Microstructural Evolution, Intermetallic Formation, and Mechanical Performance of Dissimilar Al6061–Ti6Al4V Static Shoulder Friction Stir Welds

Sundar. A, Saravana; Mugada, Krishna Kishore; Kumar, Adepu

doi:10.1002/adem.202300973

Cited by 10 publications

(3 citation statements)

References 55 publications

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“…Friction stir welding (FSW), as a solid-state joining technology, offers several advantages when it comes to joining dissimilar metals [1-5], including Al/Cu [6][7][8], Al/Ti [9][10][11], Al/Al [12][13][14], Al/Mg [15][16][17], and Al/Steel [18][19][20]. Due to the formation of intermetallic compounds and element diffusions, the mechanical properties can differ significantly from the parent metals after FSW.…”

Section: Introductionmentioning

confidence: 99%

Subregion Based Prediction of Residual States in Friction Stir Welding of Dissimilar Metals

Zhang,

Wang,

Liu

et al. 2023

Coatings

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Mechanical property changes in friction stir welding can directly affect the rebalance of the stress field in friction stir welding. This means that it reveals a high relevance with the residual states of friction stir welding. Here, we propose a subregion model in which the mechanical property changes are considered to predict the residual states in friction stir welding of dissimilar metals. Results indicate that the accuracy of the predicted distortion can be greatly increased when the different mechanical properties are considered in friction stir welding of 2024-T3 and 6061-T6. The final mechanical property is determined by the mixture of the materials at retreating and advancing sides. The final mechanical property in the stirring zone can be increased to 171 MPa for yield strength and 194 MPa for tensile strength when the strength of the advancing side material is higher. The shrinkage of material in the stirring zone during the cooling stage is the key reason for the formation of the tensile residual stress and the V-shape distortion on the cross-section in the as-weld state.

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Section: Introductionmentioning

confidence: 99%

Subregion Based Prediction of Residual States in Friction Stir Welding of Dissimilar Metals

Zhang,

Wang,

Liu

et al. 2023

Coatings

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“…This suggests that at higher deformation amount, DRX surpasses DRV as the primary softening mechanism.Figure15j-l show the Kernel Average Misorientation (KAM) maps of Ti6Al4V alloy at different thinning rates. The KAM maps characterize the substructure density of the material, with higher values indicating greater defect concentration[32]. At a thinning rate of 5%, the substructure density is higher, indicating numerous defects like dislocations generated during deformation.…”

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confidence: 99%

Hot Deformation Behavior and Microstructure Evolution Mechanisms of Ti6Al4V Alloy under Hot Stamping Conditions

Qu,

Gu,

et al. 2024

Materials

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Through the study of the thermal rheological behavior of Ti6Al4V alloy at different temperatures (500 °C, 600 °C, 700 °C, and 800 °C) and different strain rates (0.1 s−1, 0.05 s−1, 0.01 s−1, and 0.005 s−1), a constitutive model was developed for Ti6Al4V alloy across a wide temperature range in the hot stamping process. The model’s correlation coefficient reached 0.9847, indicating its high predictive accuracy. Hot processing maps suitable for the hot stamping process of Ti6Al4V alloy were developed, demonstrating the significant impact of the strain rate on the hot formability of Ti6Al4V alloy. At higher strain rates (>0.05 s−1), the hot processing of Ti6Al4V alloy is less prone to instability. Combining hot processing maps with hot stamping experiments, it was found that the forming quality and thickness uniformity of parts improved significantly with the increase in stamping speed. The phase composition and microstructures of the forming parts under different heating temperature conditions have been investigated using SEM, EBSD, XRD, and TEM, and the maximum heating temperature of hot stamping forming was determined to be 875 °C. The recrystallization mechanism in hot stamping of Ti6Al4V alloys was proposed based on EBSD tests on different sections of a hot stamping formed box-shaped component. With increasing deformation, the effect of dynamic recrystallization (DRX) was enhanced. When the thinning rate reached 15%, DRX surpassed dynamic recovery (DRV) as the dominant softening mechanism. DRX grains at different thinning rates were formed through both discontinuous dynamic recrystallization (DDRX) and continuous dynamic recrystallization (CDRX), with CDRX always being the dominant mechanism.

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“…Figure 4. Optical macro and micrographs indicate the weld cross section and adiabatic shear band formation during (a) CFSW and (b) SSFSW[33] …”

mentioning

confidence: 99%

The Feasibility of Static Shoulder Friction Stir Welding in Joining Dissimilar Metals of Al6061 and Ti6Al4V

Sundar,

Kar,

Mugada

et al. 2024

Metals

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In this study, static shoulder friction stir welding (SSFSW) is innovatively employed to join Al6061 and Ti6Al4V, aiming to minimize material mixing and intermetallic formation, significantly influencing the interfacial microstructure and joint strength. The results revealed that SSFSW reduced the intermetallic layer thickness at the interface, improving joint quality. The mutual interdiffusion of Al and Ti at the interface was influenced by an exothermic chemical reaction, forming an Al5Ti2–Al3Ti sequence due to the diffusion of Al into the Ti matrix. The microstructural analysis demonstrated better interfacial microstructural homogeneity in SSFSW joints than conventional FSW (CFSW), with finer titanium particle distribution. The larger particles resulted in coarser grains in CFSW, affecting the mobility of dislocations, which potentially led to the inhomogeneous concentration of dislocations at the interface. Recrystallization mechanisms varied between CFSW and SSFSW, with the Ti interface showing equiaxed and recrystallized grains due to the dynamic recovery driven by adiabatic shear bands. The tensile testing results of SSFSW exhibited a joint efficiency of 88%, demonstrating a 20.2% increase compared to CFSW, which can be attributed to differences in fracture modes. This study contributes to an understanding of dissimilar Al-Ti joining and provides insights for industries seeking to leverage the benefits of such combinations in lightweight and high-performance structures.

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Microstructural Evolution, Intermetallic Formation, and Mechanical Performance of Dissimilar Al6061–Ti6Al4V Static Shoulder Friction Stir Welds

Cited by 10 publications

References 55 publications

Subregion Based Prediction of Residual States in Friction Stir Welding of Dissimilar Metals

Subregion Based Prediction of Residual States in Friction Stir Welding of Dissimilar Metals

Hot Deformation Behavior and Microstructure Evolution Mechanisms of Ti6Al4V Alloy under Hot Stamping Conditions

The Feasibility of Static Shoulder Friction Stir Welding in Joining Dissimilar Metals of Al6061 and Ti6Al4V

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