Scholarlink

<p>Internal defects in friction stir welded (FSW) joints can undermine weld integrity, while the release of ultrafine particulates (UFPs) during welding presents significant occupational health concerns. This study evaluates the effectiveness of induction preheating-assisted FSW for marine-grade AA6082 aluminium alloy by comparing preheated (250&#xa0;°C) and non-preheated conditions, using identical welding parameters (58&#xa0;mm/min traverse speed; tool rotation speeds of 636, 900, and 1224&#xa0;rpm). UFP emissions were measured with a scanning mobility particle sizer (SMPS), while internal defects were assessed via phased array ultrasonic non-destructive testing. Additionally, the study also examines the microstructural evolution of the joints using field-emission scanning electron microscopy (FE-SEM) and optical microscopy, alongside comprehensive assessments of mechanical properties through tensile and microhardness testing. The results showed that induction preheating reduced UFP emissions by 41% to 59% across all tool rotation speeds, highlighting its potential to lower health risks for workers. Internal weld defects were successfully mitigated in joints produced with induction preheating. Microstructural analysis showed the formation of finer grains (~ 4–6&#xa0;μm) in the stir zone of preheated joints. Mechanically, the highest transverse tensile strength of 161.94&#xa0;MPa, representing 97.06% of the work material’s strength, was achieved in preheated joints, along with notable improvements in hardness compared to conventional FSW joints. These findings demonstrate that induction preheating-assisted FSW offers substantial benefits for both weld quality and environmental safety, providing a promising approach for the fabrication of high-performance aluminium joints.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Mitigation of internal weld defects and ultra-fine particulate emission by induction preheating in friction stir welding

  • 期刊论文

  • 发表日期：

    2025年8月30日

查看全文
  • Subhrajyoti Saroj,
  • Rubal Dhiman,
  • Adarsh Prakash,
  • Priyabrata Sahoo,
  • Anirudha Ambekar,
  • Thaseem Thajudeen,
  • Sachin Dnyandeo Kore

摘要

Internal defects in friction stir welded (FSW) joints can undermine weld integrity, while the release of ultrafine particulates (UFPs) during welding presents significant occupational health concerns. This study evaluates the effectiveness of induction preheating-assisted FSW for marine-grade AA6082 aluminium alloy by comparing preheated (250 °C) and non-preheated conditions, using identical welding parameters (58 mm/min traverse speed; tool rotation speeds of 636, 900, and 1224 rpm). UFP emissions were measured with a scanning mobility particle sizer (SMPS), while internal defects were assessed via phased array ultrasonic non-destructive testing. Additionally, the study also examines the microstructural evolution of the joints using field-emission scanning electron microscopy (FE-SEM) and optical microscopy, alongside comprehensive assessments of mechanical properties through tensile and microhardness testing. The results showed that induction preheating reduced UFP emissions by 41% to 59% across all tool rotation speeds, highlighting its potential to lower health risks for workers. Internal weld defects were successfully mitigated in joints produced with induction preheating. Microstructural analysis showed the formation of finer grains (~ 4–6 μm) in the stir zone of preheated joints. Mechanically, the highest transverse tensile strength of 161.94 MPa, representing 97.06% of the work material’s strength, was achieved in preheated joints, along with notable improvements in hardness compared to conventional FSW joints. These findings demonstrate that induction preheating-assisted FSW offers substantial benefits for both weld quality and environmental safety, providing a promising approach for the fabrication of high-performance aluminium joints.