Microstructural Evaluation of Similar and Dissimilar Welding of Aluminum Metal Matrix Hybrid Composite by Friction Stir Welding

Abstract:

To address the challenges of reducing the CO₂ emission in automotives, Aluminum metal matrix hybrid composites have been extensively used in automotive and aerospace industries for the fabrication of light weight structure. Huge demand in joining dissimilar metals increased day by day, because it reduces the weight and cost of components by utilizing hybrid structures. The friction stir welding is adopted for dissimilar AA5754 rheo-squeeze cast (RSC) with AA7075 stir casted hybrid composite. Micro sized B₄C and nanosized Al₂O₃ are reinforced into this material. Friction stir welding of these alloys by varying the tool material, pin and shoulder profiles, rotational speed, tool traverse speed and tilt angle. Microstructure of the joint are studied and inferences drawn are presented. The better welding was obtained with triangular and square pin profile when compared to cylindrical pin whereas triangular pin profile was more better than square pin. Tapered shoulder possessed greater strength, which resulted in a good weld in contrast to flat shoulder. The high carbon high chromium steel (HCHCr) tool exhibited a higher tool wear rate than stainless steel (SS) tool and found to be an appropriate one to weld aluminum hybrid composite.

• Periodical: Materials Science Forum (Volume 979)
• Pages: 124-128
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.979.124
• Online since: March 2020
• Authors: Kannan Sekar*, Pandian Vasanthakumar
• Keywords: AA5754, AA7075 Metal Matrix Hybrid Composites, Dissimilar FSW, Mild Steel, Rheo-Squeeze Casting, Similar FSW, Stir Casting

References

[1] J. R. Davis, Aluminum and Aluminum Alloys, 351–416 (2001).

[2] Devanathan, C., Babu, A.S., Friction Stir Welding of Metal Matrix Composite using Coated tool, Proced. Mater. Sci. 6 (2014) 1470-1475.

DOI: 10.1016/j.mspro.2014.07.126

[3] Chowdhury, S.H., Chen, D.L., Bhole, S.D., Cao, X., Wanjara, P., Lap shear strength and fatigue life of friction stir spot welded AZ31 magnesium and 5754 aluminum alloys, Mater. Sci. & Eng. A 556 (2012) 500-509.

DOI: 10.1016/j.msea.2012.07.019

[4] Cho, J.-H., Kim, W.J., Lee, C.G., Evolution of microstructure and mechanical properties during friction stir welding of A5083 and A6082 , Proced. Eng. 81(2014) 2080-2085.

DOI: 10.1016/j.proeng.2014.10.289

[5] Casalino, G., Campanelli, S., Mortello, M., 2014, Influence of Shoulder Geometry and Coating of the Tool on the Friction Stir Welding ofAluminum Alloy Plates , Proced. Eng. 69 (2014) 1541-1548.

DOI: 10.1016/j.proeng.2014.03.153

[6] Dehghani, M., Amadeh, A., Mousavi, S.A.A.A., Investigations on the effects of friction stir welding parameters on intermetallic and defect formation in joining aluminum alloy to mild steel, Mater. & Des. 49 (2013) 433-441.

DOI: 10.1016/j.matdes.2013.01.013

[7] K. Sekar , Gudla Jayachandra , S.Aravindan, Mechanical and Welding Properties of A6082-SiC-ZrO2 Hybrid Composite Fabricated by Stir and Squeeze Casting, Materials Today: Proceedings 5 (2018) 20268–20277.

DOI: 10.1016/j.matpr.2018.06.398

[8] K. Sekar, M. Manohar and K. Jayakumar, Mechanical and Tribological Properties of A356/Al2O3/MoS2 Hybrid Composites Synthesized Through Combined Stir and Squeeze Casting, Advances in Materials and Metallurgy, Lecture Notes in Mechanical Engineering, https://doi.org/10.1007/978-981-13-1780-4_13.

DOI: 10.1007/978-981-13-1780-4_13