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Mechanical Engineering

Mechanical & Aerospace Engineering Faculty Publications

Friction stir welding

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Numerical Simulation Of The Donor-Assisted Stir Material For Friction Stir Welding Of Aluminum Alloys And Carbon Steel, Joseph Maniscalco, Abdelmageed A. Elmustafa, Srinivasa Bhukya, Zhenhua Wu Jan 2023

Numerical Simulation Of The Donor-Assisted Stir Material For Friction Stir Welding Of Aluminum Alloys And Carbon Steel, Joseph Maniscalco, Abdelmageed A. Elmustafa, Srinivasa Bhukya, Zhenhua Wu

Mechanical & Aerospace Engineering Faculty Publications

In this research effort, we explore the use of a donor material to help heat workpieces without wearing the tool or adding more heat than necessary to the system. The donor material would typically be a small piece (or pieces) of material, presumably of lower strength than the workpiece but with a comparable melting point. The donor, a sandwich material, is positioned between the tool head and the material to be welded, where the tool initially plunges and heats up in the same manner as the parent material that is intended for welding. The donor material heats up subsequent to …


Post-Weld Heat Treatment Effects On Microstructure, Crystal Structure, And Mechanical Properties Of Donor Stir–Assisted Friction Stir Welding Material Of Aa6061-T6 Alloy, Aiman H. Al-Allaq, Manish Ojha, Yousuf S. Mohammed, Srinivasa N. Bhukya, Zhenhua Wu, Abdelmageed A. Elmustafa Jan 2023

Post-Weld Heat Treatment Effects On Microstructure, Crystal Structure, And Mechanical Properties Of Donor Stir–Assisted Friction Stir Welding Material Of Aa6061-T6 Alloy, Aiman H. Al-Allaq, Manish Ojha, Yousuf S. Mohammed, Srinivasa N. Bhukya, Zhenhua Wu, Abdelmageed A. Elmustafa

Mechanical & Aerospace Engineering Faculty Publications

Friction stir welding (FSW) technology combines heat input from friction and extreme plastic deformation to produce high-quality joints in aluminum and other alloy systems. This necessitates examining the final welded joint’s mechanical and structural properties. Post-weld heat-treated AA6061-T6 alloy that resulted from the application of a Cu donor stir–assisted (CDSA) friction stir welding (FSW) material was examined for crystal structure and mechanical properties. CDSA FSW samples were tested at a constant tool rotational speed of 1400 rpm and a welding translational speed of 1 mm/s. CDSA samples of 20% and 60% thickness of the AA6061-T6 base alloy were selected to …