properties. The microstructural analysis is studied by SEM. Artificial Neural Network (ANN) simulation model is developed for validation. ANOVA is applied for validation of output results of mechanical properties and optimal process parameters are determined. Research shows that joints are influenced by profile of tool pin and, therefore, the rotational speed of the tool.
| Author | : Ulises Alfaro Mercado |
| Publisher | : |
| Total Pages | : 0 |
| Release | : 2011 |
| Genre | : |
| ISBN | : |
| Author | : J. B. Lumsden |
| Publisher | : |
| Total Pages | : 12 |
| Release | : 2002 |
| Genre | : |
| ISBN | : |
Friction stir welding (FSW), a relatively new solid state joining process, is used to join aluminum alloys of all compositions including alloys essentially considered unweldable. During FSW, a rotating tool provides a continual hot working action, plasticizing metal within a narrow zone at the join line, while transporting metal from the leading face of the probe to the trailing edge as the tool moves along the interface. Although melting does not occur during FSW, temperatures are sufficiently high and times at temperature sufficiently long to cause dissolution, nucleation, and/or coarsening of strengthening precipitates. The temperature-time profile changes with distance from the nugget causing a gradient in micro structure and precipitate morphology. The altered micro structure in the weld zone becomes sensitized in some high strength aluminum alloys. Results presented assess the pitting, intergranular, and SCC corrosion behavior of FSW 7XXX and 2XXX alloys. Progress in understanding the changes in microstructure responsible for the sensitization will be discussed. The presentation also will include evaluations of approaches for corrective measures.
| Author | : Erik Klinckman |
| Publisher | : |
| Total Pages | : 80 |
| Release | : 2016 |
| Genre | : Corrosion resistant alloys |
| ISBN | : |
The purpose of this research was to examine the corrosion resistance properties of Aluminum Alloy (AA) 7475-T73. Friction stir welding (FSW) this alloy causes the corrosion resistance of the alloy to drop around the weld region through resolutionizing MgZn2 precipitates. Therefore, a post weld artificial aging (PWAA) heat treatment was developed to attempt to restore corrosion resistance by causing precipitation back into the aluminum matrix. Varying heat inputs, through utilizing a variable forge force, allowed the author to distinguish if heat input had significance as well. Through previous work on a similar alloy, AA 7075, the PWAA treatment chosen was a stabilizing heat treatment of 24 hours at 225°F followed by 4 hours of aging at 325°F. Tensile testing, microhardness, and optical examination were used to quantify the effect of the heat treatment upon physical properties. Two forms of corrosion testing were utilized in measuring corrosion resistance. The two tests used to examine the corrosion resistance were alternate immersion and electrochemical corrosion testing. Electrical conductivity measurements were also taken to help diagnose the resulting state of the alloy after PWAA. Corrosion resistance was returned to that of parent material after PWAA, while tensile strength, conductivity, and microhardness measurements were consistent with those present in friction stir weld literature.
| Author | : Ulises Alfaro Mercado |
| Publisher | : |
| Total Pages | : 130 |
| Release | : 2011 |
| Genre | : |
| ISBN | : |
