Layer Stability and Material Properties of Friction Stir Welded Cu-Nb Nanolamellar Composite Plates
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nuclear (including radiation effects), defects, me↗
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Stirring Unmagnetized Plasma
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Collins, C↗
High-Powered, Ultrasonically Assisted Thermal Stir Welding
This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a distance equal to the thickness of the material being welded. The TSW process can be significantly improved by reducing the draw forces. This can be achieved by reducing the friction forces between the weld workpieces and the containment plates. High-power ultrasonic (HPU) vibrations of the containment plates achieve friction reduction in the TSW process. Furthermore, integration of the HPU energy into the TSW stir rod can increase tool life of the stir rod, and can reduce shear forces to which the stir rod is subjected during the welding process. TSW has been used to successfully join 0.500-in (≈13-mm) thick commercially pure (CP) titanium, titanium 6AL- 4V, and titanium 6AL-4V ELI in weld joint lengths up to 9 ft (≈2.75-m) long. In addition, the TSW process was used to fabricate a sub-scale hexagonally shaped gun turret component for the U.S. Navy. The turret is comprised of six 0.5000-in (≈13-mm) thick angled welds. Each angled weld joint was prepared by machining the mating surfaces to 120deg. The angled weld joint was then fixtured using an upper and lower containment plate of the same geometry of the angled weld joint. The weld joint was then stirred by the stir rod as it and the upper and lower containment plates traverse through the angled joint prep.
Ding, Robert↗
On the Alternate Stirring Mode of F-EMS for Bloom Continuous Castings
Local solute transportation behaviors under different alternate stirring parameters of final electromagnetic stirring (F-EMS) and their influences on the internal quality of the as-cast bloom are compared and evaluated based on a developed coupled model of electromagnetism, heat, and solute transport. To this end, plant trials were conducted in Shaoguan Steel, China. Under the action of F-EMS, a negative segregation band in an ellipse shape is observed at the central area of strand cross section, where the minimum carbon segregation degree is decreased from 0.98 to 0.84 as the stirring duration increases from 15 to 35 seconds in the alternate stirring mode, while it is reduced to 0.805 in the continuous stirring mode. The white band and shrinkage cavity are simultaneously observed at strand center under the conditions of continuous stirring mode, and alternate stirring mode with a stirring period of 35 seconds because of the local over-sustaining melt rotation. In contrast, the V-shape porosity belt width and strand center segregation fluctuation range increase from 60 to 90 mm and from 0.12 to 0.30, respectively, as the stirring duration is reduced from 25 to 15 seconds in the alternate stirring mode because of the poor mixing of the local melt at the strand center.
36 MATERIALS SCIENCE↗
Elucidation of microstructural evolution of beta-type titanium alloy joint during friction stir welding using liquid CO2 cooling
Highlights: • Microstructural evolution during FSW was elucidated along real material flow line. • Stirring and cooling stages of FSW can be investigated separately using CO{sub 2} cooling. • In stirring stage, discontinuous dynamic recrystallization predominantly occurred. • In cooling stage, static recovery and grain growth mainly occurred. - Abstract: Normal friction stir welding (FSW) and liquid CO{sub 2} cooling FSW were conducted on the β-type Ti-15V-3Cr-3Al-3Sn (Ti-15-3, mass%) alloy plates under a processing condition. Since liquid CO{sub 2} cooling with high cooling efficiency can freeze the microstructure formed during the high-temperature stirring stage of FSW, it is possible to separately elucidate the microstructural evolution of the Ti-15-3 alloy during the high-temperature stirring stage and the post-stirring cooling stage in FSW. The deformation temperature during the normal and the CO{sub 2} cooling FSW was similar in the top and the bottom of stir zone, which is considered to be owing to that the top and bottom are located adjacent to the heat sources, i.e., the shoulder and probe surfaces. In the high-temperature stirring stage of FSW, discontinuous dynamic recrystallization predominantly occurred, and a simple shear texture generated in an early stage of the material flow around the tool, then the microstructure started to evolve steadily after a steady-state dynamic recrystallization. In the post-stirring cooling stage of FSW, static recovery and grain growth were found to mainly occur within the stir zone.
36 MATERIALS SCIENCE↗
The effect of postprocessing on tensile property and microstructure evolution of friction stir welding aluminum alloy joint
Friction stir welding is an efficient manufacturing method for joining aluminum alloy and can dramatically reduce grain size conferring excellent plastic deformation properties. Consequently, friction stir welding is used to manufacture tailor welded blanks to optimize weight or performance in the final component. In the study, the microstructural evolution and mechanical properties of friction stir welding joint during plastic forming and subsequent heat treatment were investigated. The microstructural characteristics of the friction stir welding joints were studied by Electron Backscattered Diffraction and Transmission Electron Microscopy. The mechanical properties were evaluated by tensile and microhardness tests. It is found that the tensile and yield strengths of friction stir welding joints are significantly improved after severe plastic deformation due to the grain refinement. Following heat treatment, the strength of the friction stir welding joints significantly decrease due to the obvious abnormal grain growth. Careful attention must be given to the processing route of any friction stir welding joint intended for plastic forming, especially the annealing between forming passes. Severe plastic deforming of the friction stir welding joint leads to a high level of stored energy/dislocation density, which causes the abnormal grain growth during subsequent heat treatment, and consequently reduce the mechanical properties of the friction stir welding joint. - Highlights: • Great changes are observed in the microstructure of FSW joint after postprocessing. • Postprocessing shows great effect on the microstructure stability of FSW joint. • The weld shows more significant decrease in strength than the BM due to the AGG. • Attention must be given to the processing route of FSW joint for plastic forming.
36 MATERIALS SCIENCE↗
Tool For Friction Stir Tack Welding of Aluminum Alloys
A small friction-stir-welding tool has been developed for use in tack welding of aluminum-alloy workpieces. It is necessary to tack-weld the workpieces in order to hold them together during friction stir welding because (1) in operation, a full-size friction-stir-welding tool exerts a large force that tends to separate the workpieces and (2) clamping the workpieces is not sufficient to resist this force. It is possible to tack the pieces together by gas tungsten arc welding, but the process can be awkward and time-consuming and can cause sufficient damage to necessitate rework. Friction stir tack welding does not entail these disadvantages. In addition, friction stir tack welding can be accomplished by use of the same automated equipment (except for the welding tool) used in subsequent full friction stir welding. The tool for friction stir tack welding resembles the tool for full friction stir welding, but has a narrower shoulder and a shorter pin. The shorter pin generates a smaller workpiece-separating force so that clamping suffices to keep the workpieces together. This tool produces a continuous or intermittent partial-penetration tack weld. The tack weld is subsequently consumed by action of the larger tool used in full friction stir welding tool.
Bjorkman, Gerald W.↗
Morphological Evolution of Mg-Al-La-Ca Alloy Induced by a Mechanical Stirring Process
This paper aims to evaluate the morphological evolution of a magnesium-aluminum alloy (Mg-6Al-3La-1Ca) processed by a mechanical stirring process (MSP) with different stirring times. An apparatus for semisolid metal alloy processing was used to melt and obtain rheocast material. Transformation temperatures were determined at a slow cooling rate using computer-aided cooling curve thermal analysis (CA-CCTA) and differential scanning calorimetry (DSC). Isothermal mechanical stirring (605 °C), at 950 rpm, was carried out with a solid fraction of 0.29 and stirring times of 0, 1, 2, 4, 8 and 10 min, followed by fast cooling in water. The results showed that the microstructure after conventional casting (0 min—no stirring) is composed of an α-Mg dendritic matrix, Al{sub 11}La{sub 3}, (Al,Mg){sub 2}Ca and Mg{sub 2}Ca compounds. With the 1-min stirring time, it was not possible to obtain globular structures. For stirring times longer than 2 min, a primary α-Mg globular morphology was obtained. Microstructures with 2 min of stirring time showed better globularization than those obtained under the other conditions. Morphological changes were observed for Al{sub 11}La{sub 3} and (Al,Mg){sub 2}Ca after the MSP followed by fast cooling.
36 MATERIALS SCIENCE↗
Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications
Friction stir welding is an innovative weld process that continues to grow in use, in the commercial, defense, and space sectors. It produces high quality and high strength welds in aluminum alloys. The process consists of a rotating weld pin tool that plasticizes material through friction. The plasticized material is welded by applying a high weld forge force through the weld pin tool against the material during pin tool rotation. The high weld forge force is reacted against an anvil and a stout tool structure. A variation of friction stir welding currently being evaluated is self-reacting friction stir welding. Self-reacting friction stir welding incorporates two opposing shoulders on the crown and root sides of the weld joint. In self-reacting friction stir welding, the weld forge force is reacted against the crown shoulder portion of the weld pin tool by the root shoulder. This eliminates the need for a stout tooling structure to react the high weld forge force required in the typical friction stir weld process. Therefore, the self-reacting feature reduces tooling requirements and, therefore, process implementation costs. This makes the process attractive for aluminum alloy circumferential weld applications. To evaluate the application of self-reacting friction stir welding for aluminum alloy circumferential welding, a feasibility study was performed. The study consisted of performing a fourteen-foot diameter aluminum alloy circumferential demonstration weld using typical fusion weld tooling. To accomplish the demonstration weld, weld and tack weld development were performed and fourteen-foot diameter rings were fabricated. Weld development consisted of weld pin tool selection and the generation of a process map and envelope. Tack weld development evaluated gas tungsten arc welding and friction stir welding for tack welding rings together for circumferential welding. As a result of the study, a successful circumferential demonstration weld was produced leading the way for future circumferential weld implementation.
Bjorkman, Gerry↗
Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys
Friction stir welding is a solid state welding process used in the fabrication of various aerospace structures. Self-reacting and conventional friction stir welding are variations of the friction stir weld process employed in the fabrication of cryogenic propellant tanks which are classified as pressurized structure in many spaceflight vehicle architectures. In order to address damage tolerance behavior associated with friction stir welds in these safety critical structures, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data describing fracture behavior, residual strength capability, and cyclic mission life capability of friction stir welds at ambient and cryogenic temperatures have been generated and will be presented in this paper. Fracture behavior will include fracture toughness and tearing (R-curve) response of the friction stir welds. Residual strength behavior will include an evaluation of the effects of lack of penetration on conventional friction stir welds, the effects of internal defects (wormholes) on self-reacting friction stir welds, and an evaluation of the effects of fatigue cycled surface cracks on both conventional and selfreacting welds. Cyclic mission life capability will demonstrate the effects of surface crack defects on service load cycle capability. The fracture data will be used to evaluate nondestructive inspection and proof test requirements for the welds.
McGill, Preston↗
Chloride-Induced Stress Corrosion Cracking of Friction Stir-Welded 304L Stainless Steel: Effect of Microstructure and Temperature
Dry storage canisters of used nuclear fuels are fabricated using SUS 304L stainless steel. Chloride-induced stress corrosion cracking (CISCC) is one of the major failure modes of dry storage canisters. The cracked canisters can be repaired by friction stir welding (FSW), a low-heat input ‘solid-phase’ welding process. It is important to evaluate the ClSCC resistance of the friction stir welded material. Stress corrosion cracking (SCC) studies were carried out on mill-annealed base materials and friction stir welded 304L stainless U-bend specimens in 3.5% NaCl + 5 N H2SO4 solution at room temperature and boiling MgCl2 solution at 155 °C. The engineering stress on the outer fiber of the FSW U-bend specimen was ~60% higher than that of the base metal (BM). In spite of the higher stress level of the FSW, both materials (FSW and BM) showed almost similar SCC failure times in the two different test solutions. The SCC occurred in the thermo-mechanically affected zone (TMAZ) of the FSW specimens in the 3.5% NaCl + 5 N H2SO4 solution at room temperature, while the stirred zone (SZ) was relatively crack-free. The failure occurred at the stirred zone when tested in the boiling MgCl2 solution. Hydrogen reduction was the cathodic reaction in the boiling MgCl2 solution, which promoted hydrogen-assisted cracking of the heavily deformed stirred zone. The emergence of the slip step followed by passive film rupture and dissolution of the slip step could be the SCC events in the 3.5% NaCl + 5 N H2SO4 solution at room temperature. However, the slip step height was not sufficient to cause passivity breakdown in the fine-grained SZ. Therefore, the SCC occurred in the partially recrystallized softer TMAZ. Overall, the friction-stirred 304L showed higher tolerance to ClSCC than the 304L base metal.
304L austenitic stainless steel↗
Thermal Stir Welding: A New Solid State Welding Process
Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.
Ding, R. Jeffrey↗
Thermal Stir Welding: A New Solid State Welding Process
Thermal stir welding is a new welding process developed at NASA's Marshall Space Flight Center in Huntsville, AL. Thermal stir welding is similar to friction stir welding in that it joins similar or dissimilar materials without melting the parent material. However, unlike friction stir welding, the heating, stirring and forging elements of the process are all independent of each other and are separately controlled. Furthermore, the heating element of the process can be either a solid-state process (such as a thermal blanket, induction type process, etc), or, a fusion process (YG laser, plasma torch, etc.) The separation of the heating, stirring, forging elements of the process allows more degrees of freedom for greater process control. This paper introduces the mechanics of the thermal stir welding process. In addition, weld mechanical property data is presented for selected alloys as well as metallurgical analysis.
Ding, R. Jeffrey↗
Thermal Stir Welding Development at Marshall Space Flight Center
Solid state welding processes have become the focus of welding process development at NASA's Marshall Space Flight Center. Unlike fusion weld processes such as tungsten inert gas (TIG), variable polarity plasma arc (VPPA), electron beam (EB), etc., solid state welding processes do not melt the material during welding. The resultant microstructure can be characterized as a dynamically recrystallized morphology much different than the casted, dentritic structure typical of fusion weld processes. The primary benefits of solid state processes over fusion weld processes include superior mechanic properties and the elimination of thermal distortion and residual stresses. These solid state processes attributes have profoundly influenced the direction of advanced welding research and development within the NASA agency. Thermal Stir Welding (TSW) is a new solid state welding process being developed at the Marshall Space Flight Center. Unlike friction stir welding, the heating, stirring and forging elements of the weld process can be decoupled for independent control. An induction coil induces energy into a workpiece to attain a desired plastic temperature. An independently controlled stir rod, captured within non-rotating containment plates, then stirs the plasticized material followed by forging plates/rollers that work the stirred weld joint. The independent control (decoupling) of heating, stirring and forging allows, theoretically, for the precision control of microstructure morphology. The TSW process is being used to evaluate the solid state joining of Haynes 230 for ARES J-2X applications. It is also being developed for 500-in (12.5 mm) thick commercially pure grade 2 titanium for navy applications. Other interests include Inconel 718 and stainless steel. This presentation will provide metallurgical and mechanical property data for these high melting temperature alloys.
Ding, Robert J.↗
Gimballed Shoulders for Friction Stir Welding
In a proposed improvement of tooling for friction stir welding, gimballed shoulders would supplant shoulders that, heretofore, have been fixedly aligned with pins. The proposal is especially relevant to self-reacting friction stir welding. Some definitions of terms, recapitulated from related prior NASA Tech Briefs articles, are prerequisite to a meaningful description of the proposed improvement. In friction stir welding, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a pin that rotates with the shoulder and protrudes from the shoulder into the depth of the workpiece. In conventional friction stir welding, the main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional friction stir welding is augmented with an auto-adjustable pin-tool (APT) capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or forcecontrol system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding as practiced heretofore, there are two shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. Both shoulders rotate with the pin and remain aligned coaxially with the pin. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft into the friction-stir-welding machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. This concludes the prerequisite definitions of terms.
Carter, Robert↗
Characterization of Multilayered Multipass Friction Stir Weld on ASTM A572 G50 Steel
A multilayered multipass friction stir weld (MM-FSW) on ASTM A572 Grade 50 steel was characterized to understand its potential application for thick-section structures. The 15-mm-thick section was fabricated by stacking up three steel plates and then friction stir welding the plates together in a total of 5 passes. The unique butt/lap joint configuration encountered in the multilayer weld was examined to understand the effect of tool rotation direction on the joint quality especially the formation of hooking defect. Charpy V-notch impact toughness tests showed generally higher impact toughness energy for the stir zone than the base metal with a ductile fracture mode. The microhardness value was measured from 195 to 220 HV in the stir zone, while the base metal showed an average value of 170 HV. The microstructure in the stir zone and the adjacent heat affected zone was quantified using Optical and Scanning Electron Microscopy (SEM) including Electron Backscatter Diffraction (EBSD). The increased toughness and hardness were correlated with the refined microstructure in stir zone, resulting from severe plastic deformation and subsequent dynamic recrystallization during friction stir welding.
Lim, Yong Chae↗
Study of Low Flow Rate Ladle Bottom Gas Stirring Using Triaxial Vibration Signals
Secondary steelmaking plays a great role in enhancing the quality of the final steel product. The metal quality is a function of metal bath stirring in ladles. The metal bath is often stirred by an inert gas to achieve maximum compositional and thermal uniformity throughout the melt. Ladle operators often observe the top surface phenomena, such as level of meniscus disturbance, to evaluate the status of stirring. However, this type of monitoring has significant limitations in assessing the process accurately especially at low gas flow rate bubbling. The present study investigates stirring phenomena using ladle wall triaxial vibration at a low flow rate on a steel-made laboratory model and plant scale for the case of the vacuum tank degasser. Cold model and plant data were successfully modeled by partial least-squares regression to predict the amount of stirring. In the cold model, it was found that the combined vibration signal could predict the stirring power and recirculation speed effectively in specific frequency ranges. Plant trials also revealed that there is a high structure in each data set and in the same frequency ranges at the water model. In the case of industrial data, the degree of linear relationship was strong for data taken from a single heat.
36 MATERIALS SCIENCE↗
Transient Microstructure Evolutions and Local Properties of Dual-Phase 980 MPa Grade Steel Via Friction Stir Spot Processing
Friction stir processing is a novel solid-state process to modify microstructures and their properties by intense, localized plastic deformation. However, little research has been reported for microstructure evolutions of advanced high-strength steels during the process. The present work focuses on the study of transient microstructure changes and local mechanical properties for friction stir spot processed dual-phase (DP) 980 MPa grade steel (DP980) under different peak temperatures. A pinless silicon nitride ceramic tool was used to produce relatively simple material deformation and flow near the tool. Friction stir spot processed steel samples were characterized by optical and electron microscopies. Furthermore, Vickers microhardness and nano-indentation measurements were used to study local mechanical properties for correlation with microstructures. A swallow layer of refined grains (<0.6 µm) was obtained with a low peak temperature (under 400 °C), whereas higher peak temperatures (>Ac 1 ) led to a change in grain size with different microstructures (fine-grained DP or martensite). Electron back-scattered diffraction characterizations revealed a large deformation in the as-received microstructures (mixture of ferrite and tempered martensite) induced by friction stir spot processing, leading to recrystallization and grain refinement around the stirred zone. Also, nano-indentation measurements showed a higher hardness than the hardness of the as-received DP980. Friction stir processing with different process conditions effectively changed microstructures and local mechanical properties.
36 MATERIALS SCIENCE↗