THE EFFECT OF TOOL PRESS FORCE

TO WELDABILITY OF AA5754 AND

AA6061 ALLOYS WITH FRICTION STIR
WELDING METHOD

Tevfik Küçükömeroğlu, Hasan Yılmaz, Semih Mahmut Aktarer

 

Karadeniz Technical University-Engineering Faculty, Department of Mechanical Engineering,

Trabzon, Turkey- tkomer@ktu.edu.tr

Giresun University, Giresun, Turkey- hayilmaz28@hotmail.com

Rize University-Vocational High School, Automotive Programme, Rize, Turkey-

semih.aktarer@rize.edu.tr
 CONTENTS
• Introduction
Friction Stir Welding
AA 5754 and AA 6061 alloys
• Experimental Procedure
• Result and Discussion
• Conclusions
 Quescion:

 Two different materials or two different

kind alloy of a material are can be welded
together successfully ?
 Yes, different kind of materials can weld
together successfully.

• It is possible with friction stir welding for

being a solid state method …
 Friction Stir Welding

a) Rotating of the tool

b) Plung into the abutting edges of plates
c) Heating of the workspace by friction
d) Traversed along the line of joint
 Advantages of Fsw
 No protective gas
 No filler metal
 No surface cleaning process
 No chips
 Enviroment friendly
Energy efficiency (% 2,5 of laser welding
energy)
 Weldability of complex shaped materials
 Susceptible to automation
 Why Fsw of aluminum alloys ?
• Being a strategic metal (high strenght and
low weight
• Being various difficulties of welding of Al-
alloys
• Low fuel consumption on light aircraft,
automotive and marine applications
 Why fsw of aluminum alloys?

• Being solid state method

• Low heat input contrary to arc welding
• No missing of alloy elements
• High-quality micro-structure
 Why fsw of aluminum alloys?

• Excellent metallurgical properties in joined

area
• Low internal stress of the structure
• The reproducibility of the process
• Monolithic final state occurs
 AA 5754 Alloy

• Increased strength by strain hardening

method
• Has corrosion resistance properties
• Widely used in automotive and ship
building industry
 AA 6061 Alloy

• Increased strength by aging method

• Defence, ship building and aerospace
industry
Grain growth in welding zone

Overaging in welding zone

Laser welded aluminum alloy
Why welding of two different
aluminum alloys

• Made of two different ways but have

similiar mechanical properties
• Can use common industry
 Why welding of two different
aluminum alloys

• Can be used together in defence, marine and

automotive industry
• Was determined to be the most suitable
method
 Experimental Procedure

The mechanical properties of AA5754-H22 and AA6061-T6 alloys

Tensile Young’s Elongatio Energy at

Yield Point Hardness
Material Strength Modulus n at Break Break
[MPa] (VH0,2)
[MPa] [Gpa] [%] [J]
AA5754-
190 253 78 60,9 13,6 12,4
H22
AA6061-
217 242 90 66,2 12,1 10,6
T6
Fsw mechanism
Hydrolic loading unit
The state of thermocouple
• The tool made from hard work tool steel
• Screwed triangular pyramid
 Welding Parametres
Rotational speed : 800 rpm Welding speed : 270 mm/min
Tool press force :(6,8,10) kN Tool tilt angle : 2°
F=10 kN experiment video
Extraction plan of test samples from combined plates
a)Longitudinal b) Transverse
c) Metallography d) Bending
 Results and Discussion

• Temperature values measured as 330°C,

339 °C, 376 °C
• Dynamic recrystallization and grain growth
is observed
• Very low surface roughness.
• No visible voids.
Sem images of 6 kN affected material
A: 130 X B:130 X b:650 X
Sem images of 6 kN affected material
C: 650 X D:130 X E:130 X e: 650X
 Mechanical Properties
Hardness Test

The hardness distribution of the welding zone

 Mechanical Properties
Tensile Test

6 kN

8 kN

10 kN

Transverse Tensile Samples

 Mechanical Properties
Tensile Test

6 kN

8 kN

10 kN

Longitudinal Tensile Samples

 Mechanical Properties

Mechanical Properties Obtained from Tensile Samples

Tensile
Yield Point Elongation at Energy at Break
Tensile Samples Strength
[MPa] Break [%] [J]
[MPa]
Base AA5754 253 190 13,6 12,37
Base AA6061 242 217 12,1 10,6
Transverse 6kN 203 138 7,2 5,33
Transverse 8kN 209 148 6,84 4,86
Transverse 10kN 215 155 6,44 4,59
Longitudinal 6kN 291 196 20 -
Longitudinal 8kN 320 229 40,3 -
Longtudinal 10kN 293 199 39,1 -
• Tensile strength of transverse sample is %86±3 of base material
• Tensile strength of longitudinal sample is %25 more than base material
• Yield strength of transverse samle is %78±5 of base material
• Elongation values of longitudinal samples are %170 more
than that obtained from the base material
 Mechanical Properties
Bending Test

6 kN affected sample
 Mechanical Properties
Bending Test

10 kN affected sample
 Conclusions

1. AA5754-H22 and AA6061-T6 alloys can be

successfully joined by FSW process.
2. The weakest zone in the welding process
stays out of the joint zone. Stays in the HAZ
of AA6061 alloy.
3. Decrease of the welding structure’s strength
is approximately 14% to the base materials.
 Conclusions

4. The temperature occurs from welding more

affected AA6061 alloy than AA5754 alloy .
5. Strength and hardness of welded structure
increased with incresing tool press force.
6. The welding region has acceptable shape
change ability for engineering applications.
The End!
Thanks for your attention…