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Journal of Materials Engineering and Performance
Published in: Journal of Materials Engineering and Performance 11/2015

18-09-2015

Nondestructive Evaluation of Friction Stir-Welded Aluminum Alloy to Coated Steel Sheet Lap Joint

Authors: H. Das, A. Kumar, K. V. Rajkumar, T. Saravanan, T. Jayakumar, Tapan Kumar Pal

Published in: Journal of Materials Engineering and Performance | Issue 11/2015

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Abstract

Dissimilar lap joints of aluminum sheet (AA 6061) of 2 mm thickness and zinc-coated steel sheet of 1 mm thickness were produced by friction stir welding with different combinations of rotational speed and travel speed. Ultrasonic C- and B-scanning, and radiography have been used in a complementary manner for detection of volumetric (cavity and flash) and planar (de bond) defects as the defects are in micron level. Advanced ultrasonic C-scanning did not provide any idea about the defects, whereas B-scanning cross-sectional image showed an exclusive overview of the micron-level defects. A digital x-ray radiography methodology is proposed for quality assessment of the dissimilar welds which provide three-fold increase in signal-to-noise ratio with improved defect detection sensitivity. The present study clearly shows that the weld tool rotational speed and travel speed have a decisive role on the quality of the joints obtained by the friction stir welding process. The suitability of the proposed NDE techniques to evaluate the joint integrity of dissimilar FSW joints is thus established.
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Metadata
Title
Nondestructive Evaluation of Friction Stir-Welded Aluminum Alloy to Coated Steel Sheet Lap Joint
Authors
H. Das
A. Kumar
K. V. Rajkumar
T. Saravanan
T. Jayakumar
Tapan Kumar Pal
Publication date
18-09-2015
Publisher
Springer US
Published in
Journal of Materials Engineering and Performance / Issue 11/2015
Print ISSN: 1059-9495
Electronic ISSN: 1544-1024
DOI
https://doi.org/10.1007/s11665-015-1713-9

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