Dissimilar metals are pretty challenging to attain enhanced mechanical properties in the conventional friction stir spot welding (FSSW) process. In this research, a new filler added friction stir spot welding (FAFSSW) process is adopted for welding dissimilar aluminium alloys of AA5052 with AA6061 by using five different tapered tool pins to enhance the mechanical and metallurgical properties of the joints. Magnesium (Mg) powder with 4.5 mg in volume fraction is considered filler material to fabricate the joints. Mechanical properties of the spot weldments like tensile shear strength test, microhardness test, and metallurgical characterizations like microstructure analysis were carried out for FAFSSW joints. The results show that a tool pin profile with 5 mm upper diameter, 2 mm lower diameter and a pin length of 1.2 mm produce a sound joint with 202.85 MPa tensile shear strength and 119.9 HV microhardness. The FAFSSW joint shows 34% higher strength than the normal FSSW joints. The microstructure analysis indicates that the Mg filler mixes well in the weld zone, and a fine grain structure is gained without any defects.

Influence of tool pin profiles on the filler added friction stir spot welded dissimilar aluminium alloy joints

The evolution of subgrains, dislocations and mechanical properties in a 2524Al alloy during high-strain rolling is investigated in this work. The results show that there are numerous coarse second phases of Al2Cu and Al2CuMg along the dendritic grain boundaries in the cast 2524Al alloy. The second phases are mostly dissolved into the matrix after homogenization. After hot rolling, solution treatment and aging, and cold rolling, the grains are elongated in the rolling direction, a large number of fine and disperse precipitates are present in the grains and along the grain boundaries, and the deformation process generates a mass of subgrains and a high density of dislocations. After cold rolling, the mechanical properties of the 2524 alloy sheet are improved, i.e., ultimate tensile strength of 684 MPa, yield strength of 581 MPa and elongation of 3%. The high strength may be due to the high dislocation density, the mass of fine and dispersed distribution precipitates and the many subgrains.

Evolution of Subgrains, Dislocations, and Mechanical Properties in a 2524Al Alloy during High-Strain Rate Rolling

Base on the copper foil tracer method,the parameters for friction stir spot welding 2mm-thick 6061-T6 aluminum alloy sheet was optimized. The influence of different plunge depths on the characteristic evolution and mechanical properties of joint interface was investigated by setting the geometric characteristic parameters of interface distortion. The experimental results reveal that the effect of plunge depth on the interface distortion morphology was most significant,comparing to other welding parameters. Increasing the plunge depth could almost eliminate the interface warping,increase the width of effective bonded area and shear strength of the joint.

Effect of plunge depth on interface distortion in friction stir spot welding

The different creep-aging forming processes of 2524 aluminum alloy were taken as the research object, and the effects of creep-aging temperature and creep stress on the fatigue-crack propagation properties of the alloy were studied. The research results showed the following under the same sintering time of 9 h, at creep-aging temperatures of 100 °C, 130 °C, 160 °C, and 180 °C, respectively, with an increase in creep-aging temperature: the fatigue-crack propagation rate was promoted, the spacing of fatigue striations increased, and the sizes of dimples decreased while the number was enlarged; this proves that the fatigue property of the alloy was weakened. Compared with the specimens with creep deformation radii of 1000 mm and 1500 mm, the creep deformation stress was the smallest when the forming radius was 1800 mm, with a higher threshold value of fatigue-crack growth in the near-threshold region of fatigue-crack propagation (ΔK ≤ 8 MPa·m1/2). Under the same fatigue cycle, the specimens under the action of larger creep stress endured a longer fatigue stable-propagation time and a faster fracture speed. Comparing the effect of creep-aging temperature and creep stress, the creep-aging temperature plays a dominant role in the fatigue-crack propagation of creep-aged 2524 aluminum alloy.

https://www.mdpi.com/1996-1944/15/9/3244/pdf?version=1651309865

Fatigue Fracture Analysis on 2524 Aluminum Alloy with the Influence of Creep-Aging Forming Processes

Friction stir spot welding (FSSW) is a clean, environmentally-friendly and cost-effective welding technology. To weld joints with improved mechanical properties, an FSSW experiment with a 2 mm-thick 2524 aluminum alloy sheet was performed to explore the influence of ambient cooling (AC), forced air cooling (FAC), waterflow cooling (WC), and an increasing rotational speed under WC, and to evaluate the welding method with regard to the resulting structural and tensile properties of the joint. The results showed that cooling-assisted welding reduced the width of the heat-affected zone (HAZ) and marginally increased the microhardness of the welding nugget zone (WNZ). The maximum tensile shear load (L) and effective width (W) values were 4673 N and 1958 μm at FAC, respectively, which were higher than the values of 4296 N and 1763 μm found with AC, respectively; in addition, the minimum values were 2946 N and 948 μm with WC, respectively. These results are not consistent with the idea that the joint strength can typically be improved with WC, because water absorbs a large amount of welding heat and reduces the plastic deformation capacity of the structure, thereby decreasing the W and L of the joint. Increasing the rotation speed of the welding tool can increase the heat input, which requires increasing the rotation speed along with WC. L and W reach their maximum values of 7652 N and 3320 μm, respectively, at 2500 r·min−1. As the rotation speed increases, L and W decrease. All joints underwent ductile fracturing, and the dispersion distribution of the second-phase particles at the bottom of the dimple exhibited good performance.

https://iopscience.iop.org/article/10.1088/2053-1591/abe5ff/pdf

Effect of a cooling method on the structural and mechanical properties of friction stir spot welding with a 2524 aluminum alloy

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Effect of a cooling method on the structural and mechanical properties of friction stir spot welding with a 2524 aluminum alloy