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Metals
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Advances in Friction Stir Welding of Alloys and Metals
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Advances in Friction Stir Welding of Alloys and Metals

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Welding and Joining".

Deadline for manuscript submissions: closed (20 May 2024) | Viewed by 1591

Special Issue Editors

Prof. Dr. Abdelmageed A. Elmustafa

E-Mail Website
Guest Editor
NanoMaterials and Properties Testing Laboratory (NMPTL), Department of Mechanical and Aerospace Engineering, The Applied Research Center-Thomas Jefferson National Accelerator Facility, Old Dominion University, Newport News, VA 23606, USA
Interests: thin films fabrication; nanomechanical structural properties; nanomechanics; nanomaterials
Prof. Dr. Rajiv S. Mishra

E-Mail Website
Guest Editor
Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA
Interests: high-entropy alloys; laves phases; entropy

Special Issue Information

Dear Colleagues,

Friction stir welding (FSW) is a cutting-edge welding process developed by The Welding Institute in Cambridge, United Kingdom and patented by W.M. Thomas et al in 1991. Friction stir welding is not a conventional welding process because the joining of materials occurs in the solid state below the melting point of the materials being joined. It is the ability to create a solid state union which makes the process highly desired by the industry. Compared to other processes, friction stir welds have low distortions, excellent post weld mechanical properties, no filler wire, no gas shielding, no toxic fumes, no porosity, no spatter, low shrinkage, and is energy efficient. 

We invite investigators to contribute original research articles as well as review articles that will stimulate the continuing efforts to understand advances in FSW. We are particularly interested in articles describing FSW materials processing, materials behavior, and modeling, simulation, and optimization efforts of FSW.

Potential topics include, but not limited to:

  • Recent developments in FSW techniques.
  • Recent developments in FSW materials processing.
  • Latest technologies for mechanical properties evaluation and measurement of the thermomechanical-plastic properties of materials.

Prof. Dr. Abdelmageed A. Elmustafa
Prof. Dr. Rajiv S. Mishra
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. Metals is an international peer-reviewed open access monthly 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

  • FSW
  • FSW processing
  • mechanical and structural properties

Published Papers (2 papers)

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Research

15 pages, 3872 KiB  
Article
Assessing Tensile Strength and Electrical Conductivity of Friction Stir-Welded Joints of Copper and Aluminum Alloys
by Elizabeth Hoyos, María Camila Serna, Yesid Montoya and Jorge Hernán Córdoba
Metals 2024, 14(6), 631; https://doi.org/10.3390/met14060631 - 26 May 2024
Viewed by 269
Abstract
Dissimilar aluminum joints have widespread applications across various industries, including the electronics and automotive sectors, owing to their unique combination of advantages, including reduced density and enhanced mechanical properties. These characteristics make them an innovative solution for multi-material processing challenges presented in the [...] Read more.
Dissimilar aluminum joints have widespread applications across various industries, including the electronics and automotive sectors, owing to their unique combination of advantages, including reduced density and enhanced mechanical properties. These characteristics make them an innovative solution for multi-material processing challenges presented in the engineering industry. This article focuses on Friction Stir-Welded butt joints made using a weld–flip–weld approach between aluminum AA6061-T6 and pure copper C11000, exploring the effects of varying rotational speeds (1000, 1200, and 1400 RPM), offsets (0 and 1 mm) in the joint soundness, mechanical strength, and electrical conductivity. The welds were evaluated using non-destructive testing with phased-array ultrasound and tensile testing. Additionally, the electrical conductivity was measured to assess their response to electrical currents. The findings reveal a significant correlation between joint efficiency and electrical conductivity, with the highest values corresponding to a weld executed with a rotational speed of 1400 rpm, traverse speed of 40 mm/min, and 1 mm offset towards the aluminum, achieving the highest joint efficiency, reaching a joint efficiency of approximately 75% and 82.42% of the IACS for electrical conductivity. Full article
(This article belongs to the Special Issue Advances in Friction Stir Welding of Alloys and Metals)
25 pages, 27142 KiB  
Article
Parametric Optimization of Friction Stir Welding of AA6061-T6 Samples Using the Copper Donor Stir-Assisted Material Method
by Aiman H. Al-Allaq, Joseph Maniscalco, Srinivasa Naik Bhukya, Zhenhua Wu and Abdelmageed Elmustafa
Metals 2024, 14(5), 536; https://doi.org/10.3390/met14050536 - 30 Apr 2024
Viewed by 944
Abstract
This study presents an optimization of the process parameters for the effect of copper (Cu) donor material percentage on the friction stir welding (FSW) of AA6061-T6 alloy. Extensive factorial experiments were conducted to determine the significance of the rotational speed (ω), the transverse [...] Read more.
This study presents an optimization of the process parameters for the effect of copper (Cu) donor material percentage on the friction stir welding (FSW) of AA6061-T6 alloy. Extensive factorial experiments were conducted to determine the significance of the rotational speed (ω), the transverse speed (v), the interface coefficient of friction (μ), and the Cu donor material percentage in the plunge, left, right, and downstream zones. Design Expert 13 software was used to identify the number of simulation experiments to be conducted using the Abaqus simulation software. From Design Expert 13, which is a thorough multi-objective optimization analysis software, we were able to identify ideal welding parameters such as a rotational speed of 1222 rpm, transverse speed of 1.1 mm/s, the coefficient of friction of 0.9, and a 19% donor material percentage for the plunge zone. Significant findings demonstrate that increasing the Cu donor material substantially reduced the temperature from 502 °C to 134 °C when the Cu content is increased from 0% to 50%. This integrated modeling and optimization approach provides a practical procedure to identify the best experimental parameters for the process and a new understanding to guide advances for high-quality FSW of aluminum alloys. This work offers a methodology for optimizing the FSW parameters aligned with multifaceted thermomechanical physics. Full article
(This article belongs to the Special Issue Advances in Friction Stir Welding of Alloys and Metals)
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