Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding
Abstract This study focuses into strategizing the usage of self-reacting bobbin tool friction stir welding (SRBT-FSW) to obtain consistent microstructural homogeneity along the thickness of AA6061 aluminium alloy (AA) thick plates during welding. The SRBT-FSW technology, distinguished by its dual-sh...
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| Format: | Article |
| Language: | English |
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Springer
2024-11-01
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| Series: | Discover Materials |
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| Online Access: | https://doi.org/10.1007/s43939-024-00138-x |
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| author | Aishwary Mishra Md Saad Patel Ilyas Hussain Gaurav Chandra Tripathi Atul Kumar Choudary P. Chakravarthy Rahul Jain R. Jose Immanuel |
| author_facet | Aishwary Mishra Md Saad Patel Ilyas Hussain Gaurav Chandra Tripathi Atul Kumar Choudary P. Chakravarthy Rahul Jain R. Jose Immanuel |
| author_sort | Aishwary Mishra |
| collection | DOAJ |
| description | Abstract This study focuses into strategizing the usage of self-reacting bobbin tool friction stir welding (SRBT-FSW) to obtain consistent microstructural homogeneity along the thickness of AA6061 aluminium alloy (AA) thick plates during welding. The SRBT-FSW technology, distinguished by its dual-shoulder design, represents a significant step forward in FSW by eliminating the requirement for a backing anvil and promoting balanced heat distribution. This study seeks to address the issues of maintaining uniform microstructural characteristics throughout the weld zone, which is crucial for the mechanical performance and durability of welded joints in structural applications. The experimental study entails the systematic welding of AA6061 plates of 6 mm thickness using a self-reacting bobbin tool under a fixed processing condition. Electron backscatter diffraction (EBSD) was used to characterize the grain structure and phase distribution over the weld. Mechanical parameters like as tensile strength and hardness were determined to establish correlations between microstructure and mechanical performance. The results demonstrated that SRBT-FSW significantly enhances microstructural homogeneity across the weld zone, leading to improved mechanical properties. In the Bottom Zone (BZ), a refined grain structure with an average grain size (AGS) of 3.53 µm and a random or weak texture was observed, contributing to enhanced hardness and mechanical performance, with an ultimate tensile strength (UTS) of 220 MPa. In contrast, the Top Zone (TZ) exhibited a coarser AGS of 4.33 µm with a pronounced {111} crystallographic texture, resulting in a slightly lower UTS of 205 MPa. The Middle Zone (MZ), influenced by the greater heat input from both the TZ and BZ, showed an intermediate AGS of 3.99 µm, predominantly oriented along the {101} plane, and achieved a UTS of 194 MPa, with a slight reduction in ductility. This study highlights the potential of self-reacting bobbin tool friction stir welding as a reliable method for making high-quality, homogeneous welds in thick aluminium plates and paving way for their wider application in the aerospace, automotive, and shipbuilding industries, where homogeneous microstructural qualities are of significant importance. |
| format | Article |
| id | doaj-art-ca17719d448f4e76b1f3db54502ec9ff |
| institution | OA Journals |
| issn | 2730-7727 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Springer |
| record_format | Article |
| series | Discover Materials |
| spelling | doaj-art-ca17719d448f4e76b1f3db54502ec9ff2025-08-20T02:18:35ZengSpringerDiscover Materials2730-77272024-11-014111110.1007/s43939-024-00138-xAchieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir weldingAishwary Mishra0Md Saad Patel1Ilyas Hussain2Gaurav Chandra Tripathi3Atul Kumar Choudary4P. Chakravarthy5Rahul Jain6R. Jose Immanuel7Advanced Material Development and Characterization Group, Indian Institute of Technology BhilaiAdvanced Material Development and Characterization Group, Indian Institute of Technology BhilaiAdvanced Material Development and Characterization Group, Indian Institute of Technology BhilaiAdvanced Material Development and Characterization Group, Indian Institute of Technology BhilaiDepartment of Mechanical Engineering, Indian Institute of Technology BhilaiIndian Institute of Space Science and TechnologyDepartment of Mechanical Engineering, Indian Institute of Technology BhilaiAdvanced Material Development and Characterization Group, Indian Institute of Technology BhilaiAbstract This study focuses into strategizing the usage of self-reacting bobbin tool friction stir welding (SRBT-FSW) to obtain consistent microstructural homogeneity along the thickness of AA6061 aluminium alloy (AA) thick plates during welding. The SRBT-FSW technology, distinguished by its dual-shoulder design, represents a significant step forward in FSW by eliminating the requirement for a backing anvil and promoting balanced heat distribution. This study seeks to address the issues of maintaining uniform microstructural characteristics throughout the weld zone, which is crucial for the mechanical performance and durability of welded joints in structural applications. The experimental study entails the systematic welding of AA6061 plates of 6 mm thickness using a self-reacting bobbin tool under a fixed processing condition. Electron backscatter diffraction (EBSD) was used to characterize the grain structure and phase distribution over the weld. Mechanical parameters like as tensile strength and hardness were determined to establish correlations between microstructure and mechanical performance. The results demonstrated that SRBT-FSW significantly enhances microstructural homogeneity across the weld zone, leading to improved mechanical properties. In the Bottom Zone (BZ), a refined grain structure with an average grain size (AGS) of 3.53 µm and a random or weak texture was observed, contributing to enhanced hardness and mechanical performance, with an ultimate tensile strength (UTS) of 220 MPa. In contrast, the Top Zone (TZ) exhibited a coarser AGS of 4.33 µm with a pronounced {111} crystallographic texture, resulting in a slightly lower UTS of 205 MPa. The Middle Zone (MZ), influenced by the greater heat input from both the TZ and BZ, showed an intermediate AGS of 3.99 µm, predominantly oriented along the {101} plane, and achieved a UTS of 194 MPa, with a slight reduction in ductility. This study highlights the potential of self-reacting bobbin tool friction stir welding as a reliable method for making high-quality, homogeneous welds in thick aluminium plates and paving way for their wider application in the aerospace, automotive, and shipbuilding industries, where homogeneous microstructural qualities are of significant importance.https://doi.org/10.1007/s43939-024-00138-xFriction stir weldingSelf-reacting bobbin toolMicrostructural evolutionMechanical performanceElectron backscatter diffractionAluminium alloy |
| spellingShingle | Aishwary Mishra Md Saad Patel Ilyas Hussain Gaurav Chandra Tripathi Atul Kumar Choudary P. Chakravarthy Rahul Jain R. Jose Immanuel Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding Discover Materials Friction stir welding Self-reacting bobbin tool Microstructural evolution Mechanical performance Electron backscatter diffraction Aluminium alloy |
| title | Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding |
| title_full | Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding |
| title_fullStr | Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding |
| title_full_unstemmed | Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding |
| title_short | Achieving microstructural homogeneity in the stir zone across thick AA6061 welds using self-reacting bobbin tool friction stir welding |
| title_sort | achieving microstructural homogeneity in the stir zone across thick aa6061 welds using self reacting bobbin tool friction stir welding |
| topic | Friction stir welding Self-reacting bobbin tool Microstructural evolution Mechanical performance Electron backscatter diffraction Aluminium alloy |
| url | https://doi.org/10.1007/s43939-024-00138-x |
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