Effect of Welding Parameters on Mechanical Properties and Microstructure of Friction Stir Welded AA7075-T651 Aluminum Alloy Butt Joints

Kosturek, Robert; Torzewski, Janusz; Wachowski, Marcin; Śnieżek, Lucjan

doi:10.3390/ma15175950

Cited by 13 publications

(5 citation statements)

References 37 publications

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“…These values were lower than those given with AA7075-T6 BM. Similar results have been reported in different works when the T6 material was subjected to thermomechanical processes [62,64,[67][68][69]. The DP processed at 3 mm/min attained 90% of the AA7075 BM.…”

Section: Mechanical Propertiessupporting

confidence: 89%

“…After the AFSD process, the ultimate compressive strength of the DPs was higher than the AA7075-T6 BM at the deposition rate of 3 mm/min, where the maximum compressive strength was 1320 MPa and for the asreceived material was 910 MPa. This improvement in compressive strength of the deposited specimen is due to the grain refining and highly dispersed fragmented intermetallics of the DPs [68]. Finally, for the AA7075-T6 DPs, it can be said that the compressive strength is highly affected by grain refining, while the hardness is highly affected by the precipitates.…”

Section: Mechanical Propertiesmentioning

confidence: 98%

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Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts

Elshaghoul,

El-Sayed Seleman,

Bakkar

et al. 2023

Applied Sciences

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In the aircraft industry, the high-strength aluminum alloys AA7075 and AA2024 are extensively used for the manufacture of structural parts like stringers and skins, respectively. Additive manufacturing (AM) of the AA7075-T6 aluminum alloy via friction stir deposition to build continuously multilayered parts on a substrate of AA2024-T4 aluminum has not been attempted so far. Accordingly, the present work aimed to explore the applicability of building multilayers of AA7075-T6 alloy on a substrate sheet of AA2024-T4 alloy via the additive friction stir deposition (AFSD) technique and to optimize the deposition process parameters. The experiments were conducted over a wide range of feed rates (1–5 mm/min) and rotation speeds (200–1000 rpm). The axial deposition force and the thermal cycle were recorded. The heat input to achieve the AFSD was calculated. The AA7075 AFSD products were evaluated visually on the macroscale. The microstructures were also investigated utilizing an optical microscope and scanning electron microscope (SEM) equipped with an advanced EDS technique. As well as the presence phases, the mechanical performance of the deposited materials in terms of hardness and compressive strength was also examined. The results showed that the efficiency of the deposition process was closely related to the amount of heat generated, which was governed by the feeding rate, the rotational speed, and the downward force. AA7075 defect-free continuously multilayered parts were produced without any discontinuity defects at the interface with the substrate at deposition conditions of 1, 2, 3, and 4 mm/min and a constant 400 rpm consumable rod rotation speed (CRRS). The additively deposited AA7075-T6 layers exhibited a refined grain structure and uniformly distributed fragment precipitates compared to the base material (BM). The gain size decreased from 25 µm ± 4 for the AA7075-T6 BM to 1.75 µm ± 0.41 and 3.75 µm ± 0.78 for the AFSD materials fabricated at 1 and 4 mm/min deposition feeding rates, respectively, at 400 rpm/min. Among the feeding rates used, the 3 mm/min and 400 rpm rod rotation speed produced an AA7075 deposited part possessing the highest average hardness of 165 HV ± 5 and a compressive strength of 1320 MPa.

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Section: Mechanical Propertiessupporting

confidence: 89%

Section: Mechanical Propertiesmentioning

confidence: 98%

Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts

Elshaghoul,

El-Sayed Seleman,

Bakkar

et al. 2023

Applied Sciences

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“…The difference between FSW and FSP technology lies in the purpose of these methods. FSW technology is used to join materials [7][8][9][10][11], while FSP technology is used to modify the surface layer of materials [12][13][14][15][16]. In both technologies, the source of heat is the friction of a special tool against the surface of the modified material and the strong plastic deformation of the material [17].…”

Section: Introductionmentioning

confidence: 99%

The Use of Ashes in Surface Metal Matrix Composites Produced by Friction Stir Processing

Iwaszko,

Kudła,

Sajdak

2024

Applied Sciences

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The article presents an assessment of the possibility of using ashes from the combustion of coal and biomass as a reinforcing phase in metal matrix composites. The composite surface layer was produced by means of the FSP (friction stir processing) method, using an original hole solution with a shifted working zone of the pin. The composite matrix was AA7075 alloy. The obtained composite was subjected to microscopic observations, tribological tests, and hardness measurements. The microscopic examinations revealed favorable changes in the microstructure, in particular, strong refinement of the grains, uniform distribution of the reinforcing phase, and good bonding of the particles of this phase with the matrix material. Changes in the microstructure resulted in a significant increase in the hardness (from 36 to 41% depending on the type of reinforcing phase) and wear resistance (from 24.1 to 32.9%), despite partial dissolution of the intermetallic phases. It was found that the effect of strengthening the matrix and the uniformity of the distribution of the reinforcing phase depend on the physicochemical properties of the used powders, especially on the shape and size of the particles. The research shows that the use of ashes as a reinforcing phase in composites is fully justified.

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“…The difference in mechanical properties or asymmetry created in AS and RS of similar parts is not significant [15]. This defect can be reduced by changing the welding parameters such as rotational speed, translational speed, tilt angle, tool offset, and plunging depth [16]. But when joining dissimilar parts and materials, this asymmetry can strongly impact the final strength of the joint and cause a significant drop in the joint efficiency [17].…”

Section: Introductionmentioning

confidence: 99%

Effects of tool translation direction and tool rotation direction on mechanical and metallurgical properties of two-pass FSW joint of dissimilar AA6061-T6 and AA7075-T6 alloys

Alsayyad,

Alwan,

Albaghdadi

et al. 2023

Preprint

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In the current research, the experimental investigation of the Friction Stir Welding (FSW) of two dissimilar aluminum alloys, AA6061-T6 and AA7075-T6, was done. The effect of three parameters, the number of welding passes, the tool translation direction in the second pass, and the tool rotation direction in the second pass, on the tensile properties, microhardness, and microstructure of the joint was carried out. Based on the results, the value of UTS and the elongation percentage of the welded samples are significantly dependent on the number of welding passes, the tool translation direction in the second pass, and the tool rotation direction in the second pass. Adding a secondary pass significantly increased the tensile strength of the welding samples. All samples welded with two passes experienced higher strength and elongation than the singlepass welded sample. The highest tensile strength belonged to TP-D sample. The TP-D sample experienced a 44% increase in tensile strength compared to the CF sample, and the tensile strength efficiency of this sample compared to the softer alloy (AA6061-T6) was equal to 89.6%. Also, the highest elongation percentage belonged to TP-D, TP-B, TP-C, TP-A, and CF samples, respectively. Regardless of the placement of dissimilar alloys on the Advancing side (AS) and Retreating side (RS), the number of welding passes, the tool translation direction in the second pass, and the tool rotation direction in the second pass, the lowest hardness values in all samples occurred in the HAZ region. It was found that the increase in the number of welding passes increased the microhardness in different weld areas. The highest and lowest average hardness belonged to the TP-D and CF welded samples, respectively.

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Effect of Welding Parameters on Mechanical Properties and Microstructure of Friction Stir Welded AA7075-T651 Aluminum Alloy Butt Joints

Cited by 13 publications

References 37 publications

Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts

Additive Friction Stir Deposition of AA7075-T6 Alloy: Impact of Process Parameters on the Microstructures and Properties of the Continuously Deposited Multilayered Parts

The Use of Ashes in Surface Metal Matrix Composites Produced by Friction Stir Processing

Effects of tool translation direction and tool rotation direction on mechanical and metallurgical properties of two-pass FSW joint of dissimilar AA6061-T6 and AA7075-T6 alloys

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