Enhancement of the mechanical characteristics for Inconel 700 alloy using friction stir welding with a unique tool shape

Ibrahim Sabry; Omar Awayssa; Abdel Hamid I. Mourad; Majid Naseri; Ahmed Hewidy

doi:10.1016/j.ijlmm.2025.02.005

Enhancement of the mechanical characteristics for Inconel 700 alloy using friction stir welding with a unique tool shape

Ibrahim Sabry, Omar Awayssa, Abdel Hamid I. Mourad, Majid Naseri, Ahmed Hewidy

Research output: Contribution to journal › Article › peer-review

1 Citation (Scopus)

Abstract

For the first time, a systematic study of the influence of tool geometry on the friction stir welding (FSW) process of Inconel 700 through response surface methodology (RSM) for modeling purposes was investigated. The tool design implemented two distinct pin probe geometries: a threaded pin with three intermittent flat faces (D1) and a fully threaded cylindrical pin (D2). The present study primarily examines the effects of these varying pin geometries on FSW performance in Inconel 700 joints. Additionally, experimental analyses, i.e., Vickers hardness number (VHN), ultimate tensile strength (UTS), and surface roughness (SR), were conducted to evaluate key mechanical properties. The response surface methodology (RSM) was evaluated as a suitable approach for determining the weld properties, with mathematical models achieving confidence levels of 93 % and 98 % for the D1 and D2 tool configurations, respectively. Meanwhile, the D1 pin geometry produced superior mechanical properties, i.e., UTS from 630 to 662 MPa, VHN from 93 to 110 HV, and improved surface finish compared to the D2 configuration, highlighting the design's effectiveness in enhancing FSW joint quality.

Original language	English
Pages (from-to)	415-430
Number of pages	16
Journal	International Journal of Lightweight Materials and Manufacture
Volume	8
Issue number	4
DOIs	https://doi.org/10.1016/j.ijlmm.2025.02.005
Publication status	Published - Jul 2025

Keywords

Friction stir welding
Inconel 700
Mechanical properties
Response surface methodology
Tool geometry

ASJC Scopus subject areas

General Materials Science
Mechanics of Materials
Industrial and Manufacturing Engineering

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10.1016/j.ijlmm.2025.02.005

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title = "Enhancement of the mechanical characteristics for Inconel 700 alloy using friction stir welding with a unique tool shape",

abstract = "For the first time, a systematic study of the influence of tool geometry on the friction stir welding (FSW) process of Inconel 700 through response surface methodology (RSM) for modeling purposes was investigated. The tool design implemented two distinct pin probe geometries: a threaded pin with three intermittent flat faces (D1) and a fully threaded cylindrical pin (D2). The present study primarily examines the effects of these varying pin geometries on FSW performance in Inconel 700 joints. Additionally, experimental analyses, i.e., Vickers hardness number (VHN), ultimate tensile strength (UTS), and surface roughness (SR), were conducted to evaluate key mechanical properties. The response surface methodology (RSM) was evaluated as a suitable approach for determining the weld properties, with mathematical models achieving confidence levels of 93 % and 98 % for the D1 and D2 tool configurations, respectively. Meanwhile, the D1 pin geometry produced superior mechanical properties, i.e., UTS from 630 to 662 MPa, VHN from 93 to 110 HV, and improved surface finish compared to the D2 configuration, highlighting the design's effectiveness in enhancing FSW joint quality.",

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author = "Ibrahim Sabry and Omar Awayssa and Mourad, {Abdel Hamid I.} and Majid Naseri and Ahmed Hewidy",

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AU - Naseri, Majid

AU - Hewidy, Ahmed

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N2 - For the first time, a systematic study of the influence of tool geometry on the friction stir welding (FSW) process of Inconel 700 through response surface methodology (RSM) for modeling purposes was investigated. The tool design implemented two distinct pin probe geometries: a threaded pin with three intermittent flat faces (D1) and a fully threaded cylindrical pin (D2). The present study primarily examines the effects of these varying pin geometries on FSW performance in Inconel 700 joints. Additionally, experimental analyses, i.e., Vickers hardness number (VHN), ultimate tensile strength (UTS), and surface roughness (SR), were conducted to evaluate key mechanical properties. The response surface methodology (RSM) was evaluated as a suitable approach for determining the weld properties, with mathematical models achieving confidence levels of 93 % and 98 % for the D1 and D2 tool configurations, respectively. Meanwhile, the D1 pin geometry produced superior mechanical properties, i.e., UTS from 630 to 662 MPa, VHN from 93 to 110 HV, and improved surface finish compared to the D2 configuration, highlighting the design's effectiveness in enhancing FSW joint quality.

AB - For the first time, a systematic study of the influence of tool geometry on the friction stir welding (FSW) process of Inconel 700 through response surface methodology (RSM) for modeling purposes was investigated. The tool design implemented two distinct pin probe geometries: a threaded pin with three intermittent flat faces (D1) and a fully threaded cylindrical pin (D2). The present study primarily examines the effects of these varying pin geometries on FSW performance in Inconel 700 joints. Additionally, experimental analyses, i.e., Vickers hardness number (VHN), ultimate tensile strength (UTS), and surface roughness (SR), were conducted to evaluate key mechanical properties. The response surface methodology (RSM) was evaluated as a suitable approach for determining the weld properties, with mathematical models achieving confidence levels of 93 % and 98 % for the D1 and D2 tool configurations, respectively. Meanwhile, the D1 pin geometry produced superior mechanical properties, i.e., UTS from 630 to 662 MPa, VHN from 93 to 110 HV, and improved surface finish compared to the D2 configuration, highlighting the design's effectiveness in enhancing FSW joint quality.

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KW - Tool geometry

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Enhancement of the mechanical characteristics for Inconel 700 alloy using friction stir welding with a unique tool shape

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