Effect of the static shoulder on microstructural, textural, and mechanical characteristics during friction stir welding of Al6061

In the present investigation, a novel static shoulder friction stir welding (SSFSW) tool has been designed and fabricated. The designed tool works both as rotating shoulder FSW (RS-FSW) and SSFSW. To evaluate the effectiveness of the developed tool, Al6061 plates have been subjected to both RS-FSW a...

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Bibliographic Details
Published in:Proceedings of the Institution of Mechanical Engineers. Part L, Journal of materials, design and applications Journal of materials, design and applications, 2023-01, Vol.237 (1), p.144-154
Main Authors: Saravana Sundar, A, Adepu, Kumar, Mugada, Krishna Kishore, Satyanarayana, MVNV
Format: Article
Language:English
Subjects:
Aluminum base alloys
Axial forces
Dislocation density
Friction stir welding
Grain boundaries
Hardness
Heat generation
Homogeneous structure
Magnesium compounds
Mechanical properties
Metal silicides
Microstructure
Tensile tests
Texture
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Summary:In the present investigation, a novel static shoulder friction stir welding (SSFSW) tool has been designed and fabricated. The designed tool works both as rotating shoulder FSW (RS-FSW) and SSFSW. To evaluate the effectiveness of the developed tool, Al6061 plates have been subjected to both RS-FSW and SSFSW using the indigenously developed tool. The microstructure evolution, axial force, texture development, and mechanical properties were evaluated and compared for both RS-FSW and SSFSW. Adequate heat generation in SSFSW resulted in a homogeneous structure at the stir zone. Electron back scattered diffraction analysis demonstrated the presence of red-colored regions along the grain boundaries indicative of more dislocation density. These regions acted as preferable sites for precipitate (Mg2Si) accumulation, which greatly affected the mechanical properties of the joint. SSFSW joints contained a strong {111} texture of R-cube and S component with a maximum intensity of 6.85, while RS-FSW joints contained A and A* components with a maximum intensity of 4.85. The hardness plots showed a wide lower hardness region in RS-FSW with a maximum hardness of 101HV and 110HV (SSFSW). During the tensile test, both the joints failed in the lower hardness region after achieving 88% (SSFSW) and 75% (RS-FSW) strength of base material.
ISSN:1464-4207
2041-3076
DOI:10.1177/14644207221105387