Effect of shoulder features during friction spot extrusion welding of 2024-T3 to 6061-T6 aluminium alloys
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(2020) 20:84
ORIGINAL ARTICLE
Effect of shoulder features during friction spot extrusion welding of 2024‑T3 to 6061‑T6 aluminium alloys Jinzhen Han1 · M. Paidar2 · R. Vaira Vignesh3 · Kush P. Mehta4,5 · A. Heidarzadeh6 · O. O. Ojo7 Received: 21 April 2020 / Revised: 4 June 2020 / Accepted: 22 June 2020 © The Author(s) 2020
Abstract Friction spot extrusion welding process is successfully performed on dissimilar aluminum alloys of AA2024-T3 and AA6061T6 under the influence of shoulder features. The joints were analysed by microstructural features and mechanical properties using conventional and advanced tools of visual inspection, optical microscopy, scanning electron microscopy, transmission electron microscopy, electron back scattered diffractions, tensile testing and hardness testing. The results revealed that the joining was obtained by combination of mechanical locking from extruded material of top surface to predrilled bottom surface and diffusion in solid state. The stir zone and plastically deformed metal flow zone were influenced by scroll shoulder and smooth shoulder features. The tensile specimen of scroll shoulder was resulted to higher fracture load of 6381 N whereas the same was 4916 N in case of smooth shoulder. The interface of between plastically deformed metal flow zone and base material of AA6061-T6 can be considered as critical/weakest zone in case of friction spot extrusion. The variations of hardness were observed in stir zone, plastically deformed metal flow zone and thermo-mechanically affected zone in case of friction spot extrusion welding process. Keywords Dissimilar joints · Friction spot extrusion · Friction stir · Mechanical properties · Microstructure · Probeless tool · Welding
1 Introduction * Jinzhen Han [email protected] * Kush P. Mehta [email protected]; [email protected] 1
Zhejiang Industry Polytechnic College, Shaoxing 312000, Zhejiang, China
2
Department of Material Engineering, South Tehran Branch, Islamic Azad University, 1459853849 Tehran, Iran
3
Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, India
4
Advanced Manufacturing and Materials Research Group, Department of Mechanical Engineering, School of Engineering, Aalto University, Espoo, Finland
5
Department of Mechanical Engineering, School of Technology, Pandit Deendayal Petroleum University, Gandhinagar, Gujarat, India
6
Department of Materials Engineering, Azarbaijan Shahid Madani University, Tabriz, Iran
7
Department of Industrial and Production Engineering, Federal University of Technology Akure, Akure, Nigeria
The demand of dissimilar aluminum (Al) welds is extensively increasing to meet the requirements of cost reduction, light weight structures and enhanced working efficiency of transport industries. Ojo et al. [1] mentioned that the spot lap welds of transport industries are conventionally produced by resistance spot welding, which are then advanced by frictionbased spot welding processes in recent time. Friction
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