Joining and Analysis of

AA7075-T651 using
Friction Stir Welding Process

Guide : Dr H. S. Patil Presented by: Neelsai R. Sharma

Kairav J. Patel
Abhishek V. Patel
Viral N. Patel
 Contents

• Abstract
• Introduction to Welding
• Friction Stir Welding
- Introduction
- Working of FSW
• Aluminium alloy (AA7075 T-651)
• Literature Review
• Experimental Procedure
• Various tests performed
- Radiography Analysis
-Microstructure Analysis
- Hardness Test
- Tensile Test
- Bending Test
• TIG Welding
• References
 Abstract

In today’s modern world there are many different welding techniques to join
metals. They range from the conventional oxy-acetylene torch welding to laser
welding. The two general categories in which all the types of welding can be
divided is fusion welding and solid state welding. Friction stir welding is also
a solid state welding process; this remarkable up gradation of friction welding
was invented in 1991 in The Welding Institute (TWI).Friction stir welding was
performed for three different tool rotation speeds namely 800, 900 and 1000
rpm. Defects were analyzed using radiography. The scope of the present
project work was to evaluate the effects of friction stir welding parameters like
Tool Rotation Speed, Feed rate, Tool, Tip Plunge Depth, Tool Tilt on
mechanical properties of aluminium alloy 7075-T651 weld joints and the
effect of the same were analysed using Mechanical and Microstructural
analysis.
 Friction Stir Welding

• Friction Stir Welding (FSW) was invented by Wayne Thomas at TWI Ltd. in
1991 and overcomes many of the problems associated with traditional joining
techniques.
• FSW is a solid state process which produces welds of high quality in difficult to
weld materials such as aluminium and is fast becoming the process of choice for
manufacturing light weight transport structures such as boats, trains and
aeroplanes.
• In the process a rotating non consumable FSW tool is plunged between two
clamped plates, the frictional heat causes a plasticized zone to form around the
tool. The rotating tool moves along the joint line so by this a consolidated solid-
phase joint is formed.
• In this context, friction stir welding (FSW) appeared as an easy, ecologic and
promisingly productive weld method that enables to diminish material waste
and to avoid radiation and harmful gas emissions, usually associated with the
fusion welding processes.
Working of FSW
Actual FSW performed
 7075 Aluminium Alloy
• Aluminium alloy 7075 is an aluminium alloy, with zinc as the primary alloying
element. It is strong, with a strength comparable to many steels, and has good fatigue
strength and average machinability, but has less resistance to corrosion than many other
Al alloys. Its relatively high cost limits its use to applications where cheaper alloys are
not suitable.
• 7075 aluminium alloy's composition roughly includes
- 5.6–6.1% Zinc
- 2.1–2.5% Magnesium
- 1.2–1.6% Copper
- And less than half a percent of Si, Fe, Mn, Ti, Cr, and other metals.

AA7075 - T651
• T651 temper 7075 has an ultimate tensile strength of at least 67,000–78,000 psi (462–
538 MPa) and yield strength of 54,000–67,000 psi (372–462 MPa). It has a failure
elongation of 3–9%.
• The 51 suffix has no bearing on the heat treatment but denotes that the material is stress
relieved by controlled stretching.
 Literature Review
Sr. Author Title Journal / Points Covered Conclusion
No. Publisher

1. W. Thomas, Friction stir International Development of process The no. of light

E. Nicholas, Butt Welding patent Find difficulty of the process weight material for
J. Needham application automotive, rail,
et al. no. marine, aerospace
PCT/GB92/0 industries can be
2203 & GB fabricated by FSW.
patent No.
9125978.8
(1991)

2 FU-Zhi- Friction Stir Journal of Developed beyond laboratory, Factors affecting on

Hong, HE- Welding of Wuhan and give practical welding welding process is
Di-qui, Aluminium University of technique offers low distortion, tool’s material,
Wang Alloys technology- high quality, low cost field from rotational speed,
Hong, Master Sci. simple concept machine tool welding speed, press
Ed. (Nov welding equipment. force of tool.
2003)
Sr. Author Title Journal / Points Covered Conclusion
No. Publisher

3 J. Friction Stir Journal of Properties & Microstructural Mechanical resistance

Adamowsk Welding of Achievements changes in 6082-T6 of test welds increased
, M. AA 6082-T6 in Material & Used laminated plate. with increases of
Szkodo Manufacturing Microstructural zone is welding speed with
Engineering. observed by optimal constant rotational
Vol. 20 issue 1- microscope. speed.
2 Tensile strength is
(Jan 2007) directly proportional to
welding speed.

4 H.S. Patil, Influence of Elixir Mech. Produce different weld Yield strength &
P. D. Ahir, Process Engg. 30, PP specimen by varying Ductility play major
S. N. Parameter on 1823-1825, rotational & welding speed role in deciding weld
Soman Tensile (January-2011) (900, 1200 rpm, 50,63 quality and formation of
Properties of mm/min). FSP region.
Friction Stir Evaluate the yield strength,
Welded Butt tensile strength & % of
Joints In 6082 elongation by means of tensile
Aluminium test.
Alloy
Sr. Author Title Journal / Points Covered Conclusion
No. Publisher

5 K. Microstructur International Analyse the structure and Good quality weld

Mroczka, e and Scientific mechanical properties of FSW achieved.
J. properties of Journal – joints. The decrease of
Dutkiewic FSW joints of Archives of Welding carried out at room temperature prior to
z, L. 2017A /6013 Materials temperature. welding and the
Lityñska- aluminium Science & Rotational speed 450rpm, intensive cooling during
Dobrzyñsk alloys sheets Engg. (Vol-33, linear velocity 280 mm/min. the process causes
a, A. Issue-2) (Oct, reduction of the size of
Pietras 2008) (Pg-93- nugget.
96)

6 H. S. Patil, Experimental International Effect of different welding Pin profile has a

& S. N. study on the Journal of speeds and tool pin profile on significant effect on the
Soman effect of Engineering, AA6082-O. joint structure &
welding Science & Used tri-flutes & Taper mechanical properties.
speed and Technology. Screw Thread Pin. Ultimate tensile
tool pin (Vol. 2 No. 5) Taken rotational speed strength of the taper
profiles on (pp 268-275) constant (1200 rpm). screw thread reaches
AA6082-O (2010) upto 92.30% of the base
al. FSW butt metal strength.
joints
Sr. Author Title Journal / Points Covered Conclusion
No. Publisher

7 V. Relationship Materials Used five different grades of The yield strength,

Balasub- between base Science & al. alloys (AA1050,AA6061, ductility and hardness
ramanian metal Engineering A AA2024, AA7039 and of the aluminium alloys
properties and 480 (pp 397- AA7075) using different play a major role in
friction stir 403), (2008) combinations of process deciding weld quality .
welding parameters . Relationships
process Macrostructural analysis established in this
parameters done to check the weld quality investigation can be
. effectively used to
established Empirical predict the FSW process
relationships between base parameters to fabricate
metal properties and tool defect free joints from
rotational speed and welding the known base metal
speed, respectively properties of aluminium
alloys.
8 Kudzanay Friction Stir International Analysed several tool Tool material selected
iChiteka Welding/Proce Journal of materials and the material should not be a source
ssing Tool Engineering which they could be used to of contamination to the
Materials and Research & join have also outlined. final joint.
Selection Technology,
ISSN: 2278-
0181, Vol: 2,
Issue 11, PP 8-
Sr. Author Title Journal / Points Covered Conclusion
No. Publisher

9 Dr.A.K. Influence of IRACST- Proposed three tool pin The tensile strength of
Shaik Tool Design on Engineering profile (Square, Circle, FS weld is affected by
Dawood the Mechanical Science & Threaded) tool pin profile.
and M. Properties and Technology: Rotational speed 900 & Among the three tool
Karthikey Microstructure An 1350 rpm and weld speed 75 straight square tool at
-an in Friction Stir International mm/min. 900 rpm give more
Welding of Journal Weld structure evaluated by strength ad hardness by
AA6351 (ESTIJ), tensile & Vickers micro others.
Aluminium ISSN: 2250- hardness.
Alloy 3498, Vol: 2,
No:2 , (April.
2012)
10 K. Influences of Science Direct Use five different tool pin Square pin profiled
Elangova tool pin profile , Materials & profiles ( cylindrical, taper tool produced defect
n & V. and tool Design 29 cylindrical, threaded free FSP region
Balasubra shoulder (2007) (pp cylindrical, triangular &
-manian diameter on the 362-373) square) with different shoulder Square pin profiled
formation of diameter & rotational speeds. tool produced defect
friction stir The formation of FSP zone free FSP region
processing zone has been analyzed and tensile
in AA6061 properties of the joints have
aluminium been evaluated and correlated
alloy”. with the FSP zone formation.
 Experimental Procedure

• Following figures shows the step by step experimental procedure which was carried out
during this project work,

1 2
3 4 5

6 7 8
9 10

11 12 13
14 15 16

17 18 19
20 21

22 23 24
 Radiography Analysis

• Radiographic Testing (RT), or industrial radiography, is a non destructive

testing (NDT) method of inspecting materials for hidden flaws by using the
ability of short wavelength electromagnetic radiation (high energy photons)
to penetrate various materials.
 Microstructure Analysis

The solid-state nature of the FSW process, combined with its unusual tool and
asymmetric nature, results in a highly characteristic microstructure.
The microstructure can be broken up into the following zones:
a) Stir Zone
b) Thermo-mechanically affected zone (TMAZ)
c) Heat affected zone (HAZ)
d) Base metal
 144-YG/2016 (S1000, FR35)

• Detailed viewing of samples is done with a metallurgical microscope having

magnification capacity of 100x. Scanning Electron Microscopes (SEMs) are
capable of much higher magnifications and are utilized for highly detailed
microstructural study.
 Hardness test

• The FSW & TIG specimen was mounted on to the machine and the machine was
loaded with load of 250kgf for time of 20 seconds and then removed using 10 mm
indenter.
BHN values for FSW and TIG welding

Rotation Speed Transverse Speed Impression (d)

Sample BHN
(RPM) (mm)

FSW 900 30 mm/min 1.62 121

TIG - 15 mm/sec 2.50 50.1

 Tensile Test

• Tensile tests was performed to determine the tensile properties of the weld
material such as tensile strength and percentage of elongation.
• The tensile specimen was prepared as per the ASTM E8M-09 guidelines
(ASTM E8 M-09, 2009).
 Bending Test

• Bend tests was performed on face side of the weld.

• Face bend test is used as an important tool to understand about the
ductility and toughness of friction stir welds.

• The specimens were cut as per the ASTM B 557 size on the 6.35 mm
thick plate. Mandrel base has radius of 4-times of thickness of plate
and 180 degrees of bend angle.
 TIG Welding

• TIG welding was carried out on AA7075-T651 and AA6061 in order to

check which process (FSW or TIG) provides an efficient weld.
• Constant voltage supply and current of 80V & 230A respectively were kept
while performing TIG welding.
 Results & Discussions
1. Macrostructure Analysis

Spindle speed Feed Rate Tool tip plunge feed Tool tilt angle
(RPM) (mm/min) (mm/min) (in degrees)

800, 900, 1000 30, 35, 40 10 0

Observations:

• The material did not flash out during welding.

• The temperature of sample was within plastic deformation range.
• There was no vibration on VMC machine during welding process.
• Material did not stick on back plate.
• The clamping force and back plate pressure were effective, result
in good forging force.
• Thermal expansion of tool was minor.
• The material flow was good resulting in good surface finish.
• A perfect and an ideal FSW weld was obtained if we see it with
our naked eyes.
Report of FSW Report of TIG Welding
 References
• W M Thomas, E. Nicholas, J. Needham et al. Friction Stir Butt Welding.
International patent application, No. PCT/GB92/02203 and GB patent
application, No. 9125978.8, (1991).
• FU Zhi-hong, HE Di-qiu, WANG Hong. “Friction Stir Welding of Aluminum
Alloys”, Journal of Wuhan University of Technology- Mater. Sci. Ed., Volume 19,
No.1, (March-2004).
• J. Adamowski and M. Szkodo, “Friction Stir Welds (FSW) of aluminium alloy
AW6082-T6”, Journal of Achievements in Materials and Manufacturing
Engineering, Volume-20, Issues-1-2, PP 403-406, (January-February 2007).
• H. S. Patil, P. D. Ahir and S. N. Soman, “Influence of Process Parameter on
Tensile Properties of Friction Stir Welded Butt Joints in 6082 Aluminium Alloy”,
Elixir Mech. Engg. 30, PP 1823-1825, (January-2011).
• Kudzanayi Chiteka, “Friction Stir Welding/Processing Tool Materials and
Selection”, International Journal of Engineering Research & Technology, ISSN:
2278-0181, Vol 2, Issue 11, PP 8-11, (November-2013).
• Dr.A.K.Shaik Dawood, M.Karthikeyan, “Influence of Tool Design on the
Mechanical Properties and Microstructure in Friction Stir Welding of AA6351
Aluminium Alloy”, IRACST- Engineering Science and Technology: An
International Journal (ESTIJ), ISSN: 2250-3498, Vol. 2, No. 2, PP 233-237,
(April 2012).
Contd…
• K. Elangovan, V. Balasubramanian, “Influences of Tool Pin Profile and Tool
Shoulder Diameter On The Formation Of Friction Stir Processing Zone In
AA6061 Aluminium Alloy”, Materials & Design, published by ELSEVIER,
available online at Science Direct, 29 , PP 362-373, (2008),.
• K. Colligan, “Material Flow Behavior during Friction Stir Welding of Aluminum”
supplement to the welding journal, sponsored by the American Welding Society
(AWS) and the Welding Research Council (WRC), (July 1999).
• K. Kumar, Satish V. Kailas, “The Role of Friction Stir Welding Tool on Material
Flow and Weld Formation”, Materials Science and Engineering A, published by
ELSEVIER, 485, PP 367-374, (2008).
• R.S. Mishra, Z.Y. Ma, “Friction Stir Welding and Processing”, Materials Science
and Engineering R, published by ELSEVIER, available on Science Direct, 50, PP
1-78, (2005).
• H. S. Patil & S. N. Soman, “Experimental Study on The Effect of Welding Speed
and Tool Pin Profiles on Aluminium Friction Stir Welded Butt Joints”,
International Journal of AA6082-O Engineering, Science and Technology,
published by Multicraft, Volume- 2, No. 5, PP. 268-275, (2010).
• V. Balasubramanian, “Relationship between Base Metal Properties and Friction
Stir Welding Process Parameters”, Materials Science and Engineering A,
published by ELSEVIER, 480, PP 397–403, (2008).
• www.en.wikipedia.org/wiki/Friction_stir_welding