The microstructure and residual stresses of an AA6040 Al to AZ31B Mg friction stir weld are studied using scanning electron microscopy and X-ray diffraction. The complex material flow promoted by the friction stir welding process results in a fine grained structure in the stir zone of both materials due to dynamic/recovery recrystallization. The interface between the materials is characterized ...

Over the last decade attempts have been made to fabricate aluminum matrix composites (AMCs) reinforced with several ceramic particles. Aluminum reinforced with ZrB2 particles is one such AMC. The successful application of new kind of AMCs lies in the development of secondary processes such as machining and joining. Friction stir welding (FSW) is a relatively new solid state welding which overco...

The general principles behind the global mechanical tensioning technique for controlling weld residual stresses are examined using a finite lement model to follow their evolution throughout the welding process. While we focus specifically on friction stir welding, the tool is represented imply as a heat source. As a result, the findings have relevance to a wide range of welding processes. For a...

Three-dimensional nonlinear thermal and thermo-mechanical numerical simulations are conducted for the friction stir welding (FSW) of 304L stainless steel. The finite element analysis code—WELDSIM, developed by the authors specifically for welding simulation, was used. Two welding cases with tool rotational speeds of 300 and 500 rpm are analyzed. The objective is to study the variation of transi...

Recognition of the friction stir welding process is growing in the aeronautical and aero-space industries. To make the process more available to the structural fabrication industry (buildings and bridges), being able to model the process to determine the highest speed of advance possible that will not cause unwanted welding defects is desirable. A numerical solution to the transient two-dimensi...

The welding of materials by applying Friction Stir Welding technique is a new solid-state joining technique. The main advantage of this method compared to the traditional joining process is that it minimizes problem-related to metal resolidification as the method incorporates no melting phase. In this experimental work, the effect of friction stir welding (FSW) technique on the microstructu...