Skip to main content
SpringerLink
Log in

Formation and fracture characteristics of friction stir lap joint of Alclad 2A12-T42 aluminum alloy at different tilt angles

  • Research Paper
  • Published:
Welding in the World Aims and scope Submit manuscript

Abstract

The focus of the current investigation is on how tilt angle (TA) affects the formation and fracture characteristics of friction stir lap welded in 2A12-T42 aluminum alloy. The results demonstrated that as the TA increased from 2° to 5°, the material flow state varied throughout the welding process, resulting in modifications to the surface and internal formation (including stirring zone (SZ), hook, and cold lap defects) of the joints. The maximum lap shear failure load of 3961.3 N was obtained for joints with 3° TA. The distribution of the alclad layer in the SZ has a significant impact on the lap shear failure loads and fracture mode of the joint.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. Meng XC, Huang YX, Cao J et al (2021) Recent progress on control strategies for inherent issues in friction stir welding. Prog Mater Sci 115:100706. https://doi.org/10.1016/j.pmatsci.2020.100706

    Article  CAS  Google Scholar 

  2. Nandan R, Debroy T, Bhadeshia H (2008) Recent advances in friction-stir welding – Process, weldment structure and properties. Prog Mater Sci 53:980–1023. https://doi.org/10.1016/j.pmatsci.2008.05.001

    Article  CAS  Google Scholar 

  3. Liu ZL, Cui HT, Ji SD et al (2016) Improving joint features and mechanical properties of pinless fiction stir welding of Alcald 2A12-T4 aluminum alloy. J Mater Sci Technol 32:1372–1377. https://doi.org/10.1016/j.jmst.2016.07.003

    Article  CAS  Google Scholar 

  4. Mishra RS, Ma ZY (2005) Friction stir welding and processing. Mater Sci Eng R Rep 50:1–78. https://doi.org/10.1016/j.mser.2005.07.001

    Article  CAS  Google Scholar 

  5. Song YB, Yang XQ, Cui L et al (2014) Defect features and mechanical properties of friction stir lap welded dissimilar AA2024-AA7075 aluminum alloy sheets. Mater Des 55:9–18. https://doi.org/10.1016/j.matdes.2013.09.062

    Article  CAS  Google Scholar 

  6. Salari E, Jahazi M, Khodabandeh A, Ghasemi-Nanesa H (2014) Influence of tool geometry and rotational speed on mechanical properties and defect formation in friction stir lap welded 5456 aluminum alloy sheets. Mater Des 58:381–389. https://doi.org/10.1016/j.matdes.2014.02.005

    Article  CAS  Google Scholar 

  7. Li B, Shen YF (2012) A feasibility research on friction stir welding of a new-typed lap–butt joint of dissimilar Al alloys. Mater Des 34:725–731. https://doi.org/10.1016/j.matdes.2011.05.033

    Article  CAS  Google Scholar 

  8. Baskoro AS, Nugroho AAD, Rahayu D et al (2013) Effects of welding parameters in micro friction stir lap welding of aluminum A1100. AMR 789:356–359. https://doi.org/10.4028/www.scientific.net/AMR.789.356

    Article  CAS  Google Scholar 

  9. Barlas Z (2017) The influence of tool tilt angle on 1050 aluminum lap joint in friction stir welding process. Acta Phys Pol A 132:679–681. https://doi.org/10.12693/APhysPolA.132.679

    Article  CAS  Google Scholar 

  10. Banik A, Saha Roy B, Deb Barma J, Saha SC (2018) An experimental investigation of torque and force generation for varying tool tilt angles and their effects on microstructure and mechanical properties: Friction stir welding of AA 6061–T6. J Manuf Process 31:395–404. https://doi.org/10.1016/j.jmapro.2017.11.030

    Article  Google Scholar 

  11. Zhang S, Shi QY, Liu Q et al (2018) Effects of tool tilt angle on the in-process heat transfer and mass transfer during friction stir welding. Int J Heat Mass Transf 125:32–42. https://doi.org/10.1016/j.ijheatmasstransfer.2018.04.067

    Article  Google Scholar 

  12. Long L, Chen GQ, Zhang S et al (2017) Finite-element analysis of the tool tilt angle effect on the formation of friction stir welds. J Manuf Process 30:562–569. https://doi.org/10.1016/j.jmapro.2017.10.023

    Article  Google Scholar 

  13. Chitturi V, Pedapati SR, Awang M (2019) Effect of tilt angle and pin depth on dissimilar friction stir lap welded joints of aluminum and steel alloys. Materials 12:3901. https://doi.org/10.3390/ma12233901

    Article  CAS  Google Scholar 

  14. Rajendran C, Srinivasan K, Balasubramanian V et al (2019) Effect of tool tilt angle on strength and microstructural characteristics of friction stir welded lap joints of AA2014-T6 aluminum alloy. Trans Nonferrous Metals Soci China 29:1824–1835. https://doi.org/10.1016/S1003-6326(19)65090-9

    Article  CAS  Google Scholar 

  15. Liu HJ, Zhao YQ, Hu YY et al (2015) Microstructural characteristics and mechanical properties of friction stir lap welding joint of Alclad 7B04-T74 aluminum alloy. Int J Adv Manuf Technol 78:1415–1425. https://doi.org/10.1007/s00170-014-6718-2

    Article  Google Scholar 

  16. Fu BL, Shen JJ, Suhuddin UFHR et al (2021) Revealing joining mechanism in refill friction stir spot welding of AZ31 magnesium alloy to galvanized DP600 steel. Mater Des 209:109997. https://doi.org/10.1016/j.matdes.2021.109997

    Article  CAS  Google Scholar 

  17. Yaemphuan P, Triwanapong S, Kimapong K (2018) Shear Strength and Fracture Location of Dissimilar A6063 Aluminum Alloy and SUS430 Stainless Steel Lap Joint. KEM 773:196–201. https://doi.org/10.4028/www.scientific.net/KEM.773.196

    Article  Google Scholar 

  18. Huang YX, Wan L, Lv SX et al (2012) New technique of in situ rolling friction stir welding. Sci Technol Weld Joining 17:636–642. https://doi.org/10.1179/1362171812Y.0000000056

    Article  CAS  Google Scholar 

  19. Yue YM, Zhou ZL, Ji SD et al (2017) Effect of welding speed on joint feature and mechanical properties of friction stir lap welding assisted by external stationary shoulders. Int J Adv Manuf Technol 89:1691–1698. https://doi.org/10.1007/s00170-016-9240-x

    Article  Google Scholar 

  20. Cederqvist L, Reynolds AR (2001) Factors affecting the properties of friction stir welded aluminum lap joints. Weld J 80:281S-287S

    Google Scholar 

  21. Li ZW, Yue YM, Ji S et al (2016) Joint features and mechanical properties of friction stir lap welded alclad 2024 aluminum alloy assisted by external stationary shoulder. Mater Des 90:238–247. https://doi.org/10.1016/j.matdes.2015.10.056

    Article  CAS  Google Scholar 

  22. Zhang HJ, Wang M, Zhang X et al (2016) Effect of welding speed on defect features and mechanical performance of friction stir lap welded 7B04 aluminum alloy. Metals 6:87. https://doi.org/10.3390/met6040087

    Article  Google Scholar 

  23. Liu XC, Wu CS, Padhy GK (2015) Characterization of plastic deformation and material flow in ultrasonic vibration enhanced friction stir welding. Scr Mater 102:95–98. https://doi.org/10.1016/j.scriptamat.2015.02.022

    Article  CAS  Google Scholar 

  24. Wang M, Zhang HJ, Zhang JB et al (2014) Effect of pin length on hook size and joint properties in friction stir lap welding of 7B04 aluminum alloy. J Mater Eng Perform 23:1881–1886. https://doi.org/10.1007/s11665-014-0936-5

    Article  CAS  Google Scholar 

  25. Liu HH, Fujii H (2018) Microstructural and mechanical properties of a beta-type titanium alloy joint fabricated by friction stir welding. Mater Sci Eng A-Struct Mater Prop Microstruct Process 711:140–148. https://doi.org/10.1016/j.msea.2017.11.006

    Article  CAS  Google Scholar 

  26. Song KH, Kim WY, Nakata K (2012) Evaluation of microstructures and mechanical properties of friction stir welded lap joints of Inconel 600/SS 400. Mater Des 35:126–132. https://doi.org/10.1016/j.matdes.2011.09.054

    Article  CAS  Google Scholar 

  27. Kumar SS, Murugan N, Ramachandran KK (2020) Effect of tool tilt angle on weld joint properties of friction stir welded AISI 316L stainless steel sheets. Measurement 150:107083. https://doi.org/10.1016/j.measurement.2019.107083

    Article  Google Scholar 

  28. Fu BL, Shen JJ, Suhuddin UFHR et al (2021) Improved mechanical properties of cast Mg alloy welds via texture weakening by differential rotation refill friction stir spot welding. Scr Mater 203:114113. https://doi.org/10.1016/j.scriptamat.2021.114113

    Article  CAS  Google Scholar 

  29. Seighalani KR, Givi MKB, Nasiri AM, Bahemmat P (2010) Investigations on the effects of the tool material, geometry, and tilt angle on friction stir welding of pure titanium. J Mater Eng Perform 19:955–962. https://doi.org/10.1007/s11665-009-9582-8

    Article  CAS  Google Scholar 

  30. Mehta KP, Badheka VJ (2016) Effects of tilt angle on the properties of dissimilar friction stir welding copper to aluminum. Mater Manuf Process 31:255–263. https://doi.org/10.1080/10426914.2014.994754

    Article  CAS  Google Scholar 

Download references

Acknowledgements

The research leading to these results received funding from National Natural Science Foundation of China (Grant No. 51974100), the Taishan Scholars Foundation of Shandong Province (No. tsqn201812128).

Author information

Author notes

  1. Zulai Huang and Shulei Sun are contributed equally to this work.

Authors and Affiliations

  1. Shandong Provincial Key Laboratory of Special Welding Technology, Harbin Institute of Technology (Weihai), Weihai, People’s Republic of China

    Zulai Huang, Shulei Sun, Jianhua Wang, Li Zhou & Ning Guo

  2. State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin, People’s Republic of China

    Shulei Sun, Li Zhou & Ning Guo

  3. School of Materials Science and Engineering, Changchun University of Technology, Chang Chun, People’s Republic of China

    Jianhua Wang

  4. AVIC Manufacturing Technology Institute, Beijing, People’s Republic of China

    Qiang Meng, Jihong Dong & Huaxia Zhao

Authors
  1. Zulai Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shulei Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jianhua Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Li Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Ning Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Qiang Meng
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Jihong Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Huaxia Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors contributed to the study. Material preparation, data collection, and analysis were performed by Jianhua Wang, Shulei Sun and Li Zhou. The first draft of the manuscript was written by Zulai Huang and all authors commented on previous versions. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Li Zhou.

Ethics declarations

We certify that we have participated sufficiently in the work to take public responsibility for the appropriateness of the experimental design and method, and the collection, analysis, and interpretation of the data. We have reviewed the final version of the manuscript and approve it for publication. To the best of our knowledge and belief, this manuscript has not been published in whole or in part nor is it being considered for publication elsewhere.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Huang, Z., Sun, S., Wang, J. et al. Formation and fracture characteristics of friction stir lap joint of Alclad 2A12-T42 aluminum alloy at different tilt angles. Weld World 67, 1901–1910 (2023). https://doi.org/10.1007/s40194-023-01546-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40194-023-01546-y

Keywords

Search

Navigation