Stepwise double-sided friction stir welding: an alternative for root defect mitigation in aluminium plates with lower gauge numbers

Year 2024, Volume: 8 Issue: 4, 611 - 618, 31.10.2024

Olatunji Oladimeji Ojo , Ozioma Alaba Oboro

https://doi.org/10.31127/tuje.1449966

Abstract

Penetration-induced fractional unbonded defects and flow-induced root flaws are part of the discontinuities of the conventional friction stir welded (FSW’ed) aluminium alloys with limited impact assessment/clarification in literature. The novelty of this study lies in the attempt to eliminate penetration-aided root defect via a stepwise double-sided welding process as well as identify its impact on loadbearing. As a result, the stepwise double-sided FSW welding of a thick aluminium plate (6 mm) was carried out while the microstructure, strength, and fracture modes of the ensuing welds were compared with the conventional (single-sided) friction stir welded counterparts. The stepwise double-sided FSW-welded joint demonstrated better tensile strength relative to the single-sided FSW-welded counterparts owing to its material flow consolidation (two-side deformation) and elimination of penetration-induced fractional unbonded region/root defect. The welding processes do not have a noteworthy influence on the fracture location of the welds as failure ensued via the stir zones of the respective welds. Transient breaking/brittle appearance, and ductile fracture modes were noticed in the single-sided and stepwise double-sided FSW-welded samples respectively. The stepwise double-sided FSW process is recommended as a better choice for thick workpieces relative to conventional FSW to improve the weld’s loadbearing resistance.

Keywords

Friction stir welding, Aluminium alloy, Microstructure, Mechanical Properties, Fracture

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