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Essa ARS, Eldersy RIA, Ahmed MMZ, Abd El-Aty A, Alamry A, Alzahrani B, El-Nikhaily AE, Habba MIA. Modeling and Experimental Investigation of the Impact of the Hemispherical Tool on Heat Generation and Tensile Properties of Dissimilar Friction Stir Welded AA5083 and AA7075 Al Alloys. Materials (Basel) 2024; 17:433. [PMID: 38255601 PMCID: PMC10817553 DOI: 10.3390/ma17020433] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/16/2023] [Revised: 01/09/2024] [Accepted: 01/11/2024] [Indexed: 01/24/2024]
Abstract
This study investigated the effect of a hemispherical friction stir welding (FSW) tool on the heat generation and mechanical properties of dissimilar butt welded AA5083 and AA7075 alloys. FSW was performed on the dissimilar aluminum alloys AA5083-H111 and AA7075-T6 using welding speeds of 25, 50, and 75 mm/min. The tool rotation rate was kept constant at 500 rpm. An analytical model was developed to calculate heat generation and temperature distribution during the FSW process utilizing a hemispherical tool. The experimental results were compared to the calculated data. The latter confirms the accuracy of the analytical model, demonstrating a high degree of agreement. Sound FSW dissimilar joints were achieved at welding speeds of 50 and 25 mm/min. Meanwhile, joints created at a welding speed of 75 mm/min exhibited a tunnel-like defect, which can be attributed to the minimal heat generated at this particular welding speed. At a lower welding speed of 25 mm/min, a higher tensile strength of the dissimilar FSWed joints AA5083 and AA7075 was achieved with a joint efficiency of over 97%.
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Affiliation(s)
- Ahmed R. S. Essa
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43211, Egypt; (A.R.S.E.); (R.I.A.E.); (A.E.E.-N.); (M.I.A.H.)
- Faculty of Engineering, King Salman International University, El Tor 45615, Egypt
| | - Ramy I. A. Eldersy
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43211, Egypt; (A.R.S.E.); (R.I.A.E.); (A.E.E.-N.); (M.I.A.H.)
| | - Mohamed M. Z. Ahmed
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Riyadh 11942, Saudi Arabia; (M.M.Z.A.); (A.A.); (B.A.)
- Department of Metallurgical and Materials Engineering, Faculty of Petroleum and Mining Engineering, Suez University, Suez 43211, Egypt
| | - Ali Abd El-Aty
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Riyadh 11942, Saudi Arabia; (M.M.Z.A.); (A.A.); (B.A.)
- Mechanical Engineering Department, Faculty of Engineering, Helwan University, Cairo 11795, Egypt
| | - Ali Alamry
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Riyadh 11942, Saudi Arabia; (M.M.Z.A.); (A.A.); (B.A.)
| | - Bandar Alzahrani
- Department of Mechanical Engineering, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Riyadh 11942, Saudi Arabia; (M.M.Z.A.); (A.A.); (B.A.)
| | - Ahmed E. El-Nikhaily
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43211, Egypt; (A.R.S.E.); (R.I.A.E.); (A.E.E.-N.); (M.I.A.H.)
| | - Mohamed I. A. Habba
- Mechanical Department, Faculty of Technology and Education, Suez University, Suez 43211, Egypt; (A.R.S.E.); (R.I.A.E.); (A.E.E.-N.); (M.I.A.H.)
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