The Effect of Concurrent Straining on Phase Transformations in NiAl Bronze During the Friction Stir Processing Thermomechanical Cycle

Equivalent strains up to a value of ≈2.7 were determined by evaluation of the shape changes of the phases in a duplex α(fcc)/β(bcc) microstructure formed ahead of the pin tool extraction site during the friction stir processing (FSP) thermomechanical cycle in a cast NiAl bronze alloy. Correlation of the local strains with volume fractions of the various microstructure constituents in this alloy shows that the concurrent straining of FSP results in acceleration of the α + β → β reaction in the thermomechanically affected zone (TMAZ) ahead of the pin extraction site. The resulting volume fraction of β (as determined by the volume fraction of its transformation products formed during post-FSP cooling) corresponds closely to the volume fraction expected for the peak stir zone temperature measured separately by means of thermocouples embedded within the tool pin profile along the tool path. The stir zone (SZ) in this material exhibits near-equilibrium microstructures despite brief dwells near the peak temperature (T _peak ≈ 0.95T _melt), reflecting large local strains and strain rates associated with this process.     

Microstructure and Texture Evolution during Single- and Multiple-Pass Friction Stir Processing of Heat-Treatable Aluminum Alloy 2024

Microstructure and crystallographic texture evolution during single- and multiple-pass friction stir processing (FSP) of an age-hardenable aluminum alloy 2024 (Al-Cu-Mg) was investigated. Multiple-pass experiments were carried out using two different processing strategies, multi-pass FSP, and multi-track FSP. Effect of a post-FSP heat treatment above and below the solutionizing temperature of the alloy was also studied. FSP experiments were carried out using an optimal set of parameters. Characterization tools used in the study include scanning electron microscopy (SEM), electron back-scattered diffraction (EBSD), electron probe micro-analyser (EPMA), and X-ray diffraction (XRD). Microstructural features indicate the occurrence of particle stimulated nucleation (PSN) assisted dynamic recrystallization (DRX) as the dominant microstructural evolution mechanism in the nugget zone. Geometrical coalescence occurred, leading to the formation of some larger grains in the nugget zone. Heterogenous micro-texture distribution was observed in the nugget zone with the bulk textures consisting of FCC shear texture components dominated by A ₁*/A ₂* and C. Microstructure and texture in the nugget zone remained stable after both routes of multiple-pass processing, demonstrating the possibility of FSP to produce bulk volume of fine-grained materials. Post-FSP heat treatment indicated the stability of microstructure and texture up to 723 K (450 °C) owing to relatively lower strain energies retained after FSP.

     

A New Strategy for Preparation of NiAl Bronze/Zn Composite by Friction Stir Processing

In this work, we successfully prepared a NAB/Zn composite using Zn wires by friction stir processing (FSP). During FSP, Zn-containing α matrix and (Fe, Ni)Al phases and nano α and CuZn grains with the size of less than 10 nm are formed on the top surface. The average microhardness of the composite is increased by 15 pct compared with the alloy without Zn, which originates from fine grains, CuZn particles strengthening, and more β′ phase.

     

Effect of Process Parameters on Microstructure and Mechanical Properties in Friction Stir Welding of Aluminum Alloy

Friction stir welding process is a promising solid state joining process with the potential to join low melting point materials, particularly aluminum alloys. The most attractive reason for this is the avoidance of solidification defects formed during conventional fusion welding processes. Tool rotational speed and the welding speed play a major role in deciding the weld quality. In the present work an effort has been made to study the effect of the tool rotational speed and welding speed on mechanical and metallurgical properties of friction stir welded joints of aluminum alloy AA6082-T651. The micro hardness profiles obtained on welded zone indicate uniform distribution of grains in the stir zone. The maximum tensile strength obtained is 263 MPa which is about 85% of that of base metal. Scanning electron microscope was used to show the fractured surfaces of tensile tested specimens.     

The Microstructure,Texture and Mechanical Properties of Friction Stir Welded Aluminum Alloy

Russian Journal of Non-Ferrous Metals - The microstructure and texture of 7075-T6 FSW weld with optimal parameters are investigated using optical microscopy, electron back scatter diffraction and...     

Friction Stir Processing of Investment-Cast Ti-6Al-4V: Microstructure and Properties

Investment-cast titanium components are becoming increasingly common in the aerospace industry due to the ability to produce large, complex, one-piece components that were previously fabricated by mechanically fastening multiple pieces together. The fabricated components are labor-intensive and the fastener holes are stress concentrators and prime sites for fatigue crack initiation. The castings are typically hot-isostatically-pressed (HIP) to close internal porosity, but have a coarse, fully lamellar structure that has low resistance to fatigue crack initiation. The as-cast + HIP material exhibited 1- to 1.5-mm prior β grains containing a fully lamellar α + β microstructure consistent with slow cooling from above the β transus. Friction stir processing (FSP) was used to locally modify the microstructure on the surface of an investment-cast Ti-6Al-4V plate. Friction stir processing converted the as-cast microstructure to fine (1- to 2-μm) equiaxed α grains. Using micropillars created with a dual-beam focused ion beam device, it was found that the fine-grained equiaxed structure has about a 12 pct higher compressive yield stress. In wrought products, higher strength conditions are more resistant to fatigue crack initiation, while the coarse lamellar microstructure in the base material has better fatigue crack growth resistance. In combination, these two microstructures can increase the fatigue life of titanium alloy castings by increasing the number of cycles prior to crack initiation while retaining the same low-crack growth rates of the colony microstructure in the remainder of the component. In the current study, high-cycle fatigue testing of investment-cast Ti-6Al-4V was performed on four-point bend specimens. Early results show that FSP can increase fatigue strength dramatically. This article is based on a presentation given in the symposium entitled “Materials Behavior: Far from Equilibrium” as part of the Golden Jubilee Celebration of Bhabha Atomic Research Centre, which occurred December 15–16, 2006 in Mumbai, India.     

The Effect of Cu Powder During Friction Stir Welding on Microstructure and Mechanical Properties of AA3003-H18

Friction stir welding (FSW) was used to join 3003-H18 non-heat-treatable aluminum alloy plates by adding copper powder. The copper powder was first added to the gap (0.1 and 0.2 mm) between two plates and then the FSW was performed. The specimens were joined at various rotational speeds of 800, 1000, and 1200 rpm at traveling speeds of 70 and 100 mm/min. The effects of rotational speed, second pass of FSW, and direction of second pass also were studied on copper particle distribution and formation of Al-Cu intermetallic compounds in the stir zone. The second pass of FSW was carried out in two ways; in line with the first pass direction (2F) and in the reverse direction of the first pass (FB). The microstructure, mechanical properties, and formation of intermetallic compounds type were investigated. In high copper powder compaction into the gap, large clusters were formed in the stir zone, while fine clusters and sound copper particles distribution were obtained in low powder compaction. The copper particle distribution and amount of Al-Cu intermetallic compounds were increased in the stir zone with increasing the rotational speed and applying the second pass. Al₂Cu and AlCu intermetallic phases were formed in the stir zone and consequently the hardness was significantly increased. The copper particles and in situ intermetallic compounds were symmetrically distributed in both advancing and retreating sides of weld zone after FB passes. Thus, the wider area was reinforced by the intermetallic compounds. Also, the tensile test specimens tend to fracture from the coarse copper aggregation at the low rotational speeds. At high rotational speeds, the fracture locations are placed in HAZ and TMAZ.     

Effect of Neodymium on As-Cast Microstructure and Mechanical Properties of AZ31 Wrought Alloy

Nd in the form of powder or intermediate alloy was added to AZ31 wrought alloy. The as-obtained alloy was characterized and tested with respect to its microstructure and mechanical properties. The relationship between the microstructure, mechanical properties and tensile fracture mechanism were discussed, with relevant alloys as reference for comparison. Experimental results show that the same quantity of Nd was added into AZ31 in powder form or in intermediate alloy, the absorption rate of Nd reached only 10.8% for the former case and as high as 95% for the later case. Pure Nd powder was added, no new compound was detected, but it served as reductant and purified alloy melt, resulting in improving the tensile strength while Nd was added into AZ31 as Mg-Nd intermediate alloy. The compound Al2Nd and Mg12 Nd were formed in magnesium alloy, which were distributed in the matrix in the shapes of strip and particle, evidently refined the as-cast structure. The as-cast tensile strength (228MPa) of adding pure Nd powder approximated to the figure (245MPa) of adding Mg-Nd intermediate alloy. The tensile fracture mchanism of as-cast AZ31 transformed from cleavage fracture into quasi-cleavage fracture.     

Effect of Friction Stir Processing on Microstructure and Tensile Properties of an Investment Cast Al-7Si-0.6Mg Alloy

Friction stir processing (FSP) is emerging as a promising tool for microstructural modification. The current study assesses the effects of FSP on the microstructure and mechanical properties of an investment cast Al-7Si-Mg alloy. FSP eliminates porosity and significantly refines eutectic Si particles. The extent of particle refinement varied with changes in processing conditions. A high tool rotation rate and a low-to-intermediate tool traverse speed generated a higher volume fraction of finer particles. Tensile ductility changed significantly as a result of FSP, whereas ultimate tensile strength improved only marginally. Yield strength was similar in both cast and FSP samples under various heat-treated conditions, with the highest value obtained after a T6 heat treatment. Furthermore, FSP caused significant grain refinement in the stir zone, subsequently transforming into very coarse grains as abnormal grain growth occurred during solution treatment at high temperature.     

Friction Stir Welding in Wrought and Cast Aluminum Alloys: Weld Quality Evaluation and Effects of Processing Parameters on Microstructure and Mechanical Properties

Friction stir welding (FSW) is a solid-state process widely used for joining similar and dissimilar materials for critical applications in the transportation sector. Understanding the effects of the process on microstructure and mechanical properties is critical in design for structural integrity. In this study, four aluminum alloy systems (wrought 6061-T651 and cast A356, 319, and A390) were processed in both as-fabricated and pre-weld heat-treated (T6) conditions using various processing parameters. The effects of processing and heat treatment on the resulting microstructures, macro-/micro-hardness, and tensile properties were systematically investigated and mechanistically correlated to changes in grain size, characteristic phases, and strengthening precipitates. Tensile tests were performed at room temperature both along and across the welding zones. A new method able to evaluate weld quality (using a weld quality index) was developed based on the stress concentration calculated under tensile loading. Optimum processing parameter domains that provide both defect-free welds and good mechanical properties were determined for each alloy and associated with the thermal history of the process. These results were further related to characteristic microstructural features, which can be used for component design and materials/process optimization.     

Effects of Friction Stir Processing Parameters and In Situ Passes on Microstructure and Tensile Properties of Al-Si-Mg Casting

Friction stir processing (FSP) was applied to modify the microstructure of an as-cast A356 alloy. The effects of rotation rate, travel speed, in situ FSP pass, FSP direction, and artificial aging on microstructures and tensile properties were investigated. FSP broke up the coarse eutectic Si phase into 2.5 to 3.5 μm particles and distributed them homogeneously, and resulted in the dissolution of the coarse Mg₂Si particles and the elimination of porosity, thereby improving both the strength and the ductility of the casting. Increasing the rotation rate was beneficial to breaking up and dissolving the particles, but it contributed little to eliminating the porosity. The travel speed did not affect the size of the particles apparently, but lower speed was beneficial to eliminating the porosity. 2-pass FSP showed an obvious advantage in the microstructure modification and tensile properties compared with the single-pass. However, a further increase of FSP passes only resulted in slight improvement. The FSP direction of the following pass did not show distinct effect on the microstructure and tensile properties. After post-FSP artificial aging, the strengthening phase (β″-Mg₂Si) precipitated, which increased the strength and decreased the ductility of the FSP samples.     

Influence of Friction Stir Processing Parameters on the Microstructure of Aluminum Foams

In the present study, friction stir processing (FSP) has been used to fabricate aluminium foams. The effects of the number of FSP passes, FSP tool rotational speed, foaming time and temperature on the porosity have been investigated. Aluminium foam with porosity up to 40% was successfully fabricated. In the samples foamed at 923 K (650 °C), a few irregular pores were produced as a result of high aluminium matrix stiffness in this temperature. In general with increase in foaming temperature the porosity increased. However, in the samples foamed for 30 or 60 min, lower porosity was detected at higher foaming temperature. Also, in the samples which were produced with more FSP passes, the foaming time decreased and more uniform pore structure was obtained.     

A Review on Friction Stir Processing of Titanium Alloy: Characterization,Method, Microstructure,Properties

Metallurgical and Materials Transactions B - In the past two decades, friction stir processing (FSP) technology has received considerable attention. FSP can be used to adjust and control the...     

热处理温度对高强变形铝青铜的组织和力学性能的影响

针对一种新型高强变形铝青铜合金,考察了淬火温度和回火温度对该合金的微观组织和力学性能的影响。研究结果表明,淬火温度越高,合金内部的β'马氏体相越多,材料的硬度越高,但淬火温度过高时,由于针片状α相的出现,使材料的强度和塑性有较大下降。试验合金适宜的淬火温度为900℃。淬火态材料经低温回火,强度可进一步提高,400℃回火时材料的强度和硬度达到峰值,此后随着回火温度的升高,材料的强度和硬度逐渐下降,延伸率逐渐提高。600℃回火态材料的抗拉强度和延伸率分别达到900 MPa和17%以上,具有优良的强韧配合。     

6061铝合金搅拌摩擦焊接头组织与性能研究

采用搅拌摩擦焊方法(FSW)对6 mm厚的6061-T4铝合金板材进行对接,焊后利用光学显微镜(OM)和扫描电镜(SEM)分析、对比了焊接接头和母材的显微组织和断口形貌特征,并测试了其室温拉伸性能和显微硬度。实验结果表明:选择了适合于6061-T4铝合金板材搅拌摩擦焊的工艺参数:焊接时搅拌头旋转速度为1200 r.min-1,工件的进给速度为300 mm.min-1,在此参数下获得了与母材等强度、韧性接近于母材的焊接接头,为此种合金应用于汽车关键零部件提供了可靠的工艺方法。FSW板材接头焊核区的组织和性能明显优于其他区,热影响区是接头最薄弱的部分,焊核区的硬度最高,而热影响区的硬度最低,焊缝金属发生回复再结晶使晶粒细化。断口分析表明,断裂发生在热影响区,由于搅拌头的旋转运动和热量的累积,该区存在晶粒长大、组织粗化现象。对工艺参数的优化实验表明,搅拌头旋转速度与焊接速度对接头性能的影响存在一定的适配关系,通过工艺参数的调整可以有效地控制热影响区的焊缝组织和改善焊接接头的性能。细晶强化是搅拌摩擦焊接头强度与韧性提高的主要原因。     

超细晶Cu/AI异种材料搅拌摩擦焊组织与性能研究

超细晶材料综合性能优异,但组织热稳定性较差,焊接后接头组织容易发生异常长大,使其性能急剧下降。因此,合适的连接工艺对大尺寸超细晶结构件的应用具有重要工程意义。以超细晶铜、粗晶铝以及粗晶铜、粗晶铝作为结构母材,采用热输入量小的搅拌摩擦焊（FSW）工艺进行连接探索,系统观察了铜铝接头组织与性能。结果表明,超细晶铜与铝接头界面处元素互扩散能力较强,形成较多的Al4Cu9 金属间化合物;在焊接过程中,当搅拌头转速为1000 r/min,焊接速度为50 mm/min时,粗晶铜与铝接头硬度可达HV 211,超细晶铜与铝焊接接头可获得良好的力学性能。