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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Enhancing Formability of AA2219 Aluminum Alloy Friction Stir Welded Blanks with Preheating Treatment

The deformation behaviors of FSW blank are complicated due to the incompatibility of the mechanical property and microstructure for the weld and base material. In order to improve the formability of friction stir welded (FSW) blanks, the weld and base material in this paper were subjected to preheating treatments of 250, 300, 350, 400, and 450 °C, plus a solution treatment of 535 °C. The deformation behavior of the AA2219 FSW blank was characterized using uniaxial tension, microhardness test, hydro-bulging test and electron backscattered diffraction to determine the relationship of the deformation property and microstructure for the FSW blanks. Full strain fields of the tensile and bulging specimens were used to analyze the deformation uniformity of the weld and base material under uniaxial tension and biaxial tension stress states. With the limiting bulging height under various preheating temperatures, the formability behavior of the weld and base material was analyzed during the whole bulging process. The optimum preheating temperature can increase the formability and refrain from abnormal grain growth of the weld on the premise of maintaining the weld strength. The limiting bulging height of FSW blank is obviously improved by the lower preheating temperature from 300 to 350 °C. Additionally, the weld position has a significant impact on the deformation of the whole FSW blanks.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of Rotation Speed on Microstructure and Mechanical Properties of 2060 Al-Cu-Li Alloy in Friction Stir Welding

Microstructural and mechanical properties of 2.0-mm-thick 2060 Al-Cu-Li alloy joints obtained at different rotation speeds were assessed in this study. The rotation speeds ranged from 400 to 1300 rpm, with welding speed kept at a constant value of 100 mm/min. With the increase in rotation speed, grain coarsening occurred while the density of precipitation decreased in the stir zone (SZ), and great amounts of the Al{sub 2}CuLi and Al{sub 2}Cu phases were dissolved while only small amounts of the Al{sub 3}Zr and Al{sub 3}Li phases remained. The lowest hardness was found at the interface between the heat-affected zone (HAZ) and thermo-mechanically affected zone (TMAZ); the average hardness value of SZ increased, while the lowest hardness moved in the direction away from the center of joints. The ultimate strength (UTS) of weld first increased rapidly and then slowly decreased as rotation speed increased, with a maximum value of 443 MPa obtained at a rotation speed of 600 rpm, reaching 83.58% of the base metal (BM) strength. Three fracture modes were established to illustrate the growth mechanism of the crack. Analysis of the fracture surface showed that insufficient materials flowed and coarsened secondary phases caused the joint fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Zinc Interlayer in Microstructure Evolution and Mechanical Properties in Dissimilar Friction Stir Welding of Aluminum to Titanium

The welding of aluminum (Al) and titanium (Ti) is difficult and challenging due to the differences in their chemical and physical properties, and the formation of brittle intermetallic phases. In the present experiment, a zinc (Zn) interlayer was used during friction stir welding of Al to Ti. The weld was characterized in detail to understand the mechanisms associated with microstructural evolution and improvement in mechanical properties of the weld. X-ray computed tomography results reveal three-dimensional distribution of particles and flakes of titanium in the weld nugget. It was also observed that Ti particles are inhomogeneously distributed in the weld and the distribution depends on their morphology. Such a distribution of Ti was informative in understanding material flow. In addition, the consolidation of Zn in the Al matrix reveals the nature of material flow in the weld nugget as well. The importance of the Zn interlayer and mechanism of phase formation was explored in this study. It was characterized that the mechanical mixing of Zn with Al and Ti alters phase evolution and restricts the formation of conventional Al{sub 3}Ti intermetallic phase. The presence of zinc homogenizes elemental distribution and inhibits the formation of brittle intermetallic phases, which leads to a substantial improvement in mechanical properties of the weld.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Reducing Intermetallic Compounds of Mg/Al Joint in Friction Stir Lap Welding

To reduce intermetallic compounds (IMCs) of Al{sub 12}Mg{sub 17} and Al{sub 3}Mg{sub 2} in Mg/Al friction stir lap welding joint, pin tip was plunged into the lower sheet at a small distance. Results showed that at a fixed welding speed of 50 mm/min, sound joints were obtained using rotating speeds from 750 to 500 rpm, and the IMCs zones were rather small. Cracks easily appeared inside IMCs inside onion ring and at lap interface. Therefore, reducing the IMC was beneficial for reducing the crack. Joint lap shear stress firstly increased and then decreased with decrease in the rotating speed. The maximum shear stress of 50.2 MPa was attained at a rotating speed of 500 rpm because of reduced IMC.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and Mechanical Properties of Friction Stir Welded Q235 Low-Carbon Steel

Three-millimeter-thick Q235 steel plates were friction stir welded using a tool made of tungsten-rhenium alloy in the present study. The microstructure and mechanical properties of welded joints at various traverse speeds from 50 to 150 mm/min were analyzed. It was demonstrated that traverse speed had great impacts on microstructure and mechanical properties of the joints. Phase transformation accompanied with recrystallization occurred during FSW process which resulted in different microstructures in the WNZ, and the grain size in other zones was significantly affected by traverse speed. The highest hardness was located in the nugget zone, while the lowest hardness was found in the heat-affected zone. The transverse tensile test suggested that all the joints showed slightly lower tensile strength than that of the base material, and the tensile strength increased with increasing traverse speed. All the joints fractured in the heat-affected zone with ductile fracture mode. The impact test showed that the impact toughness decreased with the increasing traverse speed and the impact fracture surface could be divided into shear lip zone and fibrous zone which showed a typical ductile fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Optimization of Tensile and Corrosion Properties of Dissimilar Friction Stir Welded AA2024-7075 Joints

In this work, we performed some joining experiments of dissimilar aluminum alloys AA2024-T351 and AA7075-T651 using friction stir welding (FSW) technique with different process parameters (rotational speed, welding speed and plunge depth). Response surface methodology based on a central composite rotatable design was used to establish the mathematical models predicting the tensile properties and corrosion rate of dissimilar FSW joints with some high confidence level. Analysis of variance method was employed to verify the developed models. Besides, the influences of FSW process parameters on tensile and corrosion properties of joints were analyzed. In order to obtain a desirable combination property of the dissimilar FSW joints, the optimum process parameters after experimental verification were proposed as: rotational speed 1495 rev/min, welding speed 187 mm/min and plunge depth 0.03 mm. This verification illustrated that the developed models are appropriate for the modeling and optimization of process.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Friction Stir Processing on the Microstructure, Damping Capacity, and Mechanical Properties of Al-Si Alloy

Friction stir processing (FSP) was conducted on an Al-Si casting alloy. The Si phase and Al grains of an Al-Si casting alloy were refined through FSP. Furthermore, FSP with high rotation rate led to the precipitation of Mg and Si atoms and the formation of Mg{sub 2}Si phase in the Al-Si alloy. Precipitation improved the low-strain damping capacity but deteriorates high-strain damping capacity of the FSP sample at room temperature. At low rotation rate, the FSP sample exhibited excellent high-temperature damping capacity mainly because of its fine grain structure and the low density of its pinning points. The plastic instability of the Al-Si alloy was eliminated by FSP because of the refinement of the Si phase. The increase in the strength of each FSP sample was attributed to the increase in second-phase and boundary strengthening effects. Thus, the mechanical properties and damping capacity of Al-Si were enhanced after FSP.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Through-Thickness Friction Stir Processing Parameters on Weld Repair and Modification of Fusion-Welded AA6061 Aluminum Alloy

Through-thickness friction stir processing was successfully carried out for microstructure modification and elimination of fusion defects of the gas metal arc welds by applying the process on as-welded joints. Variation in rotational speed from 750 to 1050 rpm and traveling speed from 50 to 200 mm/min resulted in minor changes (approximately 1 µm) in the grain size of nugget zone, while this variation in elongation result was up to 40%. The hardness profile, the width of softening zone, minimum hardness and fracture location also changed for different processing conditions. Furthermore, the defects were vanished efficiently across the welds profile by this method. The results also verified the geometric dynamic recrystallization phenomena as a dominant mechanism of microstructural modification.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Preheating and Water Cooling on the Performance of Friction-Stir-Welded Aviation-Grade Aluminum Alloy Joints

This paper examined the effect of preheating and water cooling on the thermal, mechanical, metallurgical, and texture properties of friction-stir-welded AA6082. Joints are fabricated under different preheating (FSW-P) and water cooling (FSW-C) conditions. The experimental outcomes indicate that the preheating and water cooling enhance the mechanical properties of the joint. The maximum tensile strength of 295 MPa is obtained for FSW-P1. It is also observed that preheating has more impact on microhardness. Microstructural analysis using optical microscope and electron backscatter diffraction analysis indicated that FSW produced fine equiaxed grains in the nugget zone due to dynamic recrystallization. Texture analysis shows that finer grain grains are obtained under preheating and water cooling conditions. The minimum grain size of 5.3 µm is obtained under FSW-P1. X-ray diffraction analysis shows that Mg{sub 2}Si phase in nugget zone that is an indication of dissolution and formation of strengthening precipitates. Fracture analysis indicates that preheating also improves the ductility of the joint.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Material Properties and Process Parameters on Morphology and Strength of Friction-Stir-Welded Dissimilar T-Joints

The influence of the material properties and the process parameters on the mechanical behavior of friction-stir-welded dissimilar T-joints of AA5083-H111 and AA6082-T6 aluminum alloys was investigated. The welds were produced in 3-mm-thick plates, in a T-joint configuration, but using each material either as the skin or as the stringer. Two different tools, with the same design of the shoulder and the initial part of the progressive pin, cylindrical threaded, but with different pin tip geometry, one conical threaded and the other pyramidal, were used. The transverse speed was varied between 30 and 220 mm/min. The results show that it is possible to produce welds without any defects and or reduction in the skin thickness as well as with an excellent filling of the fillets. The flow of material in the welds is very much conditioned by the geometry of the progressive pin of the tools. The welds produced with a higher traverse speed and using the threaded pin tool presented higher tensile strength than those performed with the pyramidal pin tool. The weld series in which the AA5083 alloy was used as the skin exhibited greater tensile and fatigue strength than the welds where the AA6082 alloy was used as the skin.

36 MATERIALS SCIENCE↗
DOE OSTI2019

On the Effect of Quenching on Postweld Heat Treatment of Friction-Stir-Welded Aluminum 7075 Alloy

This work focuses on the effect of postweld heat treatment (PWHT) on the mechanical properties and microstructural evolution of aluminum 7075 alloy processed via friction stir welding (FSW). FSW is known to be capable of grain refinement in the nugget zone (NZ). Two different quench media (water and air) were employed for PWHT. Regardless of the quench media, the PWHT led to the occurrence of grain growth in the NZ of the FSWed aluminum 7075 alloy. Abnormal grain growth occurred in the water quenched specimen. It is shown that ductility and strength of FSWed aluminum 7075 alloy are strongly dependent on the quenching rate. Changes in the mechanical properties and microstructure reveal that only at lower cooling rate this alloy is prone to the formation of precipitate-free zones (PFZs) in the vicinity of grain boundaries. Eventually, the PFZs deteriorate mechanical properties of this alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Friction Stir Processing on the Microhardness, Wear and Corrosion Behavior of Al6061 and Al6061/SiO{sub 2} Nanocomposites

An effect of the friction stir processing (FSP), its pass numbers and addition of the SiO{sub 2} nanoparticles on microhardness, wear behavior and corrosion performance of the Al6061 aluminum alloy was investigated. Scanning electron microscopy (SEM) and optical microscopy were utilized to characterize the microstructure of the alloy, FSPed and composite samples. SEM observations revealed that the SiO{sub 2} particles were not uniformly dispersed in the matrix after two passes of FSP. However, increasing the pass number more than two passes resulted in a great improvement in the distribution of the SiO{sub 2} particles. The application of FSP led to overall softening compared to the base metal. Softening of the Al6061 alloy was probably attributed to the coarsening of Mg{sub 2}Si. Corrosion resistance of the FSPed samples found a significant reduction compared to the base metal. Applying higher pass number of the process and also addition of the SiO{sub 2} nanoparticles improved the wear behavior of the samples.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of FSW Repairing Process on the Microstructures and Mechanical Properties of Friction Stir-Welded 6082Al Alloy

When two 42-mm 6082Al plates were welded by friction stir welding (FSW), a discontinuously distributing groove defect is formed on the surface of the joint. Subsequently, the FSW repairing process was conducted at the defect location. The influence of the repairing process on the microstructures and mechanical properties of the joints were studied, and a description of the softening mechanism of the repaired joints is provided. The results show that TMAZ at the advance side is the weakest zone of the as-welded joints. The repairing process increases the heat input into the joints and thus promotes the coarsening and transformation of the precipitates in the joints, which further weakens the repaired joints. The average tensile strength of the joints repaired with a 24-mm pin is 205 MPa, which is 91% of that of the as-welded joint. The tensile strength generally increases when the size of the repaired pin decreases. The average tensile strength of the joints repaired with an 8-mm pin is 220 MPa, which is equivalent to the initial joints.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Flow Patterns, Microstructure and Mechanical Properties of AZ31/Al6061 Dissimilar Friction Stir-Welded Joints

Dissimilar joints between die-cast AZ31 and extruded Al6061-T6 were joined using friction stir welding technology at a constant transverse speed (50 mm/min) and rotation rate of 800 or 1000 rpm. The flow patterns, microstructure evolution and intermetallic compounds in dissimilar joints were studied by optical and scanning electron microscopy. The relationship between microstructure and tensile properties was analyzed. The microhardness distribution along the horizontal centerline in cross section was investigated. Local flow without obvious mixing existed between Mg and Al metals in the tool shoulder-affected zone. For the tool-pin-affected zone, two typical zones, namely, the “extrusion zone” and “flow zone” existed because of the different flow modes of the plastic metals. The phase analysis showed that intermetallic compounds, including Al{sub 12}Mg{sub 17} and Al{sub 3}Mg{sub 2} formed in banded structures. Phase analysis showed that a joint with welding parameters of 800 rpm and 50 mm/min (Joint-500) had good mechanical properties because of the more uniform microstructure distribution and fewer intermetallic compounds. Fracture analysis indicated some microvoids and lamellate intermetallic compounds in the fracture surface of the joint with welding parameters of 1000 rpm and 50 mm/min (Joint-1000), which deteriorated its tensile strength significantly.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Refill Friction Stir Spot Welding Dissimilar Al/Mg Alloys

Dissimilar Al/Mg alloys were joined by refill friction stir spot welding (RFSSW) in this work. The effect of sleeve plunge depth on microstructure and mechanical properties of the joints was studied. The results showed that sound joint can be obtained at sleeve plunge depth of 2.4 mm. Intermetallic compounds (IMCs) layer, formed by the liquid eutectic phase, were observed at both the sleeve-affected zone and joint center. The IMC at the pin-affected zone was thicker than that at the sleeve-affected zone because of its flow characteristic. Less liquid eutectic phase formed during RFSSW when joint using Mg as the upper sheet because the oxide layer on the Al sheet was hard to break, resulting to thinner IMC layer. The maximum load of 3.6 kN was obtained at 2.6 mm when the Al alloys served as the upper sheet, and the maximum failure of 3.6 kN was also obtained at 2.4 mm when the Mg alloys served as the upper sheet. The RFSSW joint presented shear fracture mode. The XRD patterns showed that the IMC of Al{sub 3}Mg{sub 2} and Al{sub 12}Mg{sub 17} formed inside the joint.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A Weighting Grade-Based Optimization Method for Determining Refill Friction Stir Spot Welding Process Parameters

The welding process used in fabricating thin-walled structures by refill friction stir spot welding (RFSSW) should be characterized by a high strength of welds and high process repeatability which is demonstrated by a small dispersion of the load capacity of the joints. The present work is designed to optimize RFSSW process parameters for 7075-T6 Alclad aluminum alloy sheets used to fabricate aircraft structures. The optimization was performed by scalarization of the objective function using the weighting grades method. The study considers the effect of process parameters, i.e., tool plunge depth, duration of welding, tool rotational speed, on the tensile/shear strength of the joints, and dispersion of the load capacity. It was found that it was possible to choose the optimal welding parameters taking into account maximization of the load capacity and minimization of the dispersion of the joint strength via a best compromise between the tool rotational speed ensuring adequate plasticization of the base material and the duration of welding ensuring that a fine-grained joint microstructure is obtained.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Friction Stir Lap Welding 0.8-mm-Thick 2024 Aluminum Alloy with the Assistance of Stationary Shoulder

In this work, 0.8-mm-thick 2024 aluminum alloy was friction stir lap welded with the assistance of a stationary shoulder system. The joint surface formation, microstructure and mechanical properties of the welded joints were studied. The results showed that sound joints without defect could be obtained at a wide parameter range because stationary shoulder increased the material flow during welding. The stationary shoulder decreased the joint roughness from 125.5 to 58.9 µm. A thickness reduction of 4% was achieved at a welding speed of 200 mm/min. The joint fabricated by the stationary shoulder system had superior lap shear properties compared to the joint fabricated using the conventional tool. A high failure load of 7440 N was achieved at welding speed of 200 mm/min. The joint presented tensile fracture mode and the fracture morphology showed typical ductile fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Temperature and Material Flow Prediction in Friction-Stir Spot Welding of Advanced High-Strength Steel

Friction-stir spot welding (FSSW) has been shown to be capable of joining advanced high-strength steel, with its flexibility in controlling the heat of welding and the resulting microstructure of the joint. This makes FSSW a potential alternative to resistance spot welding if tool life is sufficiently high, and if machine spindle loads are sufficiently low that the process can be implemented on an industrial robot. Robots for spot welding can typically sustain vertical loads of about 8 kN, but FSSW at tool speeds of less than 3000 rpm cause loads that are too high, in the range of 11–14 kN. Therefore, in the current work, tool speeds of 5000 rpm were employed to generate heat more quickly and to reduce welding loads to acceptable levels. Si3N4 tools were used for the welding experiments on 1.2-mm DP 980 steel. The FSSW process was modeled with a finite element approach using the Forge* software. An updated Lagrangian scheme with explicit time integration was employed to predict the flow of the sheet material, subjected to boundary conditions of a rotating tool and a fixed backing plate. Material flow was calculated from a velocity field that is two-dimensional, but heat generated by friction was computed by a novel approach, where the rotational velocity component imparted to the sheet by the tool surface was included in the thermal boundary conditions. An isotropic, viscoplastic Norton-Hoff law was used to compute the material flow stress as a function of strain, strain rate, and temperature. The model predicted welding temperatures to within percent, and the position of the joint interface to within 10 percent, of the experimental results.

Miles, Michael↗