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Friction stir welding of dissimilar aluminium alloys

Francis, Michael (2015). Friction stir welding of dissimilar aluminium alloys. Bachelor of Engineering (4th Year Project) Thesis, Charles Darwin University.

Document type: Thesis
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Author Francis, Michael
Title Friction stir welding of dissimilar aluminium alloys
Institution Charles Darwin University
Publication Date 2015
Thesis Type Bachelor of Engineering (4th Year Project)
Supervisor Kannoorpatti, Krishnan
Lugg, Chris
0912 - Materials Engineering
Abstract Friction stir welding (FSW) is a solid state welding process used widely in the manufacturing industry, mainly with soft materials with poor fusion weldability such as aluminium. In this investigation the material behaviour of dissimilar friction stir welded 5XXX and 6XXX series aluminium alloys was examined. Both alloys are used extensively in the transport industry, however exhibit different properties. 5XXX series are non-heat treatable, hard alloys with poor cold working ability. In contrast, 6XXX series are softer, heat treatable alloys with better formability. FSW can be used to take advantage of these differences in mechanical properties to fuse dissimilar metals.

It was found that the overall mixability of the two materials was low, with all of the non-solutionised dissimilar samples failing the bend test. However, with the pre-weld heat treated (solutionised) samples one of the dissimilar welds passed the bend test. This suggests greater mixing between the two materials when the Al-6060 is in the solutionised and softened state. It was also found that the hardness profile of the solutionised samples was more uniform across the weld compared to the non-solutionised; this is due to the complete dissolution of precipitates before welding, meaning overaging in the HAZ does not occur. It was also found the pre-weld heat treated samples show the same grain structure as the non-heat treated, which differs from what has been found with post weld heat treatment.
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Created: Mon, 18 Apr 2016, 09:01:54 CST by Jessie Ng