Immersed friction stir welding of ultrafine grained accumulative roll-bonded Al alloy

In this research, ultrafine grained strips of commercial pure strain hardenable aluminum (AA1050) were produced by accumulative roll-bonding (ARB) technique. These strips were joined by friction stir welding (FSW) in immersed (underwater) and conventional (in-air) conditions to investigate the effect of the immersion method on the microstructure and mechanical properties of the joint, aiming to reduce the deterioration of the mechanical properties of the joint. Transmission electron microscopy and X-ray diffraction analyses were used to evaluate the microstructure, showing smaller grains and subgrains in the stir zone of the immersed FSW condition with respect to the conventional FSW method. The hardness and tensile properties of the immersed friction stir welded sample and ARBed base metal show more similarity compared to the conventional friction stir welded sample. Moreover, the aforementioned method can result in the enhancement of the superplasticity tendency of the material.     

Friction stir welding for the transportation industries

This paper will focus on the relatively new joining technology—friction stir welding (FSW). Like all friction welding variants, the FSW process is carried out in the solid-phase. Generically solid-phase welding is one of the oldest forms of metallurgical joining processes known to man. Friction stir welding is a continuous hot shear autogenous process involving a non-consumable rotating probe of harder material than the substrate itself. In addition, FSW produces solid-phase, low distortion, good appearance welds at relatively low cost. Essentially, a portion of a specially shaped rotating tool is plunged between the abutting faces of the joint. Once entered into the weld, relative motion between the rotating tool and the substrate generates frictional heat that creates a plasticised region around the immersed portion of the tool. The contacting surface of the shouldered region of the tool and the workpiece top contacting surface also generates frictional heat. The shouldered region provides additional friction treatment to the weld region as well as preventing plasticised material being expelled. The tool is then translated with respect to the workpiece along the joint line, with the plasticised material coalescing behind the tool to form a solid-phase joint as the tool moves forward. Although the workpiece does heat up during FSW, the temperature does not reach the melting point. Friction stir welding can be used to join most aluminium alloys, and surface oxide presents no difficulty to the process. Trials undertaken up to the present time show that a number of light weight materials suitable for the automotive, rail, marine, and aerospace transportation industries can be fabricated by FSW.     

Effect of initial grain size on the joint properties of friction stir welded aluminum

In this study, 2 mm-thick commercial 1050-Al plates with an ultrafine grained (UFG) structure were obtained by the accumulative roll bonding (ARB) technique after a 5 cycle process and were subsequently joined by friction stir welding (FSW) at various revolution pitches (welding speed/rotation speed) of 1 mm/r, 1.67 mm/r and 2.5 mm/r. To understand the effect of the initial grain size on the welding properties, ARB processed samples followed by annealing under H24 conditions as well as the as-received samples in the fully annealed state were also applied to the FSW process. The microstructure evolution and Vickers hardness in the stir zone of all the samples were investigated. It was revealed that the annealed samples with an intermediate grain size finally obtained the most refined grain size and highest value of Vickers hardness in the stir zone. However, for the UFG samples, significant grain growth and corresponding decrease in hardness can be found in the stir zone.     

TEM study of the FSW nugget in AA2195-T81

During friction stir welding (FSW) the material being joined is subjected to a thermal-mechanical process in which the temperature, strain and strain rates are not completely understood. To produce a defect free weld, process parameters for the weld and tool pin design must be chosen carefully. The ability to select the weld parameters based on the thermal processing requirements of the material, would allow optimization of mechanical properties in the weld region. In this study, an attempt is made to correlate the microstructure with the variation in thermal history the material experiences during the FSW process.     

Process optimisation and mechanical properties of friction stir lap welds of 7075-T6 stringers on 2024-T3 skin

This paper focuses on the results of process optimisation and mechanical tests that were used to ascertain the feasibility of using friction stir welding (FSW) to join stringers to skin. The effects of process parameters on weld quality of 1.5-mm 7075-T6 stringers lap-joined on 2.3-mm 2024-T3 skins were investigated. Advancing and retreating side locations on the joint configuration were alternated to determine optimal design arrangements. The effects of travel and rotation speeds on weld quality and defect generation were also investigated. Weld quality was assessed by optical microscopy and bending tests. It was found that: (i) the increase of the welding speed or the decrease of the rotational speed resulted in a reduction of the hooking size and top plate thinning but did not eliminated them, (ii) double pass welds by overlapping the advancing sides improved significantly the weld quality by overriding the hooking defect, and (iii) change of the rotational direction for a counter clockwise with a left-threaded probe eliminated the top sheet thinning defect. Subsequently, FSW lap joints were produced using optimum conditions and underwent extensive mechanical testing program. Several assembly configurations including discontinuous and continuous welds as well as single and double pass welds were produced. The results obtained for cyclic fatigue performance of FSW panels are compared with riveted lap joints of identical geometry. S–N curves, bending behaviour, failure locations and defect characterisation are also discussed. It was found that: (i) the tensile strength of FSW joints approached that of the base material but with a significant reduction in the fatigue life, (ii) the probe plunge and removal locations served as the key crack nucleation sites in specimens with discontinuous welds, and (iii) double pass welds with overlapping advancing sides showed outstanding fatigue life and very good tensile properties. The present work provided some valuable insight into both the fabrication and application of FSW on stringer/skin lap joints.     

Prediction of microstructural features and forming of friction stir welded sheets using cellular automata finite element (CAFE) approach

The main aim of the present work is to predict the microstructural features like grain size and dislocation density in the weld zone during friction stir welding (FSW) of similar (Al6061T6/Al6061T6) and dissimilar (Al6061T6/Al5086O) Aluminium grades using Cellular Automata Finite Element (CAFE) approach. The FSW process is not modelled with the stirring action, instead heat flux, strain-rate and strain are incorporated by analytical models. The grain size is controlled through cellular automata (CA) cells and dislocation density is related to this by two different (analytical and empirical) models. After FSW, four different methods are proposed for predicting the tensile behaviour of weld zone and the efficiency of these methods is evaluated through validations. The results indicate that the thermal, strain-rate, and strain models are accurate enough in their predictions when compared with existing results. The grain size predictions from CAFE model, which include the transition rule, are also consistent with the literature results, both for similar and dissimilar material combinations. The analytical model shows better dislocation density prediction than empirical model when compared with the experimental data. Of all the methods proposed for tensile behaviour prediction, the CAFE model that includes dislocation density evolution using the second model is efficient and accurate. The stress–strain data predicted from an averaged flow stress of many CA cells is also encouraging. Through these results, it has been demonstrated that the CAFE approach along with few validated analytical models can be used to predict the micro-features and forming aspects during FSW consistently.     

Modelling studies of sheet metal formability of friction stir processed Mg AZ31B alloy under stretch forming

Magnesium alloys have poor formability at room temperature. The formability can be improved through hot forming at the cost of deterioration in strength and other mechanical properties. Improvements in texture and grain refinement are the alternate ways for formability improvement. The economically viable process for such applications is alloying or grain refinement technologies like equal channel angular pressing (ECAP), friction stir processing (FSP), and accumulative roll bonding (ARB), etc. Friction stir processing is an emerging solid state microstructure modification technique that can produce homogeneous microstructure with fine-grains in a single pass. The desirable characteristics for sheet formability are the maximum limiting dome height under plane and biaxial strain deformation conditions and the major fracture strain limits through forming limit diagrams (FLDs). Equiaxed homogeneous microstructure with fine grains through FSP results in the enhancement of formability of the material. The objective of the present work is to establish the methodology for viable sheet metal forming practices by altering the process conditions. This needs a clear understanding of the friction stir processed Mg alloy under different strain conditions to get optimized process parameters.     

Superplastic Forming of Friction Stir Welded AA6061-T6 Alloy Sheet with Various Tool Rotation Speed

This study attempts to investigate the superplastic forming (SPF) of friction stir welded (FSW) AA6061-T6 alloy sheet at various tool rotation speeds in the range of 500 to 2000 rpm. The effect of FSW on SPF free blow forming of AA6061-T6, pole height, pole thickness, equivalent strain rate, and equivalent flow stress were investigated at constant pressure and constant temperature. Using the Cheng model the pole thickness, the equivalent strain rate, and equivalent flow stress were determined from superplastic free blow forming experiment. The finite element modeling and simulation is performed over the SPF of FSW specimens using selective superplasticity method. Experimental results indicate that tool rotation speed is the critical parameter during friction stir welding that has a greater influence on SPF. The theoretical modeling results exhibit that the SPF of friction stir welding can be practically applied to determine pole thickness, strain rate, flow stress, and strain rate sensitivity index. The finite element modeling results were found to be fairly agreeing with the experimental results. Hence, superplasticity can be significantly enhanced by friction stir welding by varying the FSW tool rotation speed.     

Thermal analysis of friction stir processing (FSP) using arbitrary Lagrangian-Eulerian (ALE) and smoothed particle hydrodynamics (SPH) meshing techniques

Friction stir processing (FSP), a derivation of friction stir welding (FSW) is a material processing method which is used to locally modify the microstructure and texture of a given material. In friction stir processing (FSP), the heat produced by the frictional force and material deformation plays a significant role in producing a good surface quality. Therefore, the thermal modeling of friction stir processing (FSP) requires accurate boundary conditions and an appropriate mesh modelling technique. In this study, the thermal behavior of friction stir processing (FSP) using the aluminum alloy 6061-T6 for different process parameters is investigated. To solve complicated governing equations, two finite element formulations have been utilized; i. e. an arbitrary Lagrangian-Eulerian (ALE) and a smoothed particle hydrodynamics (SPH). For the arbitrary Lagrangian-Eulerian (ALE), a three-dimensional (3D) fully coupled thermomechanical finite element model using a modified Coulomb friction and Johnson-Cook material law has been used. The results show that, the temperature behavior is asymmetrical in the cross section and the peak temperature is approximately around 60 %–80 % of the melting temperature of the AA6061-T6. Moreover, it is seen that as the rotating velocity increases, the peak temperature is also increased; and the peak temperature decreases as the transverse speed increases. Finally, a good correlation between the calculated values and the literature is found.     

Spatially resolved positron annihilation spectroscopy on friction stir weld induced defects

A friction stir welded (FSW) Al alloy sample was investigated by Doppler broadening spectroscopy (DBS) of the positron annihilation line. The spatially resolved defect distribution showed that the material in the joint zone becomes completely annealed during the welding process at the shoulder of the FSW tool, whereas at the tip, annealing is prevailed by the deterioration of the material due to the tool movement. This might be responsible for the increased probability of cracking in the heat affected zone of friction stir welds. Examination of a material pairing of steel S235 and the Al alloy Silafont36 by coincident Doppler broadening spectroscopy (CDBS) indicates the formation of annealed steel clusters in the Al alloy component of the sample. The clear visibility of Fe in the CDB spectra is explained by the very efficient trapping at the interface between steel cluster and bulk.     

Effect of Traverse/Rotational Speed on Material Deformations and Temperature Distributions in Friction Stir Welding

A fully coupled thermo-mechanical model was developed to study the temperature fields and the plastic deformations of alloy AL6061-T6 under different process parameters during the friction stir welding （FSW） process. Three-dimensional results under different process parameters were presented. Results indicate that the maximum temperature is lower than the melting point of the welding material. The higher temperature gradient occurs in the leading side of the workpiece. The calculated temperature field can be fitted well with the one from the experimental test. A lower plastic strain region can be found near the welding tool in the trailing side on the bottom surface, which is formed by the specific material flow patterns in FSW. The maximum temperature can be increased with increasing the welding speed and the angular velocity in the current numerical modelling.     

Establishing relationship between the base metal properties and friction stir welding process parameters of cast aluminium alloys

In friction stir welding (FSW), the material under the rotating action of non-consumable tool has to be stirred properly to get defect free welds in turn it will improve the strength of the welded joints. The welding conditions and parameters are differing based on the mechanical properties of base materials such as tensile strength, ductility and hardness which control the plastic deformation during friction stir welding. The FSW process parameters such as tool rotation speed, welding speed and axial force, etc. play a major role in deciding the weld quality. FSW Joints of cast aluminium alloys A319, A356, and A413 were made by varying the FSW process parameters and the optimum values were obtained. In this investigation, empirical relationships are established and they can be effectively used to predict the optimum FSW process parameters to fabricate defect free joints with high tensile strength from the known base metal properties of cast aluminium alloys.     

Modelling strength of cracked friction stir welded panels by means of the crack tip opening angle (CTOA)

The objective of this work is to assess numerically the strength of cracked flat friction stir welded panels for aerospace applications, on the basis of simple experiments made on small coupons of material (Kahn tear test). The transferability from a geometry to another, in particular the results obtained from Kahn tear tests to the prediction of the R-curve of cracked FSW M(T) panels is performed using the crack tip opening angle (CTOA). The Kahn tear test is reproduced first by means of finite element analysis using a debond procedure based on the attainment of a critical CTOA as a function of crack length. The CTOA extracted from Kahn tests is then used to simulate the R-curve of M(T) panels of different widths. The material considered here is a 6013-T 6 aluminium alloy. Two series of values of CTOA are determined: (i) considering the material as homogeneous with strength equal to that of the parent material; (ii) introducing different strengths locally for the weld TMAZ/HAZ and nugget.     

Analysis of high temperature plastic behaviour and its relation with weldability in friction stir welding for aluminium alloys AA5083-H111 and AA6082-T6

The influence of the plastic behaviour of two aluminium alloys, very popular in welding construction, on friction stir weldability, is analysed in this work. The two base materials, a non-heat-treatable (AA5083-H111) and a heat-treatable aluminium (AA6082-T6) alloy, are characterised by markedly different strengthening mechanisms and microstructural evolution at increasing temperatures. Their plastic behaviour, under different testing conditions, was analysed and compared. The two base materials were also welded under varied friction stir welding (FSW) conditions in order to characterise their weldability. The relation between weldability, material flow during FSW and the plastic behaviour of the base materials, at different temperatures, was analysed. It was found that the AA6082 alloy, which displays intense flow softening during tensile loading at high temperatures, and is sensitive to dynamic precipitation and overageing under intense non-uniform deformation, displays good weldability in FSW. Under the same welding conditions, the AA5083 alloy, which in quasi-static conditions displays steady flow behaviour at increasing temperatures, and is sensitive to moderate hardening at high strain rates, displays poor weldability.     

Spatially resolved positron annihilation spectroscopy on friction stir weld induced defects

Abstract

A friction stir welded (FSW) Al alloy sample was investigated by Doppler broadening spectroscopy (DBS) of the positron annihilation line. The spatially resolved defect distribution showed that the material in the joint zone becomes completely annealed during the welding process at the shoulder of the FSW tool, whereas at the tip, annealing is prevailed by the deterioration of the material due to the tool movement. This might be responsible for the increased probability of cracking in the heat affected zone of friction stir welds. Examination of a material pairing of steel S235 and the Al alloy Silafont36 by coincident Doppler broadening spectroscopy (CDBS) indicates the formation of annealed steel clusters in the Al alloy component of the sample. The clear visibility of Fe in the CDB spectra is explained by the very efficient trapping at the interface between steel cluster and bulk.     

Mixed mode I/II fracture of 2024-T3 friction stir welds

For the first time, a series of mixed mode I/II fracture experiments have been performed on both base material and three families of friction stir welds (FSWs) in 6.4 mm thick, 2024-T351 aluminum plate; the FSW joints are designated hot, medium and cold due to the level of nominal weld energy input per unit weld length (specific weld energy) during the joining process.Results from the fracture tests indicate that the measured critical crack opening displacement (COD) at a fixed distance behind the crack tip properly correlates both load-crack extension response and microstructural fracture surface features for both the base metal and all FSWs, providing measure of a quantitative fracture toughness. The COD values also indicate that transition from mode I to mode II dominant crack growth occurs at lower loading angles for FSW joints having higher specific weld energy input, with a truly mixed mode I/II COD measured during crack growth in the medium FSW joint. Using results from recent detailed FSW metallographic studies, specific features in the fracture process are correlated to the FSW microstructure. Finally, the observed ductile crack growth path in all three welds tends to exit the under-matched FSW weld region as the far-field applied shear loading is increased, with the medium FSW being the only case where the flaw remained within the FSW region for all combinations of shear and tensile loading.     

Corrosion behavior of friction stir welded AZ31B magnesium alloy with plasma electrolytic oxidation coating formed in silicate electrolyte

A protective ceramic coating of about 50 μm thick on a friction stir welded (FSW) joint of AZ31B magnesium alloy was prepared by plasma electrolytic oxidation (PEO) in silicate electrolyte. Electrochemical corrosion behavior of uncoated and coated FSW joints was evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). The equivalent circuits of EIS plots for uncoated and coated FSW magnesium alloy were suggested. The corrosion resistance of FSW magnesium alloy depended on microstructure of the FSW joint. The heat-affected zone with severe grain growth was more susceptible to corrosion than the stir zone and base metal. The PEO coating consisted of a porous outer layer and a dense inner layer. The inner layer of PEO coating played a key role on corrosion protection of the FSW joint of magnesium alloy. Meanwhile, corrosion potential, corrosion current density and impedance at different zones of coated FSW joint were almost the same. The PEO surface treatment significantly improved the corrosion resistance of FSW joints of AZ31B magnesium alloy.     

铝/钢异种金属的超声振动强化搅拌摩擦焊接工艺

采用新型超声振动强化搅拌摩擦焊接工艺实现了6061-T6铝合金以及QP980高强钢的搭接焊, 对比分析了有无超声作用下, 接头的宏观形貌、微观组织和拉伸剪切性能, 同时研究了超声振动对焊接载荷的影响。结果表明: 焊接前对母材施加超声振动, 可以起到软化母材的作用, 促进了材料的塑性流动, 扩大了铝/钢界面区和焊核区, 使更多的钢颗粒随搅拌针旋转进入铝合金侧, 在界面区边缘形成钩状结构, 进而提高了接头的失效载荷; 超声改变了FSW接头断裂位置和断口形貌, 提高了接头力学性能, 在本实验工艺参数范围内, 接头最大的平均失效载荷为4.99 kN; 当焊接速度为90 mm/min, 下压量为0.1 mm时, 施加超声振动使接头的平均失效载荷提高了0.98 kN, 拉剪性能提升28.24%;施加超声振动后轴向力F_z、搅拌头扭矩M_t和主轴输出功率分别下降2.46%, 6.44%和4.59%。     

Dissimilar titanium/aluminum friction stir welding lap joints by experiments and numerical simulation

Dissimilar lap joints were produced by friction stir welding (FSW) out of Ti6Al4V titanium alloy and AA2024 aluminum alloy sheets. The joints, welded with varying tool rotation and feed rate, were studied by analyzing the maximum shear strength, Vickers microhardness and optical observations. A dedicated numerical model, able to take into account the presence of the two different alloys, was used to highlight the effects of the process parameters on temperature distribution, strain distribution, and material flow. The combined analysis of experimental measurements and numerical predictions allowed explaining the effects of tool rotation and feed rate on the material flow. It was found that tool rotation had a larger impact on the joint effectiveness with respect to feed rate. A competition between material mixing and heat input occurs with increasing tool rotation, resulting in higher joint strength when lower values of tool rotation are used.     

A review of friction stir welding of aluminium matrix composites

As a solid state joining process, friction stir welding (FSW) has proven to be a promising approach for joining aluminium matrix composites (AMCs). However, challenges still remain in using FSW to join AMCs even with considerable progress having been made in recent years. This review paper provides an overview of the state-of-the-art of FSW of AMC materials. Specific attention and critical assessment have been given to: (a) the macrostructure and microstructure of AMC joints, (b) the evaluation of mechanical properties of joints, and (c) the wear of FSW tools due to the presence of reinforcement materials in aluminium matrices. This review concludes with recommendations for future research directions.