352832

EFFECT OF WELDING SETTINGS ON MECHANICAL CHARACTERISTICS, MICROSTRUCTURAL FEATURES, AND CORROSION PERFORMANCE IN FRICTION STIR WELDING OF DISSIMILAR AA6082-T6/7075-T6 JOINTS

Article

Last updated: 03 Jan 2025

Subjects

-

Tags

Mechanical engineering

Abstract

This research explores the influence of welding settings (tool rotational speed, travel speed) on mechanical characteristics (tensile, micro-hardness), microstructure, and corrosion performance of dissimilar butt joints between aluminum alloys AA7075-T6 and AA6082-T6, which were fabricated by friction stir welding (FSW). The study considers three varied tool rotational speeds (1600, 2000, and 2300 rpm) in conjunction with three varied tool travel speeds (30, 40, and 50 mm/min). The butt joints were created by welding plates that were 6 mm thick. The welded specimens underwent characterization through optical microscopy, SEM, tensile testing, micro-hardness testing, and corrosion testing. Macroscopic observations of the samples revealed a range of stir zone shapes and defects that resulted from both inadequate and excessive heat input during the welding process. Analysis of the microstructure and results from the tensile testing indicated that the specimens produced using FSW settings of 2000 rpm and 40 mm/min achieved a peak ultimate tensile strength, demonstrating a value of 150 MPa. The micro-hardness values exhibited variations corresponding to changes in rotational speed, attaining a peak value of 240 HV at a rotational speed of 2300 rpm and a travel speed of 40 mm/min. The best mixing of the joined materials was achieved at a maximum welding rotational speed (2300 rpm) and medium travel speed (40 mm/min). A corrosion analysis of welded joints was conducted using a potentiodynamic polarization test in a solution containing 3.5% sodium chloride (NaCl). The welded zone (WZ) exhibits a reduced corrosion current density (Icorr), attributed to the occurrence of galvanic corrosion. The performance of corrosion within the WZ is impacted by the rotational speed and tool travel speed. Lowering the speed of the rotation tool leads to a decrease in the corrosion rate. Optimal corrosion resistance is achieved in the joint created at 2300 rpm and 30 mm/min, attributable to the suitable density and size of precipitates

DOI

10.21608/auej.2024.265883.1605

Keywords

Joining dissimilar alloys, Friction Stir Welding, Microstructural analysis, Mechanical Characteristics

Authors

First Name

Rasha

Last Name

Afify

MiddleName

-

Affiliation

Department of Mechanical Engineering, Faculty of Engineering at Shoubra, Benha University, Cairo 11629, Egypt

Email

remasm7md33@gmail.com

City

-

Orcid

-

First Name

Mohammed

Last Name

Gamil

MiddleName

-

Affiliation

Department of Mechanical Engineering, Faculty of Engineering at Shoubra, Benha University, Cairo 11629, Egypt

Email

mohammed.gamil@feng.bu.edu.eg

City

-

Orcid

-

Volume

19

Article Issue

71

Related Issue

47402

Issue Date

2024-04-01

Receive Date

2024-01-27

Publish Date

2024-04-29

Page Start

677

Page End

697

Print ISSN

1687-8418

Online ISSN

3009-7622

Link

https://jaes.journals.ekb.eg/article_352832.html

Detail API

https://jaes.journals.ekb.eg/service?article_code=352832

Order

352,832

Type

Original Article

Type Code

706

Publication Type

Journal

Publication Title

Journal of Al-Azhar University Engineering Sector

Publication Link

https://jaes.journals.ekb.eg/

MainTitle

EFFECT OF WELDING SETTINGS ON MECHANICAL CHARACTERISTICS, MICROSTRUCTURAL FEATURES, AND CORROSION PERFORMANCE IN FRICTION STIR WELDING OF DISSIMILAR AA6082-T6/7075-T6 JOINTS

Details

Type

Article

Created At

24 Dec 2024