Investigation of Influence of Friction Stir Welding Parameters on Formability of Aluminum Tailor Welded Blanks

Document Type : Research Article

Author

Abstract

Aluminum tailor welded blanks consist of two or more aluminum sheet which welded together by one of the welding processes. Aluminum TWBs are used in different industries like automotive industry because they have high ratio of strength to weight. There are many different welding methods for aluminum welding, but melting methods cause to form brittle phases and decrease weld strength. Therefore, friction stir welding is a replacement method. Friction stir welding’s parameters have high influence on the weld quality. In the present study, some of the main parameters of friction stir welding are investigated. These parameters are type of welding tool, rotation velocity of welding tool and traveling speed of tool. Whereas tailor welded blanks are used in the out of plane forming processes, Erichsen formability test is used for investigation of weld quality. Therefore, a design of experiment is done using Tauguchi method and some aluminum tailor welded blank samples are welded. Aluminum 6061 and 5182 are base metal of tailor welded blank. Results of study show that type of welding tool has a much influence on the weld quality. Weld quality and formability increase by increasing of tool’s rotational velocity.

Keywords

Main Subjects


[1] Kinsey, B., Song, N., Cao, J., 1999. “Analysis of Clamping Mechanism for Tailor Welded Blank Forming”. Society of Automotive Engineering.
[2] Shi, M.F., Pickett, K.M., Bhatt, K.K., 1993.“Formability issues in the application of tailor welded
blank sheet”. In Proceedings of the Sheet Metal and Stamping Symposium, pp. 27–35.
[3] Shi, M.F., Eisenmenger, M., Bhatt, K.K., 1995.“Influence of laser welding parameters on formability
and robustness of blank manufacturing: an application to a body side frame”. SAE technical paper, Paper No.
950922.
[4] Chien, W.Y., Pan, J., Friedman, P.A., 2003. “Failure Prediction of Aluminum Laser-Welded Blanks”.
International Journal of Damage Mechanic, 12, pp.193–223.
[5] Chien, W.Y., Pan, J., Tang, S.C., 2004. “A Combined Necking and Shear Localization Analysis for
Aluminum Sheets under Biaxial Stretching Condition”.International Journal of Plasticity, 20, pp.1953-1981.
[6] Cheng, C. H., Chan, L. C., Chow, C. L., 2007.“Weldment properties evaluation and formability
study of tailor-welded blanks of different thickness combinations and welding orientations”. J Mater Sci,
42, pp. 5982–5990.
[7] Safdarian Korouyeh, R., Moslemi Naeini, H.,Torkamany, M.J., Liaghat, G., 2013. “Experimental
and theoretical investigation of thickness ratio effect on the formability of tailor welded blank”. Optics &
Laser Technology 51 (0), pp. 24-31.
[8] Safdarian, R., Moslemi Naeini, H., Sabaghzadeh, J.,Torkamany, M. J., 2012. “Effect of Laser Welding
Parameters on Forming Behavior of Tailor Welded Blanks”. Journal of Advanced Materials Research (AMR), 445, pp. 406-411.
[9] Stasikand, M. C., Wagoner, R. H., 2012. “Forming of Tailor-Welded Aluminum Blanks”, General Motors
NAO Manufacturing Center, Warren, Michigan.
[10] Shakeri, H.R., Buste, A., Worswick, M.J., Clarke,J.A., Feng, F., Jain, M., Finn, M., 2002. “Study of
damage initiation and fracture in aluminum tailor welded blanks made via different welding techniques”,
Journal of Light Metals 2: pp. 95–110.
[11] Kumbhar, N. T., Bhanumurthy, K., 2008. “Friction Stir Welding of Al 6061 Alloy”, Asian J. Exp. Sci.,
22(2), pp. 63-74.
[12] Ichinori, S., Yong-Jai, K., Saito, N., 2009. “Dissimilar Friction Stir Welding for Tailor-Welded Blanks
of Aluminum and Magnesium Alloys”, Materials Transactions, 50 (1), pp. 197-203.
[13] Miles, M.P., Melton, D.W., Nelson, T.W., 2005.“Formability of Friction-Stir-Welded Dissimilar-
Aluminum-Alloy Sheets”, METALLURGICAL AND MATERIALS TRANSACTIONS A, V. 36A.
 
[14]هنربخش رئوف، عباس ؛ غریبشاهیان، احسان؛ ” شبیهسازیالمانمحدودجوشکاریاغتشاشیاصطکاکیوتاثیرپارامترهایموثربرآندرآلیاژ 6061 آلومینیم“، مجله مدل سازی در مهندسی، سال یازدهم، شماره 35 ، زمستان 1392 .
[15]قهرمانی مقدم، دانیال؛ فرهنگ دوست، خلیل؛ رستگار، علی ؛ رمضانی مقدم، محمد؛ ” بررسیاثرسرعتابزاربرسختیوتنشپسمانددر
جوشکاریاصطکاکیاغتشاشیآلیاژآلومینیم2024-T351 باروشتجربیوشبیهسازیعددی“، مجله مهندسی مکانیک مدرس، دوره 15 ،
شماره 2، صفحه 61 - 71 ، اردیبهشت 1394 .