Parametric Study of Reinforcement of Keyhole-less Friction Stir Spot Welding using Al2O3 and TiO2 Nanopowders

Document Type : Research Paper

Authors

1 Mechanical Engineering Department, University of Birjand, Birjand 97175-376, Iran

2 Mechanical Engineering Department, Azarbaijan Shahid Madani University, Tabriz, Iran

3 Department of Mechanical and Materials Engineering, Birjand University of Technology, Birjand, Iran

Abstract

In the present paper, two-stage refilled friction stir spot welding is used to join mild steel sheets with a thickness of 2 mm. Meanwhile, alumina and titanium oxide nanopowders are also introduced to the nugget to achieve superior mechanical properties. Two non-consumable tools are used with and without pins to weld and refill the keyhole, respectively. Before refilling, the keyhole is filled with nanopowders which are then distributed by the pinless refilling tool. Three parameters are investigated; the rotational speed of the welding tool and the rotational speed and dwell time of the refilling tool. The tensile test is used to evaluate the strength of the joints. The microhardness is measured in the welding zone to evaluate the powder distribution. The results suggest an increase in the joint strength by 42% and 18% with alumina and TiO2 as reinforcement, respectively. With a 31.94% contribution, the refilling tool rotational speed is the most effective input parameter affecting the joint strength. Considering the microstructure analysis and the microhardness test, the material flow pattern is mainly downward which results in the accumulation of the reinforcing powder in the lower sheet especially when a lower refilling tool rotational speed is used.

Keywords

References

[1]    S. Sattari, H. Bisadi, M. Sajed, Mechanical properties and temperature distributions of thin friction stir welded sheets of AA5083, International Journal of Mechanics and Applications, 2(1) (2012) 1-6.
[2]    J. Derogar, S.M.H. Seyedkashi, M. Sajed, Experimental study of friction stir spot welding of a non-alloyed aluminium sheet with stationary shoulder, Karafan Quarterly Scientific Journal, 19(3) (2022) 141-161.
[3]    M. Sajed, Parametric study of two-stage refilled friction stir spot welding, Journal of Manufacturing Processes, 24 (2016) 307-317.
[4]    S. Wu, T. Sun, Y. Shen, Y. Yan, R. Ni, W. Liu, Conventional and swing friction stir spot welding of aluminum alloy to magnesium alloy, The International Journal of Advanced Manufacturing Technology, 116(7) (2021) 2401-2412.
[5]    Y. Guishen, C. Xin, W. Zitao, Mechanical performance optimization and microstructure analysis of similar thin AA6061-T6 sheets produced by swept friction stir spot welding, The International Journal of Advanced Manufacturing Technology, (2021) 1-13.
[6]    X. Wang, Y. Morisada, H. Fujii, Flat friction stir spot welding of low carbon steel by double side adjustable tools, Journal of Materials Science & Technology, 66 (2021) 1-9.
[7]    J. Iwaszko, M. Sajed, Technological aspects of producing surface composites by friction stir processing —A review, Journal of Composites Science, 5(12) (2021) 323.
[8]    B. Sadeghi, H. Abbasi, M. Atapour, S. Shafiee, P. Cavaliere, Z. Marfavi, Friction stir spot welding of TiO2 nanoparticle-reinforced interstitial free steel, Journal of Materials Science, 55 (2020) 12458-12475.
[9]    M. Sajed, S.M.H. Seyedkashi, A novel technique for keyhole-less reinforced friction stir spot welding of polyethylene sheets, ADMT Journal, 12(4) (2019) 47-56.
[10]  M. Enami, M. Farahani, M. Farhang, Novel study on keyhole less friction stir spot welding of Al 2024 reinforced with alumina nanopowder, The International Journal of Advanced Manufacturing Technology, 101(9) (2019) 3093-3106.
[11]  M.R. Adibeig, G. Marami, M.A. Saeimi-Sadigh, L.F.M. da Silva, Experimental and numerical study of polyethylene hybrid joints: friction stir spot welded joints reinforced with adhesive, International Journal of Adhesion and Adhesives, 98 (2020) 102555.
[12]  P. Gao, Y. Zhang, K.P. Mehta, Metallurgical and mechanical properties of Al–Cu joint by friction stir spot welding and modified friction stir clinching, Metals and Materials International, 27(8) (2021) 3085-3094.
[13]  S. Wang, X. Wei, J. Xu, J. Hong, X. Song, C. Yu, J. Chen, X. Chen, H. Lu, Strengthening and toughening mechanisms in refilled friction stir spot welding of AA2014 aluminum alloy reinforced by graphene nanosheets, Materials & Design, 186 (2020) 108212.
[14]  Z. Feng, M.L. Santella, S.A. David, R.J. Steel, S.M. Packer, T. Pan, M. Kuo, R.S. Bhatnagar, Friction stir spot welding of advanced high-strength steels–a feasibility study, SAE Transactions, (2005) 592-598.
[15]  X. Wang, Y. Morisada, K. Ushioda, H. Fujii, Double-sided friction stir spot welding of ultra-high strength C-Mn-Si martensitic steel by adjustable probes, Journal of Materials Processing Technology, 300 (2022) 117422.
[16]       K. Kumamoto, T. Kosaka, T. Kobayashi, I. Shohji, Y. Kamakoshi, Microstructure and fatigue behaviors of dissimilar A6061/galvannealed steel joints fabricated by friction stir spot welding, Materials, 14(14) (2021) 3877.
[17]  T. Matsuda, T. Ogaki, K. Hayashi, C. Iwamoto, T. Nozawa, M. Ohata, A. Hirose, Fracture dominant in friction stir spot welded joint between 6061 aluminum alloy and galvannealed steel based on microscale tensile testing, Materials & Design,213 (2021) 110344.
[18]  H. Dong, Z. Tang, P. Li, B. Wu, X. Hao, C. Ma, Friction stir spot welding of 5052 aluminum alloy to carbon fiber reinforced polyether ether ketone composites, Materials & Design, 201 (2021) 109495.
[19]  Y. Ogawa, H. Akebono, K. Tanaka, A. Sugeta, Effect of welding time on fatigue properties of friction stir spot welds of Al to carbon fibre-reinforced plastic, Science and Technology of Welding and Joining, 24(3) (2019) 235-242.
[20]  Z. Shen, Y. Ding, A.P. Gerlich, Advances in friction stir spot welding, Critical Reviews in Solid State and Materials Sciences, 45(6) (2020) 457-534.
[21]  O. Kalaf, T. Nasir, M. Asmael, B. Safaei, Q. Zeeshan, A. Motallebzadeh, G. Hussain, Friction stir spot welding of AA5052 with additional carbon fiber-reinforced polymer composite interlayer. Nanotechnology Reviews, 10(1) (2021) 201-209.
[22]  M. Sajed, S.M.H. Seyedkashi, Solid-state local micro-alloying of thick st37 steel plates with SiC powder using a modified friction hydro-pillar process, Journal of Materials Research and Technology, 9(4) (2020) 7158-7171.
[23]  S. Memon, J. Tomków, H.A. Derazkola, Thermo-mechanical simulation of underwater friction stir welding of low carbon steel, Materials, 14(17) (2021) 4953.
[24]  M. Sajed, H. Bisadi, Experimental failure study of friction stir spot welded similar and dissimilar aluminum alloys, Welding in the World, 60 (2016) 33-40.
[25]  M. Farshbaf Ahmadipour, M. Movahedi, A.H. Kokabi, Microstructural evaluation and mechanical properties of Al1050/TiO2-graphite hybrid nanocomposite produced via friction stir processing, Metallurgical and Materials Transactions A, 50 (2019) 2443-2461.
Iranian Journal of Materials Forming
Volume 10, Issue 2
April 2023
Pages 55-67

Files

Share

How to cite

Statistics