Lightweight aluminum joint design: Enhancement of mechanical properties through novel inter-layer and powder additives in friction stir welding

Q1 Engineering
Equbal Ahmed , Muhammed Muaz , Sajjad Arif , Ravi Kant , Syed Mohd Hamza , Md Kashif Alim , Musab Ahmad Khan , Jaber Abu Qudeiri , Sanan H. Khan
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引用次数: 0

Abstract

Friction Stir Welding (FSW) is a solid-state joining technique that has garnered significant attention for its ability to weld aluminum alloys while mitigating common issues such as porosity and thermal defects inherent in fusion welding. This study systematically evaluates the impact of inter-layers and powder additives on the mechanical properties of aluminum FSW joints. Magnesium (Mg) ribbons and Lead–Tin (Sn–Pb) alloy ribbons were employed as inter-layers, while Boron Carbide (B4C), Titanium Dioxide (TiO2), and Manganese (Mn) served as reinforcement powders. Quantitative analysis demonstrated that the combination of Manganese (Mn) powder and Sn–Pb alloy inter-layer achieved a remarkable 28 % improvement in hardness, a 35 % reduction in wear rate, and a 42 % increase in shear strength. Additionally, Mn powder alone yielded the highest shear strength, while Sn–Pb inter-layer with Mn powder provided maximum hardness and wear resistance. Mg ribbon combined with Mn powder produced the lowest surface roughness. These enhancements were corroborated by mechanical testing and morphological characterization, including scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and microstructural mapping. The findings highlight the effectiveness of tailored inter-layer and powder combinations in enhancing weld quality, providing insights into the underlying mechanisms responsible for these improvements. This study underscores the industrial relevance of these advancements, offering transformative potential for sectors such as aerospace and automotive manufacturing where superior joint properties are critical.
轻量化铝接头设计:在搅拌摩擦焊接中通过新型夹层和粉末添加剂提高机械性能
搅拌摩擦焊(FSW)是一种固态连接技术,由于其焊接铝合金的能力,同时减轻了熔焊中固有的气孔和热缺陷等常见问题,引起了人们的极大关注。本研究系统地评价了夹层和粉末添加剂对铝合金摩擦焊接头力学性能的影响。镁(Mg)带和铅锡(Sn-Pb)合金带作为中间层,碳化硼(B4C)、二氧化钛(TiO2)和锰(Mn)作为增强粉。定量分析表明,锰(Mn)粉与Sn-Pb合金夹层结合后,合金硬度提高28%,磨损率降低35%,抗剪强度提高42%。其中,单Mn粉具有最高的抗剪强度,Sn-Pb夹层中Mn粉具有最高的硬度和耐磨性。镁带与锰粉结合的表面粗糙度最低。这些增强得到了力学测试和形态学表征的证实,包括扫描电子显微镜(SEM)、能量色散x射线光谱(EDS)和微观结构制图。研究结果强调了定制层间和粉末组合在提高焊接质量方面的有效性,并提供了对这些改进的潜在机制的见解。这项研究强调了这些进步的工业相关性,为航空航天和汽车制造等行业提供了变革潜力,这些行业对卓越的关节性能至关重要。
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来源期刊
International Journal of Lightweight Materials and Manufacture
International Journal of Lightweight Materials and Manufacture Engineering-Industrial and Manufacturing Engineering
CiteScore
9.90
自引率
0.00%
发文量
52
审稿时长
48 days
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