The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys

In this work, main similar (6061 aluminum alloy) and dissimilar (commercially pure aluminum and copper) materials were butt joined via friction-stir welding (FSW). The influence of FSW parameters, namely, small pin geometry, rotational speed, welding speed, and surface roughness of material, on the...

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Format:	Thesis
Language:	English
Subjects:	Friction stir welding Aluminum Copper alloys Alloys
Online Access:	http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/1/Page%201-24.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/2/Full%20text.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/4/Hasan%20Issa%20Daw.pdf
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spelling	my-unimap-772002022-11-25T01:15:00Z The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys Kahtan S., Mohammed, Dr. In this work, main similar (6061 aluminum alloy) and dissimilar (commercially pure aluminum and copper) materials were butt joined via friction-stir welding (FSW). The influence of FSW parameters, namely, small pin geometry, rotational speed, welding speed, and surface roughness of material, on the macrostructure, microstructure, and mechanical properties of only similar material joint characteristics were evaluated. The effects of FSW tool rotational speeds, with and without preheating on the copper side for dissimilar material joints, were also examined. For tool pin geometry, the triangular tool pin profile produced the most feasible metallurgical and mechanical weld properties among other tool pin profiles. Furthermore, the lowest tensile strength and microhardness were obtained for the joint FSW with square tool pin profile. Smaller tool pin profiles and shoulder diameter led to narrow heat-affected zone (HAZ) and a desired softening level. The 6061 aluminum alloy workpieces stirred by friction were welded at different tool rotational speeds and treated with and without reinforcement of 10 vol. % SiC powder from the welding volume. The results indicated the presence of the optimal mechanical properties when the joint was fabricated at 1750 rpm rotational speed because of the pinning effect and enlarged nucleation sites associated with the insertion of SiC powder in the welding zone. The results also revealed that the ultimate tensile strength (UTS) was significantly enhanced by approximately 52% of the base material (6061 aluminum alloy), at 1750 rpm because of the effect of the SiC powder. All process parameters used in this research significantly affected the microstructure and mechanical properties. The results also indicated that the welding speed significantly influenced the joint microstructure and mechanical properties when reinforced with SiC powder. Results demonstrated that spherical nano-sized grains of the joints were produced when the top surface of the workpieces ground smoothly (i.e.98, 60, 51 and 37 nm). Experimental results also indicated that the tensile strength of FSW 6061 aluminum alloy was notably affected by the joining process at different selected values of workpiece surface roughness. However, Vickers microhardness was improved in the HAZ because of the effect of surface roughness, which narrowed the width of this zone. The FSW of commercial pure aluminum and copper demonstrated high bonding strength when preheated on the copper side compared with the optimal joint of the specimen conducted without preheating. Furthermore, X-Ray Diffraction (XRD) data showed that changes in metal alloy crystallite sizes, densities, and lattice parameters occurred over the test distances at different rotational speeds. The grains were fine and dynamically recrystallized near the weld interface and elongated at various distances. The fracture surfaces showed varied results when different parameters were used. These surfaces presented either ductile or brittle fracture. Universiti Malaysia Perlis (UniMAP) Thesis en http://dspace.unimap.edu.my:80/xmlui/handle/123456789/77200 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/3/license.txt 8a4605be74aa9ea9d79846c1fba20a33 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/1/Page%201-24.pdf cdb88ab9010a0cf4ad7640c1aa8faa95 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/2/Full%20text.pdf af2429bb9f93d63c56015298484a9c72 http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/4/Hasan%20Issa%20Daw.pdf a0cc280cc935d5b16fbd163b1ccbd458 Universiti Malaysia Perlis (UniMAP) Friction stir welding Aluminum Copper alloys Alloys School of Materials Engineering
institution	Universiti Malaysia Perlis
collection	UniMAP Institutional Repository
language	English
advisor	Kahtan S., Mohammed, Dr.
topic	Friction stir welding Aluminum Copper alloys Alloys
spellingShingle	Friction stir welding Aluminum Copper alloys Alloys The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys
description	In this work, main similar (6061 aluminum alloy) and dissimilar (commercially pure aluminum and copper) materials were butt joined via friction-stir welding (FSW). The influence of FSW parameters, namely, small pin geometry, rotational speed, welding speed, and surface roughness of material, on the macrostructure, microstructure, and mechanical properties of only similar material joint characteristics were evaluated. The effects of FSW tool rotational speeds, with and without preheating on the copper side for dissimilar material joints, were also examined. For tool pin geometry, the triangular tool pin profile produced the most feasible metallurgical and mechanical weld properties among other tool pin profiles. Furthermore, the lowest tensile strength and microhardness were obtained for the joint FSW with square tool pin profile. Smaller tool pin profiles and shoulder diameter led to narrow heat-affected zone (HAZ) and a desired softening level. The 6061 aluminum alloy workpieces stirred by friction were welded at different tool rotational speeds and treated with and without reinforcement of 10 vol. % SiC powder from the welding volume. The results indicated the presence of the optimal mechanical properties when the joint was fabricated at 1750 rpm rotational speed because of the pinning effect and enlarged nucleation sites associated with the insertion of SiC powder in the welding zone. The results also revealed that the ultimate tensile strength (UTS) was significantly enhanced by approximately 52% of the base material (6061 aluminum alloy), at 1750 rpm because of the effect of the SiC powder. All process parameters used in this research significantly affected the microstructure and mechanical properties. The results also indicated that the welding speed significantly influenced the joint microstructure and mechanical properties when reinforced with SiC powder. Results demonstrated that spherical nano-sized grains of the joints were produced when the top surface of the workpieces ground smoothly (i.e.98, 60, 51 and 37 nm). Experimental results also indicated that the tensile strength of FSW 6061 aluminum alloy was notably affected by the joining process at different selected values of workpiece surface roughness. However, Vickers microhardness was improved in the HAZ because of the effect of surface roughness, which narrowed the width of this zone. The FSW of commercial pure aluminum and copper demonstrated high bonding strength when preheated on the copper side compared with the optimal joint of the specimen conducted without preheating. Furthermore, X-Ray Diffraction (XRD) data showed that changes in metal alloy crystallite sizes, densities, and lattice parameters occurred over the test distances at different rotational speeds. The grains were fine and dynamically recrystallized near the weld interface and elongated at various distances. The fracture surfaces showed varied results when different parameters were used. These surfaces presented either ductile or brittle fracture.
format	Thesis
title	The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys
title_short	The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys
title_full	The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys
title_fullStr	The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys
title_full_unstemmed	The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys
title_sort	evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and cu alloys
granting_institution	Universiti Malaysia Perlis (UniMAP)
granting_department	School of Materials Engineering
url	http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/1/Page%201-24.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/2/Full%20text.pdf http://dspace.unimap.edu.my:80/xmlui/bitstream/123456789/77200/4/Hasan%20Issa%20Daw.pdf
_version_	1776104249032179712

The evolution of microstructures and properties due to materials tool interaction during friction stir welding of similar and dissimilar al and Cu alloys

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