Authors :
Kamran Ahmad; Dr. Praveen Kumar; Dr. Vaibhav Chandra
Volume/Issue :
RISEM–2025
Google Scholar :
https://tinyurl.com/662k87yn
Scribd :
https://tinyurl.com/5n834nse
DOI :
https://doi.org/10.38124/ijisrt/25jul613
Abstract :
This study aims to review the effect of weld lines movement on the formability and mechanical behavior of Friction Stir
Welded (FSW) joints between two different aluminum alloys using the Forming Limit Diagram (FLD) as a key evaluation tool.
FSW is a solid-state joining process that provides an excellent mechanical properties compared to other fusion welding process, but
the presence of weld lines can significantly influence the material's formability and performance under complex loading conditions.
This research paper focused on evaluating the impact of weld line positioning, movement, microstructural variations, and
mechanical heterogeneity on the forming limits of the dissimilar aluminum alloy joint. Various weld line positions, including center,
offset, and perpendicular orientations relative to the strain. The FLD is generated for both the base materials and the welded
joint, providing a comparative analysis of their formability. The study showed that use of optimizing input process parameters
such as tool rotation speed, weld speed of tool, pin diameter, shoulder diameter, and tool's pin profile could effectively reduce
the negative impact of weld line variation and play a vital role in better welding finished. It also showed that the optimized
input parameters improved the microstructure, formability and mechanical properties of the welded blank, resulting in better
forming limits and a higher resistance to deformation.
Keywords :
FSW, FLD, Limiting Dome Height (LDH) Test,Weld-Line, Optimization, Mechanical Properties.
This study aims to review the effect of weld lines movement on the formability and mechanical behavior of Friction Stir
Welded (FSW) joints between two different aluminum alloys using the Forming Limit Diagram (FLD) as a key evaluation tool.
FSW is a solid-state joining process that provides an excellent mechanical properties compared to other fusion welding process, but
the presence of weld lines can significantly influence the material's formability and performance under complex loading conditions.
This research paper focused on evaluating the impact of weld line positioning, movement, microstructural variations, and
mechanical heterogeneity on the forming limits of the dissimilar aluminum alloy joint. Various weld line positions, including center,
offset, and perpendicular orientations relative to the strain. The FLD is generated for both the base materials and the welded
joint, providing a comparative analysis of their formability. The study showed that use of optimizing input process parameters
such as tool rotation speed, weld speed of tool, pin diameter, shoulder diameter, and tool's pin profile could effectively reduce
the negative impact of weld line variation and play a vital role in better welding finished. It also showed that the optimized
input parameters improved the microstructure, formability and mechanical properties of the welded blank, resulting in better
forming limits and a higher resistance to deformation.
Keywords :
FSW, FLD, Limiting Dome Height (LDH) Test,Weld-Line, Optimization, Mechanical Properties.
