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<p>The pre-set wires in the corner of T can be employed as filler material in FSW to create a smooth transition and enhance the mechanical properties of the joint. However, inadequate heat input to the corner of T results in defects including tunnels and voids as well as bonding line defects. Thus, T-joint performance is impacted and leads to stress concentration. An increase in heat input may cause the IMCs population to develop rapidly, which presents a significant obstacle for FSW T-lap of different materials. This article suggests a novel friction stir welding technique, which involves designing two progressive pins and pre-set wires at the corners before inserting them through the skin. The technique can slow the growth of IMCs and lessen Al/Cu mixing in the big pin stirring zone. Pre-set ER6061 wires can eliminate tunnel defects on the AS in comparison with no pre-set wires, and the tensile strength of the joints increases by 23.8 and 43.8% along the skin and stringer directions, respectively. Furthermore, bonding line defects may arise from pre-set Cu wires obstructing the flow at the corner. The T-joints with pre-set ER6061 wires deform along the stringer direction initially at the AS and RS of the large pin stirring zone, as observed by the DIC characterization analysis. Additionally, the RS of the corner has a larger grain size than the AS under both progressive pins. The slight variation in the S-type tool’s pin size and the slight forging effect results in less heat transfer, less material flow stagnation, and more appropriate smoothness. When paired with the S-type tool's EBSD analysis to produce more interfacial staggered structures, it demonstrates how the threaded structure encourages more appropriate material flow, making it better suited for filling in the corners.</p>

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Effect of Progressive Pin and Pre-set Wires on the Quality of Corner Forming of Al/Cu FSW T-Lap Joints

  • 期刊论文

  • 发表日期：

    2025年1月13日

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  • Shixi Liu,
  • Furong Chen,
  • Yunxi Gao

摘要

The pre-set wires in the corner of T can be employed as filler material in FSW to create a smooth transition and enhance the mechanical properties of the joint. However, inadequate heat input to the corner of T results in defects including tunnels and voids as well as bonding line defects. Thus, T-joint performance is impacted and leads to stress concentration. An increase in heat input may cause the IMCs population to develop rapidly, which presents a significant obstacle for FSW T-lap of different materials. This article suggests a novel friction stir welding technique, which involves designing two progressive pins and pre-set wires at the corners before inserting them through the skin. The technique can slow the growth of IMCs and lessen Al/Cu mixing in the big pin stirring zone. Pre-set ER6061 wires can eliminate tunnel defects on the AS in comparison with no pre-set wires, and the tensile strength of the joints increases by 23.8 and 43.8% along the skin and stringer directions, respectively. Furthermore, bonding line defects may arise from pre-set Cu wires obstructing the flow at the corner. The T-joints with pre-set ER6061 wires deform along the stringer direction initially at the AS and RS of the large pin stirring zone, as observed by the DIC characterization analysis. Additionally, the RS of the corner has a larger grain size than the AS under both progressive pins. The slight variation in the S-type tool’s pin size and the slight forging effect results in less heat transfer, less material flow stagnation, and more appropriate smoothness. When paired with the S-type tool's EBSD analysis to produce more interfacial staggered structures, it demonstrates how the threaded structure encourages more appropriate material flow, making it better suited for filling in the corners.