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Advances in Friction Stir Welding and Processing of Metallic and...
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Advances in Friction Stir Welding and Processing of Metallic and Polymeric Materials

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

Deadline for manuscript submissions: closed (10 September 2023) | Viewed by 2559

Special Issue Editors

Prof. Dr. Mohamed Mohamed Zaky Ahmed

E-Mail Website
Guest Editor
Mechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia
Interests: friction stir welding; friction stir processing; nanocomposites; friction stir additive manufacturing, friction stir deposition; microstructure, and crystallographic texture; physical and mechanical behaviour of metals and alloys
Prof. Dr. Gürel Çam

E-Mail Website
Guest Editor
Mechanical Engineering Department, Faculty of Engineering and Natural Sciences, Iskenderun Technical University, 31200 Iskenderun-Hatay, Turkey
Interests: friction stir welding; friction stir processing; metal additive manufacturing, wire arc additive manufacturing (WAAM); high entropy alloys; light alloys and superalloys; welding metallurgy; mechanical characterization of welded joints
Prof. Dr. Mohamed M. El-Sayed Seleman

E-Mail Website
Guest Editor
Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43512, Egypt
Interests: friction stir welding; friction stir processing; composites, friction stir deposition; powder metallurgy; physical and mechanical behaviour of metals and alloys; wear behavior

Special Issue Information

Dear Colleagues,

Thermomechanical processing (TMP) in the metallurgical industry is generally identified as the deformation of metals at medium to high homologous temperatures where the heat is generated by an external source, such as a furnace. Historically, TMP has been associated with hot rolling or hot forging, where the primary aim was to obtain shape at the lowest possible deformation loads, which occurred at high temperatures. The concept of TMP developed when it was realized that controlled deformation at temperature could significantly control/alter the final microstructure, particularly producing a finer grain size, for improved properties during service. This evolution from a primary production technique to a more integrated processing technique is also being realized with a more modern process, initially developed for solid-state welding, i.e., friction stir welding (FSW). FSW was invented in 1991 at The Welding Institute (TWI) to join, what at the time was known to be, non-weldable aluminum alloys, such as the 2XXX and 7XXX series. Since then, FSW has rapidly progressed into a viable joining technology for a variety of metals and alloys and is in operation from microelectronics to the space shuttle. This complex thermomechanical process has also been adapted for microstructural modification in monolithic sections and has been termed friction stir processing (FSP) and it has been shown to have much potential for gaining enhanced mechanical properties. FSW and FSP, however, still are developing both in terms of process development and an understanding of the underlying mechanisms of microstructure formation. This Special Issue aims to address the up-to-date developments in FSW and FSP at the research and application levels in both metallic and polymeric materials.

Prof. Dr. Mohamed Mohamed Zaky Ahmed
Prof. Dr. Gürel Çam
Prof. Dr. Mohamed M. El-Sayed Seleman
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

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
  • friction stir deposition
  • solid state additive manufacturing
  • metallic materials
  • polymeric materials
  • electron backscattering diffraction
  • mechanical properties
  • microstructure
  • crystallographic texture
  • nanocomposite

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Published Papers (2 papers)

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Research

19 pages, 7437 KiB  
Article
Friction Stir-Spot Welding of AA5052-H32 Alloy Sheets: Effects of Dwell Time on Mechanical Properties and Microstructural Evolution
by Mohamed M. Z. Ahmed, Mohamed M. El-Sayed Seleman, Asmaa M. El-Sayed Sobih, Ashraf Bakkar, Ibrahim Albaijan, Kamel Touileb and Ali Abd El-Aty
Materials 2023, 16(7), 2818; https://doi.org/10.3390/ma16072818 - 1 Apr 2023
Cited by 5 | Viewed by 1738
Abstract
Friction stir-spot welding (FSSW) as a solid-state joining process for local welding offers a number of benefits for applications in the automotive, aerospace, and marine industries. In these industries, and from an economic point of view, producing spot welds at a low rotating [...] Read more.
Friction stir-spot welding (FSSW) as a solid-state joining process for local welding offers a number of benefits for applications in the automotive, aerospace, and marine industries. In these industries, and from an economic point of view, producing spot welds at a low rotating speed and in a short time is critical for saving energy and enhancing productivity. This investigation helped fill a knowledge gap in the literature about FSSW of 4 mm similar lap joints of AA5052-H32 sheet materials, in which welding takes place over a short time period with a slow tool rotation speed. Consequently, the purpose of this work was to investigate the feasibility of FSSW 2 mm thick AA5052-H32 aluminum alloy sheets to produce 4 mm thick similar spot lap joints at various low dwell times of 1, 2, and 3 s and a constant relatively low tool rotation speed of 500 rpm. The introduced heat input for the friction stir-spot welded (FSSWed) lap joints was calculated based on the applied processing parameters. Joint appearance, cross-section macrostructures, and microstructure features of all the spot welds were evaluated. The mechanical properties (hardness contour maps and maximum tensile shear loads) were also examined. The results show that joining 2 mm sheet thickness AA5052-H32 at a low heat input in defect-free similar lap joints could be successfully achieved. The stir zone (SZ) region became wider as the dwell time increased from 1 to 3 s. The hardness value of the SZ was higher than that attained by the AA5052-H32 base material (BM) for all applied dwell times. Especially at 2 s, the hardness of the SZ was approximately 48% higher than that of the BM. This increase in hardness may be attributed to the high grain refinement of the new dynamically recrystallized grain (4 µm) in the SZ compared to the cold-rolled BM grain size (40 µm). Among the tried FSSW process variables, the dwell time of 2 s at a rotation rate of 500 rpm also produced the maximum tensile shear load of 4330 N. Finally, the locations and features of the fracture surfaces of the FSSWed joints were examined using a scanning electron microscope (SEM) and the obtained results were discussed. Full article
(This article belongs to the Special Issue Advances in Friction Stir Welding and Processing of Metallic and Polymeric Materials)
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22 pages, 10324 KiB  
Article
Friction Stir Welding of AA5754-H24: Impact of Tool Pin Eccentricity and Welding Speed on Grain Structure, Crystallographic Texture, and Mechanical Properties
by Mohamed M. Z. Ahmed, Ahmed R. S. Essa, Sabbah Ataya, Mohamed M. El-Sayed Seleman, Ali Abd El-Aty, Bandar Alzahrani, Kamel Touileb, Ashraf Bakkar, Joffin J. Ponnore and Abdelkarim Y. A. Mohamed
Materials 2023, 16(5), 2031; https://doi.org/10.3390/ma16052031 - 1 Mar 2023
Cited by 15 | Viewed by 1817
Abstract
This study investigates the effect of tool pin eccentricity and welding speed on the grain structure, crystallographic texture, and mechanical properties of friction stir welded (FSWed) AA5754-H24. Three tool pin eccentricities of 0, 0.2, and 0.8 mm at different welding speeds ranging from [...] Read more.
This study investigates the effect of tool pin eccentricity and welding speed on the grain structure, crystallographic texture, and mechanical properties of friction stir welded (FSWed) AA5754-H24. Three tool pin eccentricities of 0, 0.2, and 0.8 mm at different welding speeds ranging from 100 mm/min to 500 mm/min and a constant tool rotation rate of 600 rpm were investigated. High-resolution electron backscattering diffraction (EBSD) data were acquired from each weld’s center of the nugget zone (NG) and processed to analyze the grain structure and texture. In terms of mechanical properties, both hardness and tensile properties were investigated. The grain structure in the NG of the joints produced at 100 mm/min, 600 rpm, and different tool pin eccentricities showed significant grain refining due to dynamic recrystallization with average grain sizes of 18, 15, and 18 µm at 0, 0.2, and 0.8 mm pin eccentricities, respectively. Increasing the welding speed from 100 to 500 mm/min further reduced the average grain size of the NG zone to 12.4, 10, and 11 µm at 0, 0.2, and 0.8 mm eccentricity, respectively. The simple shear texture dominates the crystallographic texture with both B¯/B texture component with the C component at their ideal positions after rotating the data to align the shear reference frame with the FSW reference frame in both the PFs and ODF sections. The tensile properties of the welded joints were slightly lower than the base material due to the hardness reduction in the weld zone. However, the ultimate tensile strength and the yield stress for all welded joints increased by increasing the friction stir welding (FSW) speed from 100 to 500 mm/min. Welding using the pin eccentricity of 0.2 mm resulted in the highest tensile strength; at a welding speed of 500 mm/min, it reached 97% of the base material strength. The hardness profile showed the typical W shape with a reduction in the hardness of the weld zone and a slight recovery of the hardness in the NG zone. Full article
(This article belongs to the Special Issue Advances in Friction Stir Welding and Processing of Metallic and Polymeric Materials)
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