Scholarlink

<p>Friction stir welding (FSW) is widely used in the automotive and aerospace industries for producing defect-minimized welds with enhanced formability. The quality of welds depends on key parameters such as tool rotational speed, welding speed, axial force, and tool pin profile. This study evaluates the influence of different tool pin designs—conventional cylindrical pin, novel dual-pin, and tapered square pin—on the mechanical properties, formability, microstructure, and texture of FSWed AA5754 sheets. A constant 1200&#xa0;rpm rotational speed and 150&#xa0;mm/min traverse speed were used for each tool design. Tensile tests (ASTM E8) revealed that the conventional pin provided maximum strength and ductility, while the tapered square pin exhibited the lowest values. Despite available literatures that suggested superior performance for dual-pin and tapered square designs, defects such as tunnels, voids, and cracks led to early failure. Macrostructural analysis confirmed significant defect formation in dual-pin and tapered square specimens, whereas the conventional pin ensured better material integrity. The microhardness testing showed uniform hardness distribution in the dual-pin specimen. Erichsen cupping tests indicated that formability trends aligned with the corresponding percentage elongation from the tensile test results. EBSD analysis of the stir zone (SZ) and near-failure regions revealed that the conventional pin formed fine, highly anisotropic &lt; 001 &gt; -oriented grains, enhancing joint strength. In contrast, the tapered square pin produced a non-uniform grain structure, promoting premature failure. Limited formability in dual-pin and tapered square specimens was linked to the dominant Cube texture and the absence of Goss texture, which induced localized stress concentration and accelerated failure.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Correlation of microstructure and micro-texture with the mechanical and formability behavior of friction stir welded similar AA5754 sheets using different tool pin designs

  • 期刊论文

  • 发表日期：

    2025年9月15日

查看全文
  • Rahul Datta,
  • Bhargava Marrapu

摘要

Friction stir welding (FSW) is widely used in the automotive and aerospace industries for producing defect-minimized welds with enhanced formability. The quality of welds depends on key parameters such as tool rotational speed, welding speed, axial force, and tool pin profile. This study evaluates the influence of different tool pin designs—conventional cylindrical pin, novel dual-pin, and tapered square pin—on the mechanical properties, formability, microstructure, and texture of FSWed AA5754 sheets. A constant 1200 rpm rotational speed and 150 mm/min traverse speed were used for each tool design. Tensile tests (ASTM E8) revealed that the conventional pin provided maximum strength and ductility, while the tapered square pin exhibited the lowest values. Despite available literatures that suggested superior performance for dual-pin and tapered square designs, defects such as tunnels, voids, and cracks led to early failure. Macrostructural analysis confirmed significant defect formation in dual-pin and tapered square specimens, whereas the conventional pin ensured better material integrity. The microhardness testing showed uniform hardness distribution in the dual-pin specimen. Erichsen cupping tests indicated that formability trends aligned with the corresponding percentage elongation from the tensile test results. EBSD analysis of the stir zone (SZ) and near-failure regions revealed that the conventional pin formed fine, highly anisotropic < 001 > -oriented grains, enhancing joint strength. In contrast, the tapered square pin produced a non-uniform grain structure, promoting premature failure. Limited formability in dual-pin and tapered square specimens was linked to the dominant Cube texture and the absence of Goss texture, which induced localized stress concentration and accelerated failure.