Effects of thread interruptions on tool pins in friction stir welding of AA6061

Reza-E-Rabby, Md.; Tang, Wei; Reynolds, Anthony P.

doi:10.1080/13621718.2017.1341363

Title: Effects of thread interruptions on tool pins in friction stir welding of AA6061

Journal Article · Wed Jun 21 00:00:00 EDT 2017 · Science and Technology of Welding and Joining

DOI:https://doi.org/10.1080/13621718.2017.1341363· OSTI ID:1376495

Reza-E-Rabby, Md. ^[1]; Tang, Wei ^[2]; Reynolds, Anthony P. ^[1]

Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

In this paper, effects of pin thread and thread interruptions (flats) on weld quality and process response parameters during friction stir welding (FSW) of 6061 aluminium alloy were quantified. Otherwise, identical smooth and threaded pins with zero to four flats were adopted for FSW. Weldability and process response variables were examined. Results showed that threads with flats significantly improved weld quality and reduced in-plane forces. A three-flat threaded pin led to production of defect-free welds under all examined welding conditions. Spectral analyses of in-plane forces and weld cross-sectional analysis were performed to establish correlation among pin flats, force dynamics and defect formation. Finally, the lowest in-plane force spectra amplitudes were consistently observed for defect-free welds.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Pacific Northwest National Lab. (PNNL), Richland, WA (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE; National Science Foundation (NSF)

Contributing Organization:: Univ. of South Carolina, Columbia, SC (United States)

Grant/Contract Number:: AC05-00OR22725; EEC-0437341

OSTI ID:: 1376495

Journal Information:: Science and Technology of Welding and Joining, Vol. 23, Issue 2; ISSN 1362-1718

Publisher:: Taylor & FrancisCopyright Statement

Country of Publication:: United States

Language:: English

Citation Metrics:

Cited by: 20 works

Citation information provided by
Web of Science

References (27)

Relationships between weld parameters, hardness distribution and temperature history in alloy 7050 friction stir welds Reynolds, A. P.; Tang, W.; Khandkar, Z. Science and Technology of Welding and Joining, Vol. 10, Issue 2 https://doi.org/10.1179/174329305X37024	journal	April 2005
Development of Microstructure and Crystallographic Texture during Stationary Shoulder Friction Stir Welding of Ti-6Al-4V Davies, P. S.; Wynne, B. P.; Rainforth, W. M. Metallurgical and Materials Transactions A, Vol. 42, Issue 8 https://doi.org/10.1007/s11661-011-0606-2	journal	January 2011
Influences of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy Elangovan, K.; Balasubramanian, V. Materials Science and Engineering: A, Vol. 459, Issue 1-2 https://doi.org/10.1016/j.msea.2006.12.124	journal	June 2007
Design and Optimization of Friction Stir Welding Tool Aissani, Mouloud; Gachi, Saliha; Boubenider, Fouad Materials and Manufacturing Processes, Vol. 25, Issue 11 https://doi.org/10.1080/10426910903536733	journal	December 2010
Force generation during friction stir welding of AA2024-T3 Trimble, D.; Monaghan, J.; O’Donnell, G. E. CIRP Annals, Vol. 61, Issue 1 https://doi.org/10.1016/j.cirp.2012.03.024	journal	January 2012
Effect of tool geometry on mechanical and microstructural behaviours in dissimilar friction stir welding of AA 5086–AA 6061 Jamshidi Aval, H.; Serajzadeh, S.; Kokabi, A. H. Science and Technology of Welding and Joining, Vol. 16, Issue 7 https://doi.org/10.1179/1362171811Y.0000000044	journal	October 2011
The influence of pin geometry on bonding and mechanical properties in friction stir weld 2014 Al alloy Zhao, Yan-hua; Lin, San-bao; Wu, Lin Materials Letters, Vol. 59, Issue 23 https://doi.org/10.1016/j.matlet.2005.04.048	journal	October 2005
Characterization of plastic flow and resulting microtextures in a friction stir weld Schneider, J. A.; Nunes, A. C. Metallurgical and Materials Transactions B, Vol. 35, Issue 4 https://doi.org/10.1007/s11663-004-0018-4	journal	August 2004
Process forces during friction stir welding of aluminium alloys Balasubramanian, N.; Gattu, B.; Mishra, R. S. Science and Technology of Welding and Joining, Vol. 14, Issue 2 https://doi.org/10.1179/136217108X372540	journal	February 2009
Grain structure formation during friction stir welding observed by the ‘stop action technique’ Prangnell, P. B.; Heason, C. P. Acta Materialia, Vol. 53, Issue 11 https://doi.org/10.1016/j.actamat.2005.03.044	journal	June 2005
Experimental defect analysis and force prediction simulation of high weld pitch friction stir welding Crawford, R.; Cook, G. E.; Strauss, A. M. Science and Technology of Welding and Joining, Vol. 11, Issue 6 https://doi.org/10.1179/174329306X147742	journal	November 2006
Effect of tool shape on mechanical properties and microstructure of friction stir welded aluminum alloys Fujii, Hidetoshi; Cui, Ling; Maeda, Masakatsu Materials Science and Engineering: A, Vol. 419, Issue 1-2 https://doi.org/10.1016/j.msea.2005.11.045	journal	March 2006
Characterization of the influences of FSW tool geometry on welding forces and weld tensile strength using an instrumented tool Hattingh, D. G.; Blignault, C.; van Niekerk, T. I. Journal of Materials Processing Technology, Vol. 203, Issue 1-3 https://doi.org/10.1016/j.jmatprotec.2007.10.028	journal	July 2008
Through-thickness crystallographic texture of stationary shoulder friction stir welded aluminium Ahmed, M. M. Z.; Wynne, B. P.; Rainforth, W. M. Scripta Materialia, Vol. 64, Issue 1 https://doi.org/10.1016/j.scriptamat.2010.08.060	journal	January 2011
Influence of the Tool Shoulder Contact Conditions on the Material Flow During Friction Stir Welding Doude, Haley R.; Schneider, Judy A.; Nunes, Arthur C. Metallurgical and Materials Transactions A, Vol. 45, Issue 10 https://doi.org/10.1007/s11661-014-2384-0	journal	June 2014
Material Flow in Friction Stir Welds Fonda, Richard; Reynolds, Anthony; Feng, C. R. Metallurgical and Materials Transactions A, Vol. 44, Issue 1 https://doi.org/10.1007/s11661-012-1460-6	journal	October 2012
Friction stir welding and processing Mishra, R. S.; Ma, Z. Y. Materials Science and Engineering: R: Reports, Vol. 50, Issue 1-2 https://doi.org/10.1016/j.mser.2005.07.001	journal	August 2005
Formation and mechanical properties of stationary shoulder friction stir welded 6005A-T6 aluminum alloy Ji, S. D.; Meng, X. C.; Liu, J. G. Materials & Design (1980-2015), Vol. 62 https://doi.org/10.1016/j.matdes.2014.05.016	journal	October 2014
Effect of friction stir processing tool probe on fabrication of SiC particle reinforced composite on aluminium surface Mahmoud, E. R. I.; Takahashi, M.; Shibayanagi, T. Science and Technology of Welding and Joining, Vol. 14, Issue 5 https://doi.org/10.1179/136217109X406974	journal	July 2009
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 Palanivel, R.; Koshy Mathews, P.; Murugan, N. Materials & Design, Vol. 40 https://doi.org/10.1016/j.matdes.2012.03.027	journal	September 2012
Development of Trivex friction stir welding tool Part 2 – three-dimensional flow modelling Colegrove, P. A.; Shercliff, H. R. Science and Technology of Welding and Joining, Vol. 9, Issue 4 https://doi.org/10.1179/136217104225021661	journal	August 2004
Processing and banding in AA2524 and AA2024 friction stir welding Yan, J. H.; Sutton, M. A.; Reynolds, A. P. Science and Technology of Welding and Joining, Vol. 12, Issue 5 https://doi.org/10.1179/174329307X213639	journal	July 2007
Optimizing weld quality of a friction stir welded aluminum alloy Doude, H.; Schneider, J.; Patton, B. Journal of Materials Processing Technology, Vol. 222 https://doi.org/10.1016/j.jmatprotec.2015.01.019	journal	August 2015
Flow visualization and simulation in FSW Reynolds, A. P. Scripta Materialia, Vol. 58, Issue 5 https://doi.org/10.1016/j.scriptamat.2007.10.048	journal	March 2008
Multi-pass friction stir welding in alloy 7050-T7451: Effects on weld response variables and on weld properties Brown, Rebecca; Tang, Wei; Reynolds, A. P. Materials Science and Engineering: A, Vol. 513-514 https://doi.org/10.1016/j.msea.2009.01.041	journal	July 2009
Effect of Tool Pin Thread Forms on Friction Stir Weldability of Different Aluminum Alloys Reza-E-Rabby, Md.; Reynolds, Anthony P. Procedia Engineering, Vol. 90 https://doi.org/10.1016/j.proeng.2014.11.784	journal	January 2014
Material Flow Modification in a FSW Through Introduction of Flats Schneider, Judy; Brooke, Shane; Nunes, Arthur C. Metallurgical and Materials Transactions B, Vol. 47, Issue 1 https://doi.org/10.1007/s11663-015-0523-7	journal	November 2015

Cited By (1)

Processing and tooling considerations in joining by forming technologies; part B—friction-based welding Salamati, Masoud; Soltanpour, Mahdi; Fazli, Ali The International Journal of Advanced Manufacturing Technology, Vol. 106, Issue 9-10 https://doi.org/10.1007/s00170-019-04845-1	journal	January 2020

Similar Records

Effect of tool pin features on process response variables during friction stir welding of dissimilar aluminum alloys

Journal Article · Wed May 13 00:00:00 EDT 2015 · Science and Technology of Welding and Joining · OSTI ID:1376495

Rabby, Reza; Tang, Wei; Reynolds, A. P.

Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer

Journal Article · Wed Jul 07 00:00:00 EDT 2021 · JOM. The Journal of the Minerals, Metals and Materials Society · OSTI ID:1376495

Olszta, Matthew J.; Overman, Nicole R.; Reza E Rabby, MD; +3 more

Improving Joint Formation and Tensile Properties of Dissimilar Friction Stir Welding of Aluminum and Magnesium Alloys by Solving the Pin Adhesion Problem

Journal Article · Thu Mar 15 00:00:00 EDT 2018 · Journal of Materials Engineering and Performance · OSTI ID:1376495

Liu, Zhenlei; Ji, Shude; Meng, Xiangchen

Related Subjects

42 ENGINEERING
friction stir welding
unthreaded pin
threaded pin
flats
in-plane forces

Title: Effects of thread interruptions on tool pins in friction stir welding of AA6061

Citation Formats

References (27)

Cited By (1)

Similar Records

Related Subjects