Influence of external weld flash on the in-plane plane-strain formability of friction stir welded sheets

Mukesh Kumar, Satish V. Kailas, R. Ganesh Narayanan

Research output: Contribution to journalArticlepeer-review

9 Scopus citations

Abstract

The main aim of the present work is to analyze the influence of external weld flash on the formability of friction stir welding sheets through in-plane plane-strain formability tests. The load-extension behavior and forming limit strains are measured to quantify the formability. The influence of friction stir welding parameters on the height of weld flash was also studied. The base materials used for welding trials are AA6061T6 and AA5052H32 alloy sheets of 2.1-mm thickness. It is observed that the influence of external weld flash on the maximum load and total extension for all the friction stir welding conditions is negligible. The effect of weld flash on the limiting major strain is also insignificant. But the presence of weld flash has changed the limiting minor strain, more toward plane-strain condition, indicating the change in strainpath toward plane-strain. This is due to the strain taken by weld flash, along with the major strain, minor strain, and thickness strain in the friction stir welding sheet plane because of constancy of volume. The formation of weld flash and its height are affected synergistically by the axial force and temperature development during friction stir welding. The higher the axial force and temperature, the higher the flash height.

Original languageEnglish
Pages (from-to)376-385
Number of pages10
JournalJournal of Strain Analysis for Engineering Design
Volume48
Issue number6
DOIs
StatePublished - 1 Aug 2013
Externally publishedYes

Keywords

  • Formability
  • Forming limit strain
  • Friction stir welding
  • Weld flash

ASJC Scopus subject areas

  • Modeling and Simulation
  • Mechanics of Materials
  • Mechanical Engineering
  • Applied Mathematics

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