Process window for friction stir lap welding of aluminum alloy 6061

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Proceedings titleAdvanced Materials Research
Conference8th International Conference on Processing and Manufacturing of Advanced Materials, THERMEC 2013, Dec. 2-6, Las Vegas, NV
Pages28392844; # of pages: 6
SubjectAluminum alloys; Corrosion resistance; Cracks; Materials handling; Welding; AA6061-T6; Excellent corrosion resistances; Friction stir lap welding; Friction stir welding(FSW); Lap welding; Process window; Solidification cracking; Transportation vehicles; Friction stir welding
AbstractPrecipitation-hardenable 6xxx series aluminum alloys are incorporated in many structural components with due consideration of their good combination of properties including a relatively high strength, outstanding extrudability and excellent corrosion resistance. Accordingly, AA6061 has been identified as a very good candidate material for structural lightweighting of transportation vehicles. However, the weldability of aluminum alloy (AA) 6061 by means of conventional technologies such as GMAW and GTAW methods is limited by sensitivity to solidification cracking. In this respect, friction stir welding (FSW) presents a tremendous potential for assembly of aluminum structures for the transportation industry due to the low heat involved that can mitigate crack formation and, thus, translate into improved mechanical performance of the assembly. In this work, FSW of 3.18 mm thick AA6061-T6 sheets in the lap joint configuration was investigated. This configuration is considered to be more challenging for assembly by FSW than the butt joint type due to the orientation of the interface with respect to the welding tools and the necessity to break the oxide layer on two aluminium alloy planar surfaces. Weld trials were performed to examine the influence of the FSW tool geometry and process parameters on the welding defects, microstructure, hardness and bend performance. Unacceptable material expulsion and/or significant thinning in one of the two overlapped sheets were produced under most conditions. A set of FSW tool geometries leading to a viable process operational window under which the risk of defects could be mitigated and/or eliminated was identified in this study. © (2014) Trans Tech Publications, Switzerland.
Publication date
AffiliationAerospace; National Research Council Canada
Peer reviewedYes
NPARC number21272254
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Record identifierd8fc9032-2ae2-47c1-bddc-0bc7d1491b18
Record created2014-07-23
Record modified2016-05-09
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