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At least 451 records · Page 25

Formation mechanisms of periodic longitudinal microstructure and texture patterns in friction stir welded magnesium AZ80

Many studies of friction stir welding have shown that periodicity of metal flow around the tool pin may result in the formation of periodic differences in microstructure and texture in the weld nugget area correlated with the weld pitch. The current work investigates the periodicity of magnesium weld microtexture in the nugget region and its association with material flow using optical and electron microscopy. Two welds created in AZ80 at different processing conditions are presented in detail, one illustrating periodic longitudinal texture change, and one showing for the first time that periodic variations in texture, grain size, or composition are not defining features of periodic nugget flow. While nugget texture is dominated by shear deformation, it was found here to be affected to a lesser degree by compaction of material behind the welding tool, which led to reduction in intensity of the shear texture fiber. The decreased tendency for magnesium based alloys to form periodic patterns as compared to aluminum based alloys is explained with reference to the shear textures. - Highlights: •It is shown here that periodic material flow in the nugget does not necessitate longitudinal texture patterns. •Longitudinal texture patterns are shown to be present or absent in Mg AZ80 based on processing conditions. •Texture in the nugget is mainly dictated by shear deformation, but has measurable effects from other deformation modes. •Explanation of why longitudinal texture change is frequently reported in aluminum but not magnesium alloys is provided. •A new vector visualization of material flow based on EBSD data analysis is shown.

36 MATERIALS SCIENCE↗

Friction stir welded AM50 and AZ31 Mg alloys: Microstructural evolution and improved corrosion resistance

One of the major drawbacks of Mg alloys is poor weldability, caused by porosity formation during conventional fusion welding processes. Friction Stir Welding (FSW) is promising technique in this context since it is a solid state technique. Contradicting results were published in the literature regarding the FSWed Mg alloys joint's properties. Current research was performed in order to investigate the microstructure and corrosion properties of FSWed Mg alloys, studying representatives of two commercial families: wrought AZ31-H24 and die cast AM50. It was found that in both alloys recrystallization occurred during the FSW. In AM50 the mechanism of the recrystallization was continuous, manifested by dislocation rearrangement into sub grain boundaries. In AZ31 discontinuous recrystallization had occurred through grain boundaries migration - twins rotated with respect to the matrix, turning into low angle grain boundaries. Corrosion resistance has improved during the FSW in both alloys to different extents. In the AM50 alloy, the nugget exhibited significantly higher surface potential than the base metal mainly due to the higher Al concentration in the matrix of the nugget, resulting from the dissolution of Al-enrichment and β-Mg{sub 17}Al{sub 12} phase. In the AZ31 alloy, no change in Al concentration had occurred, and the surface potential measured in the nugget was only slightly higher than in the base metal. These results underline the appropriateness of the FSW for Mg alloys since during the conventional welding deterioration of the corrosion resistance occurs. - Highlights: • Following FSW, AZ31-H24 experienced discontinuous recrystallization. • In AZ31 grain boundaries migration occurred, thus twins rotated. • In die cast AM50 continuous recrystallization occurred during the FSW. • In AM50 - dislocations rearranged into sub grain boundaries. • Corrosion resistance has improved during the FSW in both alloys to different extent.

36 MATERIALS SCIENCE↗

Effects of friction stir processing and minor Sc addition on the microstructure, mechanical properties, and damping capacity of 7055 Al alloy

Highlights: • Good mechanical and damping properties were obtained in the 7055 after FSP and Sc addition. • The strengthening and damping mechanisms of FSP 7055(-Sc) were analyzed. • FSP and Sc addition were found to be strategy of preparing 7xxx alloys with well damping and mechanical properties. - Abstract: This study investigated the effects of friction stir processing (FSP) and addition of 0.25% (mass ratio) Sc on the microstructure, mechanical properties, and damping capacity of AA 7055 alloy. Microstructure analyses revealed that a low tool rotation rate of 300 rpm effectively inhibited the grain coarsening in the recrystallization of the alloy during FSP. Sc addition prevented the coarsening of grains and precipitated η phase and the annihilation of dislocations in the FSP AA 7055 alloy. After being subjected to FSP at 300 rpm, the AA 7055 alloy containing Sc exhibited good mechanical and damping properties, which were mainly attributed to the fine recrystallized grain structure, fine precipitated η phase, and large number of nano-sized Al{sub 3}(Sc, Zr) particles located at the grain boundaries and dislocations. This work provides an effective strategy for preparing commercial Al alloys with excellent damping capacity and mechanical properties.

36 MATERIALS SCIENCE↗

High damping capacity of Al alloys produced by friction stir processing

Highlights: • The damping capacity of age/non-age hardened Al alloys can be improved by FSP with low rotation rates. • The damping capacity of the FSP samples decreased with increasing the grain size, and did not depend on the alloy type. • This work suggests the potential of fabricating commercial Al alloys with good damping properties by FSP. - Abstract: Friction stir processing (FSP) was performed on both age-hardened and non-age-hardened Al alloys, with excellent damping properties obtained. The improved room temperature damping capacity of the FSP Al alloys can be mainly attributed to their low amount of solute atoms and the uniform distribution and high density of incoherent phases. The FSP Al alloys also exhibited improved high temperature damping capacity due to their equiaxed grain structure. The grain refinement and grain boundary pinning phase can further optimize the damping property of the FSP Al alloys. This work provides an effective strategy to improve the damping capacity of commercial Al alloys, which are regarded as low damping materials.

36 MATERIALS SCIENCE↗

Microstructure evolution in the conventional single side and bobbin tool friction stir welding of thick rolled 7085-T7452 aluminum alloy

Highlights: • Comparison of microstructure evolution via EBSD of SS-FSW and BB-FSW was investigated. • Friction heat, strain rate and degree of recrystallization affected grain size. • Discontinuously dynamic recrystallization occurred in the weld nugget zone. • The degree of recrystallization was mainly controlled by the strain rate. - Abstract: The microstructure evolution during the conventional single side friction stir welding (SS-FSW) and the bobbin tool FSW (BB-FSW) of 7085-T7452 alloy thick plate was extensively studied by using the state-of-the-art materials characterization techniques. The Electron backscattering diffraction results reveal that a significant grain refinement and a larger percentage of high angle grain boundaries (HAGBs) exist in the weld nugget zone (WNZ) and the thermal-mechanical affected zone (TMAZ) compared with the base material. Meanwhile, more obviously inhomogeneous refined grains and HAGBs in WNZ along the thickness direction and a larger percentage of low angle grain boundaries (LAGBs) were observed in SS-FSW joint than that in BB-FSW joint. The change of the average grain size is the result of friction heat and strain rate of plastic deformation combined with a certain degree of recrystallization. Moreover, the recrystallization is mainly controlled by the strain rate during the FSW process. The presence of Cube and Cube ND after welding shows that the discontinuously dynamic recrystallization (DDRX) is a major factor in the final microstructural response. The research and findings help the understanding of the mechanism of microstructure homogenization and further optimizing the welding process for application.

36 MATERIALS SCIENCE↗

Development of microstructure and texture during single and multiple pass friction stir processing of a strain hardenable aluminium alloy

Highlights: • Development of microstructure and texture during single and multiple pass FSP of a strain hardenable aluminium alloy • Strain induced boundary migration (SIBM) is the dominant nucleation mechanism for recrystallization • Weak crystallographic texture development influenced by SIBM with the relative dominance of shear texture components • Stable microstructure and texture development after multiple pass FSP • FSP is a promising method for the secondary processing of strain hardenable aluminium alloys - Abstract: In the present study, microstructure and texture development during single and multiple pass friction stir processing (FSP) of a strain hardenable wrought AlMg alloy (AA5086) was investigated. Subtle differences were observed while comparing with heat treatable alloys in the nucleation mechanism of the recrystallized microstructure observed in the nugget zone. Strain induced boundary migration was the dominant mechanism of microstructure evolution in the alloy, which influenced the crystallographic texture development by weakening it. Micro-texture measurements reveal variations in the crystallographic texture along the thickness of the sample. Recrystallization texture components were observed in the nugget zone indicative of a pronounced static recrystallization in the alloy as compared to the heat treatable alloys. Bulk texture measurements within the nugget zone of the optimally processed sample reveal a relatively dominant C component of shear texture. Average grain size in the nugget zone remained the same and the bulk crystallographic texture components were retained during multiple-pass FSP. The lower strain energies involved and the enhanced recovery processes due to the high temperature materials processing of the alloy during FSP resulted in a stable microstructure and texture. In summary, FSP could be promoted as a competent and suitable secondary processing technique for the bulk production of ultra-fine-grained materials in strain hardenable aluminium alloys.

36 MATERIALS SCIENCE↗

Effects of in-process cryocooling on metallurgical and mechanical properties of friction stir processed Al7075 alloy

Highlights: • For in-process cryocooling (IPC) during FSP, an efficient cooling fixture was designed & fabricated. • FSP of Al7075 alloy with IPC setup suppressed precipitate coarsening as well as grain growth. • Nanosize η′ precipitates (20–30 nm) in IPC condition increased work hardening capacity & strength. • Simultaneous improvement in ductility & strength occurred for sample FSPed with IPC. - Abstract: Friction stir processing (FSP) of heat treatable aluminum alloys is reported to deteriorate strength and hardness properties in spite of huge grain size refinement. The improvement in strength due to the grain size refinement after FSP could not be able to offset the reduction in strength due to coarsening or dissolution of the strengthening precipitate(s). To overcome this, the present work investigates an effective way of heat rejection from the FSP zone to control the precipitate evolution besides the grain size refinement during FSP of Al7075 alloy. The FSP was carried out with standardized process parameters (i.e. 720 rpm, 65 mm/min traverse speed) under two different cooling environments: (i) at normal air cooling and (ii) by rushing a chilled mixture (−30 °C) of liquid nitrogen and methanol through the bottom of the backing plate. Microstructural evolution was examined through optical, scanning and transmission electron microscopy and electron backscatter diffraction to confirm the grain size and morphology of precipitate(s) formed. The in-process cryocooling during the FSP led to 65 and 72% improvement in the Vickers hardness and tensile strength, respectively, in comparison to the solutionized base metal. The results have been analyzed in terms of precipitate interface characteristics and its strengthening effect, Hall–Petch strengthening due to grain size reduction and tradeoff between them.

36 MATERIALS SCIENCE↗

Effect of niobium interlayer in dissimilar friction stir welding of aluminum to titanium

Highlights: • In the present study, FSW of Al to Ti with Nb interlayer has been characterized. • Fragmentation and distribution of Nb and Ti have been correlated with properties. • Ternary mixing and chemical reaction reduced the brittleness of the joint. • Al in the weld nugget showed a gradient in microstructural features. • The weld with Nb interlayer exhibited higher ductility. - Abstract: The most important issue associated with dissimilar welding is the formation of detrimental intermetallics and consequent reduction in mechanical properties of the weld. It was expected that addition of an interlayer would modify the pattern of the intermetallic formation. The present investigation deals with Friction Stir Welding of aluminum (Al) to titanium (Ti) in presence of niobium (Nb) interlayer. X-ray Computed Tomography results highlighted that fine particles of both Ti and Nb are homogeneously distributed. Large Ti particles are substantially fragmented whereas large Nb particles remain as flakes. Microstructural features of the nugget zone indicated a complex mixing of materials. Jointing had been perceived through elemental diffusion at the interfaces of Al/Ti and Ti/Nb. However, Nb restricted the reaction between Al and Ti, and acted as an efficient interlayer to retard the formation of brittle Al{sub 3}Ti intermetallic phase. Mechanisms of microstructural evolution in Al side of the weld have been identified as Dynamic Recovery, Dynamic Recrystallization and particle stimulated nucleation. Significant improvement in the tensile ductility had been observed due to the presence of finer particles. The presence of Nb in the weld nugget influences the microstructural evolution and tensile properties of the weld by reducing the formation of intermetallics.

36 MATERIALS SCIENCE↗

Methanol oxidation up to 100 atm in a supercritical pressure jet-stirred reactor

Methanol (CH 3 OH) has attracted considerable attention as a renewable fuel or fuel additive with low greenhouse gas emissions. Methanol oxidation was studied using a recently developed supercritical pressure jet-stirred reactor (SP-JSR) at pressures of 10 and 100 atm, at temperatures from 550 to 950 K, and at equivalence ratios of 0.1, 1.0, and 9.0 in experiments and simulations. Here, the experimental results show that the onset temperature of CH 3 OH oxidation at 100 atm is around 700 K, which is more than 100 K lower than the onset at 10 atm and this trend cannot be predicted by the existing kinetics models. Furthermore, a negative temperature coefficient (NTC) behavior was clearly observed at 100 atm at fuel rich conditions for methanol for the first time. To understand the observed temperature shift in the reactivity and the NTC effect, we updated some key elementary reaction rates of relevance to high pressure CH 3 OH oxidation from the literature and added some new low-temperature reaction pathways such as CH 2 O + HO 2 = HOCH 2 O 2 (RO 2 ), RO 2 + RO 2 = HOCH 2 O (RO) + HOCH 2 O (RO) + O 2 , and CH 3 OH + RO 2 = CH 2 OH + HOCH 2 O 2 H (ROOH). Although the model with these updates improves the prediction somewhat for the experimental data at 100 atm and reproduces well high-temperature ignition delay times and laminar flame speed data in the literature, discrepancies still exist for some aspects of the 100 atm low-temperature oxidation data. In addition, it was found that the pressure-dependent HO 2 chemistry shifts to lower temperature as the pressure increases such that the NTC effect at fuel-lean conditions is suppressed. Therefore, as shown in the experiments, the NTC phenomenon was only observed at the fuel-rich condition where fuel radicals are abundant and the HO 2 chemistry at high pressure is weakened by the lack of oxygen resulting in comparatively little HO 2 formation.

33 ADVANCED PROPULSION SYSTEMS↗

Performance evaluation of a completely stirred anaerobic reactor treating pig manure at a low range of mesophilic conditions

Highlights: • The biogas process can run stably at 20 °C at extremely low OLR after long-term acclimation of bacteria. • A biogas plant running at 28 °C seems as efficient as that operated at 38 °C at low OLR of 1.3 g ODM L{sup −1} d{sup −1}. • Lower temperature operation is inadvisable for the commercial biogas plant running at rather high OLR. • The estimated sludge yield at 28 °C is higher than that at 38 °C. - Abstract: Many Chinese biogas plants run in the lower range of mesophilic conditions. This study evaluated the performance of a completely stirred anaerobic reactor treating pig manure at different temperatures (20, 28 and 38 °C). The start-up phase of the reactor at 20 °C was very long and extremely poor performance was observed with increasing organic loading rate (OLR). At an OLR of 4.3 g ODM L{sup −1} d{sup −1}, methane production at 28 °C was comparable (3% less) with that at 38 °C, but the risk of acidification was high at 28 °C. At low OLR (1.3 g ODM L{sup −1} d{sup −1}), the biogas process appeared stable at 28 °C and gave same methane yields as compared to the reactor operating at 38 °C. The estimated sludge yield at 28 °C was 0.065 g VSS g{sup −1} COD{sub removed,} which was higher than that at 38 °C (0.016 g VSS g{sup −1} COD{sub removed})

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Nitrification in a completely stirred tank reactor treating the liquid phase of digestate: The way towards rational use of nitrogen

Highlights: • Nitrification of digestate liquid phase was simulated in a laboratory scale. • The attention was paid mainly to rationale use of nitrogen. • Nitrate was produced immediately after the process initiation. • Ammonia oxidation rate reached up to 0.59 kg/(m{sup 3} d). • The operation of the system was effectively optimized by pH control. - Abstract: The nitrification of the liquid phase of digestate (LPD) was conducted using a 5 L completely stirred tank reactor (CSTR) in two independent periods (P1 – without pH control; P2 – with pH control). The possibility of minimizing nitrogen losses during the application of LPD to the soil as well as during long-term storage or thermal thickening of LPD using nitrification was discussed. Moreover, the feasibility of applying the nitrification of LPD to the production of electron acceptors for biological desulfurization of biogas was assessed. Despite an extremely high average concentration of ammonia and COD in LPD reaching 2470 and 9080 mg/L, respectively, nitrification was confirmed immediately after the start-up of the CSTR. N-NO{sub 3}{sup −} concentration reached 250 mg/L only two days after the start of P1. On the other hand, P1 demonstrated that working without pH control is a risk because of the free nitrous acid (FNA) inhibition towards nitrite oxidizing bacteria (NOB) resulting in massive nitrite accumulation. Up to 30.9 mg/L of FNA was present in the reactor during P1, where the NOB started to be inhibited even at 0.15 mg/L of FNA. During P2, the control of pH at 7.0 resulted in nitrogen oxidation efficiency reaching 98.3 ± 1.5% and the presence of N-NO{sub 3}{sup −} among oxidized nitrogen 99.6 ± 0.4%. The representation of volatile free ammonia within total nitrogen was reduced more than 1000 times comparing with raw LPD under these conditions. Thus, optimum characteristics of the tested system from the point of view of minimizing the nitrogen losses as well as production of electron acceptors for the desulfurization of biogas were gained in this phase of reactor operation. Based on the results of the experiments, potential improvements and modifications of the tested system were suggested.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Rapid surface hardening and enhanced tribological performance of 4140 steel by friction stir processing

Tribological performance of steel materials can be substantially enhanced by various thermal surface hardening processes. For relatively low-carbon steel alloys, case carburization is often used to improve surface performance and durability. If the carbon content of steel is high enough (>0.4%), thermal treatments such as induction, flame, laser, etc. can produce adequate surface hardening without the need for surface compositional change. This paper presents an experimental study of the use of friction stir processing (FSP) as a means to hardened surface layer in AISI 4140 steel. The impacts of this surface hardening process on the friction and wear performance were evaluated under both dry and lubricated contact conditions in reciprocating sliding. FSP produced the same level of hardening and superior tribological performance when compared to conventional thermal treatment, using only 10% of the energy and without the need for quenching treatments. With FSP surface hardness of about 7.8 GPa (62 Rc) was achieved while water quenching conventional heat treatment produced about 7.5 GPa (61 Rc) hardness. Microstructural analysis showed that both FSP and conventional heat treatment produced martensite. Although the friction behavior for FSP treated surfaces and the conventional heat treatment were about the same, the wear in FSP processed surfaces was reduced by almost 2× that of conventional heat treated surfaces. Furthermore, the superior performance is attributed to the observed grain refinement accompanying the FSP treatment in addition to the formation of martensite. As it relates to tribological performance, this study shows FSP to be an effective, highly energy efficient, and environmental friendly (green) alternative to conventional heat treatment for steel.

36 MATERIALS SCIENCE↗

Effect of Iron(II) on Arsenic Sequestration by δ-MnO 2 : Desorption Studies Using Stirred-Flow Experiments and X-Ray Absorption Fine-Structure Spectroscopy

Arsenic (As) mobility in the environment is greatly affected by its oxidation state and the degree to which it is sorbed on metal oxide surfaces. Manganese (Mn) and iron (Fe) oxides are ubiquitous solids in terrestrial systems and have high sorptive capacities for many trace metals, including As. Although numerous studies have studied the effects of As adsorption and desorption onto Fe and Mn oxides individually, the fate of As within mixed systems representative of natural environments has not been resolved. In this research, As(III) was initially reacted with a poorly crystalline phyllomanganate (δ-MnO 2 ) in the presence of Fe(II) prior to desorption. This initial reaction resulted in the sorption of both As(III) and As(V) on mixed Fe/Mn-oxides surfaces. A desorption study was carried out using two environmentally significant ions, phosphate (PO 4 3– ) and calcium (Ca 2+ ). Both a stirred-flow technique and X-ray absorption fine-structure spectroscopy (XAFS) analysis were used to investigate As desorption behavior. Results showed that when As(III)/Fe(II) = 1:1 in the initial reaction, only As(V) was desorbed, agreeing with a previous study showing that As(III) is not associated with the Fe/Mn-oxides. When As(III)/Fe(II) = 1:10 in the initial reaction, both As(III) and As(V) can be desorbed from the Fe/Mn-oxide surface, and more As(III) is desorbed than As(V). Neither of the desorbents used in this study completely removed As(III) or As(V) from the Fe/Mn-oxides surface. However, the As desorption fraction decreases with increasing Fe(II) concentration in the initial reactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Interfacial reaction during friction stir assisted scribe welding of immiscible Fe and Mg alloy system

We report on interfacial characteristics and chemistry of bonded Mg-Fe interfaces welded using friction stir assisted scribe technique (FaST). Two pairs of dissimilar joints: (AZ31-DP590) and (Pure Mg-DP590) were studied to shed light on joining mechanisms responsible for bonding of “immiscible” pairs of Mg and Fe. We present first direct experimental evidence of presence of oxide layer, Al segregation by atom probe tomography and nano steel grains close to interface by transmission electron microscopy study.

36 MATERIALS SCIENCE↗

Co-introduction of precipitate hardening and TRIP in a TWIP high-entropy alloy using friction stir alloying

Tuning deformation mechanisms is imperative to overcome the well-known strength-ductility paradigm. Twinning-induced plasticity (TWIP), transformation-induced plasticity (TRIP) and precipitate hardening have been investigated separately and have been altered to achieve exceptional strength or ductility in several alloy systems. In this study, we use a novel solid-state alloying method—friction stir alloying (FSA)—to tune the microstructure, and a composition of a TWIP high-entropy alloy by adding Ti, and thus activating site-specific deformation mechanisms that occur concomitantly in a single alloy. During the FSA process, grains of the as-cast face-centered cubic matrix were refined by high-temperature severe plastic deformation and, subsequently, a new alloy composition was obtained by dissolving Ti into the matrix. After annealing the FSA specimen at 900 °C, hard Ni–Ti rich precipitates formed to strengthen the alloy. An additional result was a Ni-depleted region in the vicinity of newly-formed precipitates. The reduction in Ni locally reduced the stacking fault energy, thus inducing TRIP-based deformation while the remaining matrix still deformed as a result of TWIP. Our current approach presents a novel microstructural architecture to design alloys, an approach that combines and optimizes local compositions such that multiple deformation mechanisms can be activated to enhance engineering properties.

36 MATERIALS SCIENCE↗

Features of the microstructure development under conditions, reproducing the process of friction stir welding. Molecular-dynamics study

Friction stir welding is a recently developed technology which is used in various branches of modern engineering. The basis of this technology is the friction of the rotating cylindrical or specially shaped tool between two metal plates brought together either to meet their ends of one above another with the overlap. When applying the FSW process in various economical sectors, the important task is to study the mechanisms and identify the physical laws and factors leading to formation of structural inhomogeneities and discontinuities in the weld seam. This paper analyzes the basic mechanisms behind the structural state generation in the material subjected to severe plastic deformation and heating. To investigate the atomic mechanisms of structural changes in FSW, the modeling at atomic scale has been carried out. Results of work can be a basis for new knowledge about the microstructure evolution in FSW.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Radiographic detection of defects in friction stir welding on aluminum alloy AMg5M

In order to reveal weld defects specific to friction stir welding we undertook radiographic inspection of AMg5M aluminum alloy welded joints. Weld defects in the form of voids have been revealed in the weld obtained under the non-optimal rotation and feed rate. Both shape and size of these defects have been confirmed by examining metallographically successive sections prepared in the weld plane as well as in the plane transversal to the tool feed direction. Linear defects have been also found in the sections that are not seen in the radiographic images. Both the preferable localization and origination of the defects have been analyzed.

36 MATERIALS SCIENCE↗

The microstructure of aluminum A5083 butt joint by friction stir welding

This study presents the microstructure of the aluminum A5083 butt joint surface after it has been joined by friction stir welding (FSW) process. The FSW process is a unique welding method because it will not change the chemical properties of the welded metals. In this study, MILKO 37 milling machine was modified to run FSW process on 4 mm plate of aluminum A5083 butt joint. For the experiment, variables of travel speed and tool rotational speed based on capability of machine were used to run FSW process. The concentrated heat from the tool to the aluminum plate changes the plate form from solid to plastic state. Two aluminum plates is merged to become one plate during plastic state and return to solid when concentrated heat is gradually further away. After that, the surface and cross section of the welded aluminum were investigated with a microscope by 400 x multiplication zoom. The welding defect in the FSW aluminum was identified. Then, the result was compared to the American Welding Society (AWS) FSW standard to decide whether the plate can be accepted or rejected.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗