Application of Friction Stir Welding to dissimilar welding

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Application of Friction Stir Welding to
dissimilar welding

• L. Karlsson and E-L. Bergqvist, ESAB AB, Sweden
• H. Larsson, Volvo Car Corp., Sweden

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Applications Aim

• Space applications

• Ship building

• FSW of dissimilar materials
• Feasibility
• weldability
• mechanical properties
• microstructure

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Friction Stir Welding - Solid state joining
process

Rotating probe provides friction heat and
pressure to join the material
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Properties Productivity

• High productivity
• difficult alloys
• High and consistent quality
• Good mechanical properties
• strength
• toughness
• hardness
• fatigue strength

• Fatigue properties AA 5083

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Friction Stir Welding - Environment friendly

• No fume
• No arc
• No spatter

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ESAB SuperStir- Shipbuilding and Marine
Industries

• Panels from Extrusions welded withESAB
  SuperStirTM at Marine Aluminium, Norway

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ESAB SuperStir -Aerospace Industry (Rocket fuel
tanks)
Welding rocket fuel tanks Milling head and
welding head travelling on a vertical main beam.
Parts are loaded, edges are milled, welding is
carried out and the final length is milled.
Tanks of 5 m diameter and max 12 m length
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Contents

• Introduction of FSW
• Experimental
• Results
• AA 5083/AA 6082
• Properties microstructure
• Al-clad AA 2024
• Properties microstructure
• AA 5083/Cu
• Properties microstructure
• Conclusions

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Experimental

• 5 mm plate material
• AA 5083-H12 (4.6Mg, 0.6Mn, 0.3Si)
• AA 6082-T6 (0.7Mg, 0.5Mn, 0.9Si)
• 1.6 mm 2.3 mm plate
• Al-clad AA 2024-T3/T42 (4.6Cu, 1.5Mg,
  0.7Mn)
• Oxygen free Cu

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Contents

• Introduction of FSW
• Experimental
• Results
• AA 5083/AA 6082
• Properties microstructure
• Al-clad AA 2024
• Properties microstructure
• AA 5083/Cu
• Properties microstructure
• Conclusions

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Weld appearance and cross sections
Top surface
Root surface
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Microstructure

• Elemental distribution maps from nugget zone of
  AA 5083/AA 6082 dissimilar FSW weld

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Properties

• Bend testing

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Properties

• Transverse tensile properties

Tensile strength (MPa)
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Properties

• Location of fracture in tensile testing

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Contents

• Introduction of FSW
• Experimental
• Results
• AA 5083/AA 6082
• Properties microstructure
• Al-clad AA 2024
• Properties microstructure
• AA 5083/Cu
• Properties microstructure
• Conclusions

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FSW of Al-clad AA 2024

• Cross section (I-24-1)

• Root side detail

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Properties

• Transverse tensile properties

Tensile strength (MPa)
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Contents

• Introduction of FSW
• Experimental
• Results
• AA 5083/AA 6082
• Properties microstructure
• Al-clad AA 2024
• Properties microstructure
• AA 5083/Cu
• Properties microstructure
• Conclusions

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FSW of AA 5083 and Cu

• Micrograph
• Isolated Cu regions on Al side of nugget

• Cross section

Advancing side Retreating side
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Properties

• Transverse tensile properties

Tensile strength (MPa)
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Contents

• Introduction of FSW
• Experimental
• Results
• AA 5083/AA 6082
• Properties microstructure
• Al-clad AA 2024
• Properties microstructure
• AA 5083/Cu
• Properties microstructure
• Conclusions

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Conclusions

• A microstructure similar to typical FSW welds but
  a more pronounced nugget ring pattern consisting
  of intimately bonded regions with different
  compositions.

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Conclusions

• Tensile strength typical of FSW welds in weakest
  material with fracture in minimum hardness region

MPa
AA 6082
AA 6082/ AA 5083 dissimilar
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Conclusions

• Frictions Stir Welding is well suited to
  dissimilar joining of
• AA 5083 and AA 6082
• AA 5083 and Cu
• and to welding of Al-clad AA 2024

AA 5083 AA 6082
AA 5083 Cu
Al-clad AA 2024
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Friction Stir Welding - ESAB SuperStir
Questions ? For further information please
contact Stefan Stoltz / Rolf Larsson / Sylve
Antonsson ESAB Friction Stir Welding Team Esab
Welding Equipment AB, Automation
Engineering S-695 81 LAXÅ, SWEDEN Telephone 46
584 81 000, Telefax 46 584 41 17 21E-mail
stefan.stoltz_at_esab.se / rolf.larsson_at_esab.se /
sylve.antonsson_at_esab.se