Friction stir welding (FSW) and friction stir processing (FSP) are two of the most widely used solid-state welding techniques for magnesium (Mg) and magnesium alloys. Mg-based alloys are widely used in the railway, aerospace, nuclear, and marine industries, among others. Their primary advantage is their high strength-to-weight ratio and usefulness as a structural material. Due to their properties, it is difficult to weld using traditional gas- or electric-based processes; however, FSW and FSP work very well for Mg and its alloys. Recently, extensive studies have been carried out on FSW and FSP of Mg-based alloys. This paper reviews the context of future areas and existing constraints for FSW/FSP. In addition, in this review article, in connection with the FSW and FSP of Mg alloys, research advancement; the influencing parameters and their influence on weld characteristics; applications; and evolution related to the microstructure, substructure, texture and phase formations as well as mechanical properties were considered. The mechanisms underlying the joining and grain refinement during FSW/FSP of Mg alloys-based alloys are discussed. Moreover, this review paper can provide valuable and vital information regarding the FSW and FSP of these alloys for different sectors of relevant industries.

Friction Stir Welding/Processing of Mg-Based Alloys: A Critical Review on Advancements and Challenges.

The solid-state welding method known as friction stir welding (FSW) bonds two metallic work parts, whether the same or different, by plastically deforming the base metal. The frictional resistance between both metallic workpieces causes them to produce heat, which produces plastic deformation and welds them. However, the weldability and strength of FSW joints mainly depend on the FSW parameters. This review work highlights the previous research work on the FSW parameters and their effects on the weldability and quality of the aluminum alloys joined with similar and dissimilar metals through the FSW method. About 150 research studies were systematically reviewed, and the articles included data from peer-reviewed journals. It has been concluded that the key parameters, including welding speed, “rotational speed”, “plunge depth”, “spindle torque”, “shoulder design”, “base material”, “pin profile” and “tool type”, significantly affect the weldability of the aluminum joint through the FSW method. Also, the selection of these parameters is important and fundamental as they directly affect the joint. It is recommended that future work focuses on FSW for aluminum. Among these, the most essential is the application of artificial intelligence (AI) techniques to select the optimum FSW parameters for aluminum welding.

/pdf/the-effect-of-friction-stir-welding-parameters-on-the-jiz9t8zt.pdf

The Effect of Friction Stir Welding Parameters on the Weldability of Aluminum Alloys with Similar and Dissimilar Metals: Review

Structural health monitoring (SHM) is an essential aspect to ensure the safety and longevity of civil infrastructure. In recent years, there has been a growing interest in developing SHM systems based on Micro-Electro-Mechanical Systems (MEMS) technology. MEMS-based sensors are small, low-power, and cost-effective, making them ideal for large-scale deployment in structural monitoring systems. However, the use of MEMS-based sensors in SHM systems can be challenging due to their inherent errors, such as drift, noise, and bias instability; these errors can affect the accuracy and reliability of the measured data, leading to false alarms or missed detections. Therefore, several methods have been proposed to compensate for these errors and improve the performance of MEMS-based SHM systems. For this purpose, the authors propose the combined of a redundant configuration of cost-effective MEMS accelerometers and a Kalman Filter approach to compensate MEMS inertial sensor errors and data filtering; the performance of the method is preliminarily assessed by means of a custom-controlled oscillation generator and compared with that granted by a high-cost, high-performance MEMS reference system where amplitude differences of 0.02 m/s2 have been experienced. Finally, a sensor node for real-time monitoring has been proposed that exploits LoRaWAN and NFC protocols to access the structure information to be monitored.

/pdf/on-the-suitability-of-redundant-accelerometers-for-the-2lkvgk7z.pdf

On the suitability of redundant accelerometers for the implementation of smart oscillation monitoring system: Preliminary assessment

The contemporary automotive industry increasingly incorporates composite materials and innovative joining techniques to meet customer demands for lightweight, high-strength alloys. This research explores the feasibility of using friction stir welding (FSW) methods to fabricate dissimilar aluminum nanocomposite lap joints, integrating Al 2 O 3 nanoparticles into the weld nugget. Lap joints were prepared with varying tool rotation speeds (1000–1600 rpm) and the mechanical and metallurgical behaviors of AA6061–AA7075-T6/Al 2 O 3 lap joints were examined. The inclusion of filler material in the weld joint resulted in an 18% increase in shear strength compared to joints without filler. Dynamic crystallization impeded grain boundaries and reduced grain size in the weld stir zone (SZ), with the most enhanced mechanical characteristics observed at a tool rotation speed of 1400 rpm. The shear strength at 1400 rpm was 5780 N, representing a 17% increase compared to joints prepared at 1000 rpm. Field emission scanning electron microscopic examination revealed evenly dispersed Al 2 O 3 nanoparticles within the weld zone, supporting the lap shear test results. Notably, joints created at lower (1000 rpm) and higher tool rotational speeds (1600 rpm) exhibited brittle fracture behavior. The addition of Al 2 O 3 significantly improved lap joint tensile strength due to its uniform dispersion in the SZ. Increasing the FSW tool rotational speed from 1000 to 1400 rpm facilitated nanoparticle dispersion, further enhancing lap joint strength. 

Depriving friction stir weld defects in dissimilar aluminum lap joints

This study aims to investigate a friction stir welded joint between steel and aluminum alloy that is employed in maritime applications (i.e., connection between the ship over-structures and the hull or deck). By changing the tool rotational direction, or the advancing or retreating side, a single lap configuration was studied. Tensile tests were conducted to evaluate the mechanical resistance and the surface fracture after a preliminary investigation consisting of morphological and microstructural analyses and microhardness measurements, with the goal of considering the possibility of replacing the typical joining processes, such as traditional welding or explosion welding, with friction stir welding. The testing showed that the joint produced on the advancing side performed better (+23.5% of the maximum load) than the joint made on the retreating side.

/pdf/effect-of-tool-rotation-direction-on-mechanical-strength-of-1f96n8fe.pdf

Effect of Tool Rotation Direction on Mechanical Strength of Single Lap Friction Stir Welded Joints between AA5083 Aluminum Alloy and S355J0 Steel for Maritime Applications

This paper investigates the dissimilar friction stir lap welding of AA2198 and AA7075 sheets. The influence of processing parameters, namely welding speed and tool rotational speed on joint features, microstructure, and mechanical properties were studied by implementing a full factorial design of experiments. Axial and transversal forces were continuously measured during the welding process using a sensed fixture aiming at the correlation of processing parameters, forces, and quality of the achieved joints. Obtained outcomes showed hook formation for all the combination of parameters and the existence of a very narrow processing window in which it is possible to avoid the formation of internal defects, such as grooves and tunnels. The influence of the weld bead morphology on the lap shear strength was elucidated proving that the strength is ruled by the hook morphology. The microstructure of the joints was studied and discussed considering also the microhardness distribution.

/pdf/dissimilar-friction-stir-lap-welding-of-aa2198-and-aa7075-2eqxccrjp9.pdf

Dissimilar friction stir lap welding of AA2198 and AA7075 sheets: forces, microstructure and mechanical properties

Experimental investigation and numerical modeling of creep response of glass fiber reinforced polymer composites

Numerical and Experimental Investigation on the Influence of Tightening in a Hybrid Single Lap Joint

Experimental and Analytical Investigation of the Shear Fracture Behavior of Bonded Joints

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Dissimilar friction stir lap welding of AA2198 and AA7075 sheets: forces, microstructure and mechanical properties

Experimental investigation and numerical modeling of creep response of glass fiber reinforced polymer composites

Numerical and Experimental Investigation on the Influence of Tightening in a Hybrid Single Lap Joint

Experimental and Analytical Investigation of the Shear Fracture Behavior of Bonded Joints