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Friction Stir Welding and Processing: Materials, Processes and Applications

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 April 2022) | Viewed by 2352

Special Issue Editor

Material Science and Technology Division, Oak Ridge National Laboratory, 1 Bethel Valley Road, Oak Ridge, TN 37831-6096, USA
Interests: welding and processing; additive manufacturing; mechanical properties; microstructure; residual stress

Special Issue Information

Dear Colleagues,

Friction stir welding and processing (FSW&P) are solid-phase joining/processing technologies. FSW is arguably the most important welding innovation in the last few decades, and produces joints through local thermal-mechanical processes followed by material recrystallization. Based on the same physical and metallurgical principles, FSP was derived from FSW and can be classified as many technologies, such as friction stir surface treatment, friction stir cladding, friction stir extrusion, friction synthesis, and friction stir additive manufacturing. Because of the solid-phase metallurgical process and material recrystallization, welded/processed materials after FSW&P generally possess equiaxed fine-grain microstructures and excellent mechanical properties. Moreover, FSW can effectively join some materials which were traditionally categorized as having poor weldability by fusion welding. Since the invention of FSW&P in the 1990s, FSW&P have been widely studied with different materials, both conventional and new FSW&P processes have been developed, and FSW&P techniques have been increasingly applied in various industrial sectors, including ship building and offshore structures, airplanes and aerospace, automotive, railway rolling stock, computers and electronics, and fabrication.

This Special Issue intends to collect the newest developments in friction stir welding and processing. Topics addressed in this Special Issue may include, but are not limited to:

  • FSW&P technological innovation.
  • FSW&P fundamentals.
  • FSW&P of similar and dissimilar materials.
  • FSW&P development of special materials.
  • FSW&P process development.
    • FSW development, including but not limited to linear FSW, friction stir spot welding, self-reacting FSW, high-speed FSW, etc.
    • FSP development, including friction stir surface treatment, friction stir cladding, friction stir extrusion, friction stir additive manufacturing, friction stir synthesis, and any other innovative metallurgical process utilizing the same thermal-mechanical principles as FSW.
  • FSW&P residual stresses and distortion control.
  • FSW&P materials microstructure characterization.
  • FSW&P materials properties evaluation, which include but are not limited to mechanical properties, fracture toughness, fatigue, and corrosion resistance.
  • FSW&P industrial applications.

Dr. Wei Tang
Guest Editor

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • friction stir welding
  • friction stir processing
  • fundamental
  • materials
  • process development
  • microstructure
  • properties
  • industrial applications

Published Papers (1 paper)

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Research

18 pages, 5372 KiB  
Article
Bobbin Tool Friction Stir Welding of Aluminum: Parameters Optimization Using Taguchi Experimental Design
by Mohamed M. Z. Ahmed, Kamel Touileb, Mohamed M. El-Sayed Seleman, Ibrahim Albaijan and Mohamed I. A. Habba
Materials 2022, 15(8), 2771; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15082771 - 09 Apr 2022
Cited by 12 | Viewed by 1884
Abstract
This work aims to optimize the performance evaluation characteristics such as the temperature at the weld center of the lap joint (Tw), the tensile shear load (TSL), and the hardness using an experimental design experiment for bobbin tool friction stir welding (BT-FSW) of [...] Read more.
This work aims to optimize the performance evaluation characteristics such as the temperature at the weld center of the lap joint (Tw), the tensile shear load (TSL), and the hardness using an experimental design experiment for bobbin tool friction stir welding (BT-FSW) of AA1050 lap joints. BT-FSW is characterized by a fully penetrated pin and double-sided shoulder that promote symmetrical solid-state welds. This study contributes to improving the quality of 10 mm thick lap joints and addressing challenges to obtaining a sound weld deprived of any defects. Taguchi L9 orthogonal array (OA) experimental design was performed. Three different pin shapes (cylindrical, triangular, and square) and three levels of welding travel speeds of 200, 400, and 600 mm/min were selected as input controllable process parameters at a constant tool rotation speed of 600 rpm. A travel speed of 200 mm/min with square pin geometry significantly improves the TSL of the joint up to 6491 N. However, the hardness characteristic is optimized by using 600 mm/min travel speed and a cylindrical tool pin. The minimum temperature in the weld joint can be obtained using 600 mm/min or more with triangular pin geometry. From ANOVA results, it was seen that the BT-FSW of AA 1050 thick lap joints performance in terms of TLS and Tw were greatly influenced by travel speed; however, the tool shape influences the hardness more. For the validation of the models, BT-FSW experiments have been carried out for AA1050 using the applied processing parameters. Furthermore, regression models were developed to predict the Tw, TSL, and hardness. The calculated performance properties from the mathematical models were in an acceptable range compared to the measured experimental values. Full article
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