Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100
Aluminum's lightweight nature and corrosion resistance make it a preferred material across various industries, including marine, automotive, railway, and aerospace sectors. However, traditional fusion welding of aluminum often leads to significant defects such as porosity and distortion. Fricti...
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| Format: | Article |
| Language: | English |
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KeAi Communications Co., Ltd.
2025-09-01
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| Series: | International Journal of Lightweight Materials and Manufacture |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2588840425000411 |
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| author | Yudha Eko Widyantono Yoshihiko Uematsu Ilhamdi Sulardjaka Jos Istiyanto Muizuddin Azka Nurul Muhayat Triyono |
| author_facet | Yudha Eko Widyantono Yoshihiko Uematsu Ilhamdi Sulardjaka Jos Istiyanto Muizuddin Azka Nurul Muhayat Triyono |
| author_sort | Yudha Eko Widyantono |
| collection | DOAJ |
| description | Aluminum's lightweight nature and corrosion resistance make it a preferred material across various industries, including marine, automotive, railway, and aerospace sectors. However, traditional fusion welding of aluminum often leads to significant defects such as porosity and distortion. Friction Stir Welding (FSW), a solid-state welding technique, addresses many of these challenges but has limitations when welding thick plates, which can be alleviated through the use of a bobbin tool. This study presents a comparative analysis of a novel one-step double-acting tool, which operates dual tools simultaneously on both surfaces of the workpiece, against the bobbin tool. Aluminum AA1100 sheets measuring 200 × 240 mm and 8 mm thick were welded using both methods under standardized parameters: a tool rotation speed of 1500 rpm, a plunge depth of 0.2 mm, a travel speed of 25 mm/min, and a tilt angle of 2°. By varying the offset of the one-step double-acting tool between 0 mm and 2 mm, the impact on bead appearance and mechanical properties was assessed. Results indicated that the bobbin tool produced rougher beads and tear defects due to its design, while the one-step double-acting tool, particularly at a 2 mm offset, yielded cleaner, more uniform welds with fewer defects and enhanced material control. Microstructural analysis showed that the stir zone exhibited uniform grain refinement, and the Heat-Affected Zone (HAZ) benefited from finer grain structures due to improved heat management. Hardness testing revealed a characteristic W-shaped distribution, and tensile strength evaluations demonstrated the superior joint quality of the 2 mm offset, outperforming the bobbin tool in tensile strength and defect reduction. Although the bobbin tool showed slightly higher average strength in bending tests, the one-step double-acting tool proved to be more consistent and reliable. |
| format | Article |
| id | doaj-art-a623ab6591e34e799a07b122f0211b9d |
| institution | Kabale University |
| issn | 2588-8404 |
| language | English |
| publishDate | 2025-09-01 |
| publisher | KeAi Communications Co., Ltd. |
| record_format | Article |
| series | International Journal of Lightweight Materials and Manufacture |
| spelling | doaj-art-a623ab6591e34e799a07b122f0211b9d2025-08-23T04:48:52ZengKeAi Communications Co., Ltd.International Journal of Lightweight Materials and Manufacture2588-84042025-09-018557759410.1016/j.ijlmm.2025.05.002Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100Yudha Eko Widyantono0Yoshihiko Uematsu1 Ilhamdi2 Sulardjaka3Jos Istiyanto4Muizuddin Azka5Nurul Muhayat6 Triyono7Department of Mechanical Engineering, Institut Teknologi Nasional Yogyakarta, IndonesiaDepartment of Mechanical Engineering, Gifu University, 1-1 Yanagido, Gifu 501-1193, JapanDepartment of Mechanical Engineering, Universitas Andalas, Padang, IndonesiaDepartment of Mechanical Engineering, Universitas Diponegoro, Semarang, IndonesiaDepartment of Mechanical Engineering, Universitas Indonesia, Jakarta, IndonesiaNational Research and Innovation Agency Republic of Indonesia, (BRIN), IndonesiaDepartment of Mechanical Engineering, Universitas Sebelas Maret, Surakarta, IndonesiaDepartment of Mechanical Engineering, Universitas Sebelas Maret, Surakarta, Indonesia; Corresponding author.Aluminum's lightweight nature and corrosion resistance make it a preferred material across various industries, including marine, automotive, railway, and aerospace sectors. However, traditional fusion welding of aluminum often leads to significant defects such as porosity and distortion. Friction Stir Welding (FSW), a solid-state welding technique, addresses many of these challenges but has limitations when welding thick plates, which can be alleviated through the use of a bobbin tool. This study presents a comparative analysis of a novel one-step double-acting tool, which operates dual tools simultaneously on both surfaces of the workpiece, against the bobbin tool. Aluminum AA1100 sheets measuring 200 × 240 mm and 8 mm thick were welded using both methods under standardized parameters: a tool rotation speed of 1500 rpm, a plunge depth of 0.2 mm, a travel speed of 25 mm/min, and a tilt angle of 2°. By varying the offset of the one-step double-acting tool between 0 mm and 2 mm, the impact on bead appearance and mechanical properties was assessed. Results indicated that the bobbin tool produced rougher beads and tear defects due to its design, while the one-step double-acting tool, particularly at a 2 mm offset, yielded cleaner, more uniform welds with fewer defects and enhanced material control. Microstructural analysis showed that the stir zone exhibited uniform grain refinement, and the Heat-Affected Zone (HAZ) benefited from finer grain structures due to improved heat management. Hardness testing revealed a characteristic W-shaped distribution, and tensile strength evaluations demonstrated the superior joint quality of the 2 mm offset, outperforming the bobbin tool in tensile strength and defect reduction. Although the bobbin tool showed slightly higher average strength in bending tests, the one-step double-acting tool proved to be more consistent and reliable.http://www.sciencedirect.com/science/article/pii/S2588840425000411Friction stir weldingBobbin toolOne-step double-acting toolTool offsetAluminum |
| spellingShingle | Yudha Eko Widyantono Yoshihiko Uematsu Ilhamdi Sulardjaka Jos Istiyanto Muizuddin Azka Nurul Muhayat Triyono Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100 International Journal of Lightweight Materials and Manufacture Friction stir welding Bobbin tool One-step double-acting tool Tool offset Aluminum |
| title | Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100 |
| title_full | Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100 |
| title_fullStr | Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100 |
| title_full_unstemmed | Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100 |
| title_short | Comparative analysis of bobbin tool and one-step double-acting tool in friction stir welding of aluminum AA1100 |
| title_sort | comparative analysis of bobbin tool and one step double acting tool in friction stir welding of aluminum aa1100 |
| topic | Friction stir welding Bobbin tool One-step double-acting tool Tool offset Aluminum |
| url | http://www.sciencedirect.com/science/article/pii/S2588840425000411 |
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