66
A. K. Choudhary and R. Jain
2.8 Research Area
Investigation on the friction stir welding for similar and dissimilar metal has been
done extensively by the researchers. It has been successfully adopted in the field of
automobile spare part joining and aerospace field. It has gathered immense potential in research and development. FSW has been used for a variety of materials
ie. aluminum, copper, magnesium, titanium, and steel. It is also used for a dissimilar material like aluminum-magnesium, magnesium-copper, copper–aluminum, etc.
Research has been carried out in different domains of FSW i.e. material flow, temperature distribution, microstructural characterization, and improvement in the mechanical property of the weld. A brief overview of the literature review for the application
of FSW for different materials is explained in the following sections. Also, tool wear
during FSW has been briefly elaborated as it is important in terms of tool design and
tool life predictions in context for the optimized input process parameter. In addition,
a few variants of FSW have been explained with important literature. For a detailed
review, the reader should look for more papers in the relevant areas.
2.8.1 Overview of Friction Stir Welding for Similar Material
2.8.1.1 Aluminum Welding
Friction stir welding has progressed as a front runner for the welding of aluminum
and its alloy for high weld strength. Since its inception, extensive research efforts
have been carried out for the FSW. An investigation has been done to understand
temperature distribution, material flow, the effect of the input parameter, and pin
profile on the welding of aluminum alloy [112].
Hou et al. [113] investigated FSW of 6061-T6 aluminum alloy at a fixed welding
speed of 150 mm/min. The microstructure and mechanical properties of the joints
were observed for different rotational speeds. In SZ fine recrystallized grains of 1 μm
were formed at 400 rpm. Maximum joint strength of 188 MPa with a weld efficiency
of 66% was obtained. They reported that defect-free joints were observed between
400 and 600 rpm and defects such as void were reported at higher rotation speeds
of 700 and 800 rpm. Liu et al. [114] FSWed 7.5 mm thick 2219-T6 aluminum alloy.
A concave shoulder with a threaded conical pin tool with a tilt angle of 2.5° and a
plunge depth of 0.3 mm was used for joining. The highest tensile strength of 340 MPa
with 79% weld efficiency was obtained at 800 rpm. Defect-free weld was observed
at 600 rpm and 200 mm/min.
Marzbanrad et al. [115] investigated the performance of the tool pin profile on
weld properties of 3 mm thick AA5083. Cylindrical and square pin profiles with
a 2° tilt angle tool were employed. Weld parameters of 1120 rpm and 30 mm/min
were selected for the analysis. A strain of 50 and 40 mm/mm was observed for the
square and cylindrical profile, respectively. The peak temperature of 480 and 455 °C
A. K. Choudhary and R. Jain
2.8 Research Area
Investigation on the friction stir welding for similar and dissimilar metal has been
done extensively by the researchers. It has been successfully adopted in the field of
automobile spare part joining and aerospace field. It has gathered immense potential in research and development. FSW has been used for a variety of materials
ie. aluminum, copper, magnesium, titanium, and steel. It is also used for a dissimilar material like aluminum-magnesium, magnesium-copper, copper–aluminum, etc.
Research has been carried out in different domains of FSW i.e. material flow, temperature distribution, microstructural characterization, and improvement in the mechanical property of the weld. A brief overview of the literature review for the application
of FSW for different materials is explained in the following sections. Also, tool wear
during FSW has been briefly elaborated as it is important in terms of tool design and
tool life predictions in context for the optimized input process parameter. In addition,
a few variants of FSW have been explained with important literature. For a detailed
review, the reader should look for more papers in the relevant areas.
2.8.1 Overview of Friction Stir Welding for Similar Material
2.8.1.1 Aluminum Welding
Friction stir welding has progressed as a front runner for the welding of aluminum
and its alloy for high weld strength. Since its inception, extensive research efforts
have been carried out for the FSW. An investigation has been done to understand
temperature distribution, material flow, the effect of the input parameter, and pin
profile on the welding of aluminum alloy [112].
Hou et al. [113] investigated FSW of 6061-T6 aluminum alloy at a fixed welding
speed of 150 mm/min. The microstructure and mechanical properties of the joints
were observed for different rotational speeds. In SZ fine recrystallized grains of 1 μm
were formed at 400 rpm. Maximum joint strength of 188 MPa with a weld efficiency
of 66% was obtained. They reported that defect-free joints were observed between
400 and 600 rpm and defects such as void were reported at higher rotation speeds
of 700 and 800 rpm. Liu et al. [114] FSWed 7.5 mm thick 2219-T6 aluminum alloy.
A concave shoulder with a threaded conical pin tool with a tilt angle of 2.5° and a
plunge depth of 0.3 mm was used for joining. The highest tensile strength of 340 MPa
with 79% weld efficiency was obtained at 800 rpm. Defect-free weld was observed
at 600 rpm and 200 mm/min.
Marzbanrad et al. [115] investigated the performance of the tool pin profile on
weld properties of 3 mm thick AA5083. Cylindrical and square pin profiles with
a 2° tilt angle tool were employed. Weld parameters of 1120 rpm and 30 mm/min
were selected for the analysis. A strain of 50 and 40 mm/mm was observed for the
square and cylindrical profile, respectively. The peak temperature of 480 and 455 °C