Effect of tool wear on microstructure, mechanical properties and acoustic emission of friction stir welding 6061 Al alloy

Abstract

Abstract: Tool condition is one of the main concerns in friction stir welding (FSW), because the geometrical condition of the tool pin including size and shape is strongly connected to the microstructure and mechanical performance of the weld. Tool wear occurs during FSW, especially for welding metal matrix composites with large amounts of abrasive particles, and high melting point materials, which significantly expedite tool wear and deteriorate the mechanical performance of welds.In this study, tools with different pin-wear levels are used to weld 6061 aluminum alloy, while acoustic emission (AE) sensing, metallographic sectioning, and tensile testing are employed to evaluate the weld quality in various tool wear conditions. Structural characterization shows that the tool wear interferes with the weld quality and accounts for the formation of voids in the nugget zone. Tensile test analysis of samples verifies that both the ultimate tensile strength and the yield strength are adversely affected by the formation of voids in the nugget due to the tool wear. The failure location during tensile test clearly depends on the state of the tool wear, which led to the analysis of the relationships between the structure of the nugget and tool wear. AE signatures recorded during welding reveal that the AE hits concentrate on the higher amplitudes with increasing tool wear. Our results show that the AE sensing provides a potentially effective tool for the on-line monitoring of tool wear

Key words:

W.M. Zeng. Effect of tool wear on microstructure, mechanical properties and acoustic emission of friction stir welding 6061 Al alloy[J]. Acta Metallurgica Sinica (English Letters), 2006, 19(1): 9-19 .

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