TY - JOUR
T1 - Enhancing joint performance in friction stir welding through tailored double-butt-lap geometry
AU - Acharya, Uttam
AU - Choudhury, Smrity
AU - Sethi, Durjyodhan
AU - Akinlabi, Esther
AU - Roy, Barnik Saha
N1 - Funding information: The primary author expresses gratitude to the Science and Engineering Research Board, Government of India, for financial support through the SERB_SIRE fellowship scheme under project file no. SIR/2022/001412, which has been instrumental in facilitating the present investigation.
PY - 2024/5/1
Y1 - 2024/5/1
N2 - The study investigates the effectiveness of a novel joint configuration, the double-butt-lap (DBL), in friction stir welding (FSW) to join 6-mm-thick AA 6061-T6 plates. Four welds, including a simple square butt (SSB) configuration and three DBL variations (with UB to LB ratios of 1:2, 1:1, and 2:1), were executed. Using consistent parameters, the investigation evaluates the force distribution, macrostructure, and mechanical properties of the joints. Results show varied force profiles; spindle torque and Z-force decrease notably in DBL configurations compared to SSB, while X-force decreases overall for all DBL variations. Macrostructural analysis indicates increased weld area and finer microstructures in DBL joints. A correlation between peak temperature, grain size, and hardness highlights larger grain sizes at higher temperatures, influencing joint hardness. The DBL configuration with a 2:1 ratio exhibits the highest joint efficiency (83.76%). Fractographic analysis indicates ductile failure in all samples. Bend testing reveals increased flexural strength and bend angles in two DBL-configured joints compared to SSB. The results indicate that using a 2:1 ratio for joining 6-mm AA6061-T6 plates through FSW is viable, providing valuable insights into enhancing mechanical properties by optimizing joint geometry.
AB - The study investigates the effectiveness of a novel joint configuration, the double-butt-lap (DBL), in friction stir welding (FSW) to join 6-mm-thick AA 6061-T6 plates. Four welds, including a simple square butt (SSB) configuration and three DBL variations (with UB to LB ratios of 1:2, 1:1, and 2:1), were executed. Using consistent parameters, the investigation evaluates the force distribution, macrostructure, and mechanical properties of the joints. Results show varied force profiles; spindle torque and Z-force decrease notably in DBL configurations compared to SSB, while X-force decreases overall for all DBL variations. Macrostructural analysis indicates increased weld area and finer microstructures in DBL joints. A correlation between peak temperature, grain size, and hardness highlights larger grain sizes at higher temperatures, influencing joint hardness. The DBL configuration with a 2:1 ratio exhibits the highest joint efficiency (83.76%). Fractographic analysis indicates ductile failure in all samples. Bend testing reveals increased flexural strength and bend angles in two DBL-configured joints compared to SSB. The results indicate that using a 2:1 ratio for joining 6-mm AA6061-T6 plates through FSW is viable, providing valuable insights into enhancing mechanical properties by optimizing joint geometry.
KW - Aluminum alloy
KW - Friction stir welding
KW - Joint configuration
KW - Mechanical property
KW - Microstructure
UR - http://www.scopus.com/inward/record.url?scp=85185954255&partnerID=8YFLogxK
U2 - 10.1007/s40194-024-01737-1
DO - 10.1007/s40194-024-01737-1
M3 - Article
SN - 0043-2288
VL - 68
SP - 1089
EP - 1101
JO - Welding in the World
JF - Welding in the World
IS - 5
ER -