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In this study, friction stir welding (FSW) was employed to join AA3003-H18 sheets by incorporating in situ Al-Cu intermetallic compounds within the stir zone. The FSW process was carried out under three distinct conditions: (I) without applying powder, (II) by introducing Cu powder, and (III) by incorporating Cu-Al mixed powder (50 vol.% Cu, 50 vol...
Contexts in source publication
Context 1
... evaluate mechanical properties, both longitudinal and transverse tensile samples were machined according to ASTM E8M [28] with a gauge length of 32 mm. In the transverse tensile test specimens, indicated in Figure 2a, the stir zone was placed at the center of the gauge length. On the other hand, in the longitudinal tensile test (Figure 2b), samples were oriented parallel to the travel direction to ensure that the entire gauge length was composed of stir zone (SZ) material. ...
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... the transverse tensile test specimens, indicated in Figure 2a, the stir zone was placed at the center of the gauge length. On the other hand, in the longitudinal tensile test (Figure 2b), samples were oriented parallel to the travel direction to ensure that the entire gauge length was composed of stir zone (SZ) material. Furthermore, Vickers microhardness tests were carried out along a transverse line across the cross-section of FSWed samples. ...
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... the attempts to enhance the transverse mechanical properties by introducing in situ Al-Cu intermetallics in the stir zone, such interventions were found to be ineffective in improving the overall performance of the FSWed samples. The longitudinal tensile test samples, extracted from the reinforced stir zone as shown in Figure 2b, indicated an evident increase in strength when Cu powder and Cu-Al mixed powder were incorporated. In the longitudinal tensile test of sample II, the UTS indicated an approximate 20% surge compared to sample I. Furthermore, the introduction of Cu-Al mixed powder further enhanced the UTS, marking a notable increase of around 42% relative to sample I. ...
Context 4
... the attempts to enhance the transverse mechanical properties by introducing in situ Al-Cu intermetallics in the stir zone, such interventions were found to be ineffective in improving the overall performance of the FSWed samples. The longitudinal tensile test samples, extracted from the reinforced stir zone as shown in Figure 2b, indicated an evident increase in strength when Cu powder and Cu-Al mixed powder were incorporated. In the longitudinal tensile test of sample II, the UTS indicated an approximate 20% surge compared to sample I. Furthermore, the introduction of Cu-Al mixed powder further enhanced the UTS, marking a notable increase of around 42% relative to sample I. ...
Citations
... Thus, optimal heat is required for proper mixing and recrystallization of of the joint [21]. Thus, heat input must be within optimal limits to get high-quality welds [22,23]. ...
In the present study, similar Aluminum (AA3003) alloy pipes with a thickness of 5 mm were friction stir welded using a high-speed steel (HSS) tool with a cylindrical pin profile. Welding was done at three different rotational speeds and three traverse speeds corresponding to pipes of three different diameters. Six combinations of rotational speed and traverse speed were used to observe the effect of energy input on the properties, specifically tensile strength and microhardness, as well as grain size of the resulting microstructure. This systematic variation in welding parameters was designed to assess how changes in energy input influence both the mechanical performance and microstructural attributes of the welded joints. The tensile test results indicated that an ultimate tensile strength (UTS) of 84% relative to the base metal was achieved at a rotational speed of 900 rotations per minute(rpm) and a traverse speed of 131.94 mm/min. The impact energy corresponding to these parameters was found to be 38% more than base metal which is a remarkable contribution. This combination of welding parameters facilitated optimal material flow and bonding, resulting in improved tensile properties of the welded joint. Additionally, the tensile results showed a consistent pattern in the tensile failure of the welded samples, where the joint failure occurred at the location with the lowest hardness in the welded region. This correlation highlights the critical influence of hardness distribution on the structural integrity of the welds, indicating that areas with reduced hardness are more prone to failure under tensile loading of FSWed joints.
... Tensile testing equipment (Universal Testing Machine (INSTRON), CEG Campus, Ann University, Chennai)) (figure 5(a)) with a measuring range of 0-400 kN was used to examine the tensile characteristics of the generated samples, which included the unprocessed Al matrix coupled with different HEA vol% compositions. As per the ASTM E8 standard (figures 5(b) & (c)), testing was carried out in normal environmental circumstances at a strain rate of 10^−5 sec^−1 [44]. Specimens for the longitudinal tensile test were extracted from the core of the stir zone to match the thickness of the stir zone produced during processing. ...
This study explores integrating AlCoCrFeNiSi high-entropy alloy (HEA) particles into the Al5083 aluminum alloy matrix via Friction Stir Processing (FSP) to enhance mechanical characteristics. Microstructural analysis reveals a homogeneous distribution and size reduction of HEA particles, contributing to improved structural strength. X-ray diffraction (XRD) examination confirms the formation of solid solution phases in the HEA particles, validating their role in enhancing material properties. Through the utilization of Design of Experiments (DOE) and Response Surface Methodology (RSM), FSP parameters are systematically optimized, enabling precise predictions of mechanical behavior. Multi-response optimization identifies the optimal combination of FSP parameters, resulting in significant enhancements in Ultimate Tensile Strength (UTS) and Hardness, reaching 314 MPa, 42% elongation, and 75 HV, respectively. Scanning Electron Microscopy (SEM) analysis of tensile test specimens elucidates the impact of varied FSP parameters on microstructural features, emphasizing the importance of optimal mixing for improving interfacial bonding and mechanical properties. This study underscores the effectiveness of integrating HEA particles and optimizing FSP parameters to elevate the mechanical properties of Al5083 aluminum alloy, paving the way for tailored composite materials with enhanced performance for specific applications.
