The microstructure of friction stir processed AA5052 sheets is investigated using
Scanning Electron Microscopy (SEM) and Orientation Imaging Microscopy. The correlation between the generated forces during processing and the microstructure is evaluated. Observations indicate that the finest microstructure are achieved when the plunging forces are at minimum.
Despite the large number of studies that are being conducted to advance the friction stir
processing (FSP) technology, the effects of FSP on various mechanical and microstructural
properties are still in need for further investigations. In addition, correlations between FSP
parameters, mechanical properties and microstructural characteristics are not yet well understood.
Accurate correlations are needed for successful modeling and process optimization. It is established
that the temperature generated during FSP plays an important role in determining the microstructure
and properties of the processed sheet and defining the tool life. Process parameters must be
carefully chosen to allow the generation of enough heat to soften the material while limiting
significant grain growth. Accurate measurement of the temperature distributions during processing
are essential to understand the complicated deformation and associated mechanisms and to allow
for effective process optimization. In this work, a dual-band thermography approach is used to
measure the temperature distributions of AA5052 sheet during FSP. The setup utilizes two infrared
detectors, to neutralize the emissivity and the facial effects, with 30 Hz acquisition rate. The
variation of temperature with process parameters and their correlation to the resulting
microstructure are discussed.
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