Study on the effect of the welding environment on the dynamic recrystallization phenomenon and residual stresses during the friction stir welding process of aluminum alloy
Restricted accessResearch articleFirst published online 2021
Study on the effect of the welding environment on the dynamic recrystallization phenomenon and residual stresses during the friction stir welding process of aluminum alloy
Various methods have been proposed to modify the friction stir welding. Friction stir vibration welding and underwater friction stir welding are two variants of this technique. In friction stir vibration welding, the adjoining workpieces are vibrated normal to the joint line while friction stir welding is carried out, while in underwater friction stir welding the friction stir welding process is performed underwater. The effects of these modified versions of friction stir welding on the microstructure and mechanical characteristics of AA6061-T6 aluminum alloy welded joints are analyzed and compared with the joints fabricated by conventional friction stir welding. The results indicate that grain size decreases from about 57 μm for friction stir welding to around 34 μm for friction stir vibration welding and about 23 μm for underwater friction stir welding. The results also confirm the evolution of Mg2Si precipitates during all processes. Friction stir vibration welding and underwater friction stir welding processes can effectively decrease the size and interparticle distance of precipitates. The strength and ductility of underwater friction stir welding and friction stir vibration welding processed samples are higher than those of the friction stir welding processed sample, and the highest strength and ductility are obtained for underwater friction stir welding processed samples. The underwater friction stir welding and friction stir vibration welding processed samples exhibit about 25% and 10% higher tensile strength compared to the friction stir welding processed sample, respectively. The results also indicate that higher compressive residual stresses are developed as underwater friction stir welding and friction stir vibration welding are applied.
ZhenHYongPZhiY, et al.
Comparison of FSW and TIG welded joints in Al-Mg-Mn-Sc-Zr alloy plates. Trans Nonferrous Met Soc China2011;
21: 1685–1691.
2.
BagheriBAbbasiMAbdollahzadehA. Investigation into microstructure and mechanical characteristics of AA6061-T6 joints made by FSW, FSVW, and TIG: a comparative study.Int J Min Metal Mater2020. DOI: 10.1007/s12613-020-2085-1.
3.
BaskoroASAmatMAPratamaAI, et al.
Effects of tungsten inert gas (TIG) welding parameters on macrostructure, microstructure, and mechanical properties of AA6063-T5 using the controlled intermittent wire feeding method. Int J Manuf Technol2019;
105: 2237–2251.
4.
AbdolahzadehASafarkhanianACabreraJM, et al.
The effect of changing chemical composition on dissimilar Mg/Al friction stir welded butt joints using zinc interlayer. J Manuf Process2018;
34: 18–30.
5.
KeivaniRBagheriBSharifiF, et al.
Effects of pin angle and preheating on temperature distribution during friction stir welding operation. Trans Nonferrous Met Soc China2013;
23: 2708−2713.
6.
FallahiAAShokuhfarAMoghaddamAO, et al.
Analysis of SiC nano-powder effects on friction stir welding of dissimilar Al-Mg alloy to A316L stainless steel. J Manuf Process2017;
30: 418–430.
7.
AbbasiMBagheriB and R. Keivani.
Thermal analysis of friction stir welding process and investigation into affective parameters using simulation. J Mech Sci Technol2015;
29: 861–866.
8.
FarghadaniMKarimzadehFEnayatiMH, et al.
Fabrication of AZ91D/Cu/Mg2Cu and AZ91D/Mg2Cu/MgCu2/MgO in-situ hybrid surface nanocomposites via friction stir processing. Surf Topogr: Metrol Prop2020;
8: 045002.
9.
HamdollahzadehABahramiMFarahmand NikooM, et al.
Microstructure evolutions and mechanical properties of nano-SiC-fortified AA7075 friction stir weldment: the role of second pass processing. J Manuf Process2015;
20: 367–673.
10.
YueYZhouZJiS, et al.
Effect of welding speed on joint feature and mechanical properties of friction stir lap welding assisted by external stationary shoulders. Int J Adv Manuf Technol2017;
89: 1691–1698.
11.
AminiSAmiriMR.Pin axis effects on forces in friction stir welding process. Int J Adv Manuf Technol2015;
78: 1795–1801.
12.
HwangYMKangZWChiouYC, et al.
Experimental study on temperature distributions within the workpiece during friction stir welding of aluminum alloys. Int J Mach Tool Manuf2008;
48: 778–787.
13.
ChenGLiHZhangSH, et al.
Effects of pin thread on the in-process material flow behavior during friction stir welding: a computational fluid dynamics study. Int J Mach Tool Manuf2018;
124: 12–21.
14.
LinYLuCHWeiCH, et al.
Influences of friction stir welding and post-weld heat treatment on Al–Cu–Li alloy. Adv Eng Mater2001;
20: 1–8.
15.
BehzadiMARanjbarKHDehmolaeiR, et al.
Friction-stir-welded overaged 7020-T6 alloy joint: an investigation on the effect of rotational speed on the microstructure and mechanical properties. Int J Min Metal Mater2019;
26: 622–633.
16.
BagheriBAbbasiMAbdollahzadehA, et al.
Advanced approach to modify friction stir spot welding process. Metal Mater Int2020;
26: 1562–1573.
17.
BagheriBAbbasiMDadaeiM.Mechanical behavior and microstructure of AA6061-T6 joints made by friction stir vibration welding. J Mater Eng Perform2010; (29): 1165–1175.
18.
MoharamiA.High-temperature tribological properties of friction stir processed Al-30Mg2Si composite. Mater High Temp2020;
37: 351–356.
19.
ChenYJiangYZhangF, et al.
Water cooling effects on the microstructural evolution and mechanical properties of friction-stir-processed Al-6061 alloy. Trans Indian Inst Met2018;
71: 3077–3087.
ZhongYBWuCSPadhyGK.Effect of ultrasonic vibration on welding load, temperature and material flow in friction stir welding. J Mater Process Technol2017;
239: 273–83.
22.
ZhaoWWuCH.Constitutive equation including acoustic stress work and plastic strain for modeling ultrasonic vibration assisted friction stir welding process. Int J Machin Tool Manufact2019;
145: 103434.
23.
ShiLWuCSFuL.Effects of tool shoulder size on the thermal process and material flow behaviors in ultrasonic vibration enhanced friction stir welding. J Manuf Process2020;
53: 69–83.
24.
YangCHWuCHShiL.Effect of ultrasonic vibration on dynamic recrystallization in friction stir welding. J Manuf Process2020;
56: 87–95.
25.
MousavizadeSMPouranvariMGhainiFM, et al.
Laser-assisted friction stir processing of IN738LC nickel-based superalloy: stir zone characteristics. Sci Technol Weld Join2016;
21: 374–380.
26.
AminiSAmiriMR.Study of ultrasonic vibrations’ effect on friction stir welding. Int J Adv Manuf Technol2014;
73: 127–135.
27.
LiuXCWuCSPadhyGK.Improved weld macrosection, microstructure and mechanical properties of 2024Al-T4 butt joints in ultrasonic vibration enhanced friction stir welding. Sci Technol Weld Join2015;
20: 345–352.
28.
SharmaCDwivediDKKumarP.Influence of in-process cooling on tensile behavior of friction stir welded joints of AA7039. Mater Sci Eng A2012;
556: 479–487.
29.
ChoJHHanSHLeeCG.Cooling effect on microstructure and mechanical properties during friction stir welding of Al-Mg-Si aluminum alloys. Mater Lett2016;
180: 157–161.
30.
SedaghatiABouzaryHA.A study on the effect of cooling on microstructure and mechanical properties of friction stir-welded AA5086 aluminum butt and lap joints. J Mater Des Appl2019;
233: 1156–1165.
31.
SekhonHSKumarRDhingraP.Optimization of mechanical properties of aluminium based alloy (A356) with friction stir welding. J Sci Eng Technol2016;
3: 33–36.
32.
PapahnHBahemmatPHaghpanahiM, et al.
Study on governing parameters of thermal history during underwater friction stir welding. Int J Adv Manuf Technol2015;
78: 1101–1111.
33.
ASTM E3–11. Standard guide for preparation of metallographic specimens.
West Conshohocken, PA:
ASTM International, 2011.
34.
ASTM E8–16. Standard test methods of tension testing of metallic materials.
West Conshohocken, PA:
ASTM International, 2016.
35.
ASTM E23–07. Standard test methods for notched bar impact testing of metallic materials.
West Conshohocken, PA:
ASTM International, 2007.
36.
NoyanICCohenJB.Determination of strain and stress fields by diffraction methods, in: residual stress: measurement by diffraction and interpretation.
New York:
Springer, 1987.
37.
WangBBChenFFLiuF, et al.
Enhanced mechanical properties of friction stir welded 5083Al-H19 joints with additional water cooling. Mater Sci Technol2016;
33: 1009–1014.
38.
BagheriBAbbasiMAbdollahzadehA, et al.
Numerical analysis of cooling and joining speed effects on friction stir welding by smoothed particle hydrodynamics (SPH).Arch App Mech2020;
90: 2275–2296.
39.
BagheriBAbbasiMAbdollahzadehA, et al.
A comparative study between friction stir processing and friction stir vibration processing to develop magnesium surface nanocomposite. Int J Min Metal Mater2020;
27: 1133–1146.
40.
MoghaddamAOMazinaniAKetabchiM.Effect of accumulative roll bonding and equal channel angular rolling on microstructural and mechanical properties of Cu–Al–Mn shape memory alloys. Trans Indian Inst Met2017;
70: 1901–1909.
41.
BagheriBRiziAAMAbbasiM, et al.
Friction stir spot vibration welding: improving the microstructure and mechanical properties of Al5083 joint. Metall Micro Anal2019;
8: 713–725.
42.
HullDBaconDJ.Introduction to dislocations.
Oxford:
Butterworth-Heinemann, 2011.
43.
DieterGE.Mechanical metallurgy.
Singapore:
McGraw-Hill Book Company, 1988.
44.
CallisterWD.Materials science and engineering: an introduction.
New York:
John Wiley & Sons, 2003.
45.
ChangCILeeCJHuangJC.Relationship between grain size and Zener–Holloman parameter during friction stir processing in AZ31 Mg alloys. Scripta Mater2008;
51: 509–514.
46.
PorterDAEasterlingKESherifM.Phase transformation in metals and alloys. 3rd ed.New York:
CRC Press, 2009.
47.
KaibyshevRShipilovaKMusinF, et al.
Continous dynamic recrystallization in an Al-Li-Mg-Sc alloy during equal-channel angular extrusion. Mater Sci Eng A2005;
396: 341–351.
48.
LinHPChenDKuoJC.Grain boundary evolution of cold-rolled fepd alloy during recrystallization at disordering temperature. Materials2015;
8: 3254–3267.
49.
SuJQNelsonTWSterlingCJ.Microstructure evolution during FSW/FSP of high strength aluminum alloys. Mater Sci Eng A2005;
405: 277–286.
ZhaoYWangQChenH, et al.
Microstructure and mechanical properties of spray formed 7055 aluminum alloy by underwater friction stir welding. Mater Des2014;
56: 725−730.
52.
MoghaddamAOKetabchiMAfrasiabiY.Accumulative roll bonding and post-deformation annealing of Cu-Al-Mn shape memory alloy. J Mater Eng Perform2014;
23: 4429–4435.
53.
MishraRSMaZY.Friction stir welding and processing. Mater Sci Eng R2005;
50: 1–78.
54.
AfrinNChenDCaoX, et al.
Microstructure and tensile properties of friction stir welded AZ31B magnesium alloy. Mater Sci Eng: A2008;
472: 179–186.
55.
McNelleyTRSwaminathanSSuJQ.Recrystallization mechanisms during friction stir welding/processing of aluminum alloys. Scripta Mater2008;
58: 349–354.
56.
BagheriBAbbasiM.Development of AZ91/SiC surface composite by FSP: Effect of vibration and process parameters on microstructure and mechanical characteristics. Adv Manuf2020;
8: 82–96.
57.
EstrinYZZabrodinPABraudeIS, et al.
Low temperature plastic deformation of AZ31 magnesium alloy with different microstructures. Low Temp Phys2010;
36: 1100–1112.
58.
DasSHofmannFTarletonE.Consistent determination of geometrically necessary dislocation density from simulations and experiments. Int J Plast2018;
109: 18–42.
59.
YangCNiDRXueP, et al.
A comparative research on bobbin tool and conventional friction stir welding of Al–Mg–Si alloy plates. Mater Charact2018;
145: 20–28.
60.
PerezMDunontMAcevedo-ReyesD.Implementation of classical nucleation and growth theories for precipitation. Acta Mater2008;
56: 2119–2132.
61.
BagheriBAbdollahzadehAAbbasiM, et al.
Numerical analysis of vibration effect on friction stir welding by smoothed particle hydrodynamics (SPH). Int J Adv Manuf Technol2020; (110): 209–228
62.
ShiLWuCSPadhyGK, et al.
Numerical simulation of ultrasonic field and its acoustoplastic influence on friction stir welding. Mater Des2016;
104: 102–115.
63.
KobayashiT.Strength and toughness of materials.
New York:
Springer, 2004.
64.
NaderiMAbbasiMSaeed-AkbariA.Enhanced mechanical properties of a hot-stamped advanced high-strength steel via tempering treatment. Metal Mater Trans A2013;
44: 1852–1861.
65.
FathiJEbrahimzadehPFarasatiR, et al.
Friction stir welding of aluminum 6061-T6 in presence of watercooling: analyzing mechanical properties and residual stress distribution. Int J Lightweight Mater Manuf2019;
2: 107–115.
66.
BagheriBAbbasiMHamzelooR.The investigation into vibration effect on microstructure and mechanical characteristics of friction stir spot vibration welded aluminum: simulation and experiment. Proc IMechE, Part C: J Materials: Design and Applications2020;
234: 1809–1822.
67.
BagheriBAbbasiMAbdollahzadehA, et al.
The effect of second phase particle size and presence of vibration on AZ91/SiC surface composite layer produced by FSP. Trans Nonferrous Met Soc China2020;
30: 905–916.
68.
UthaisangsukV.Microstructure based formability modeling of multiphase steels. PhD Thesis, IEHK, Germany, 2009.
