The distribution of residual stresses (RS) in repairs generated by Friction Hydro-Pillar Processing (FHPP) in AISI H13 was investigated. Three axial force levels, with consequent different deposition rates, were applied to replicate possible repaired conditions. The contour (CM) and X-ray diffraction (XRD) methods were employed for RS analysis in samples that were also evaluated through metallography, microhardness analysis, micro-tensile and Charpy testing. CM produced 2D maps of the RS in the joints, showing symmetrical distributions around the welded rod for all welded conditions. Other common features for all conditions were the maximum level of compressive RS, which was found in the TMAZ of the rod, and the maximum tensile residual stress, which was found near the HAZ of the base block. There was good agreement between the RS measurement techniques. Mechanical tests show similar tensile resistance for all conditions and an apparent increase in toughness at higher force levels.
Friction Stir Welding (FSW) is a solid-state joining process that has been demonstrating to be an excellent alternative for joining aluminum alloys. Therefore, this work presents the influence of process parameters (rotational speed, welding speed, and tool shoulder penetration) on mechanical properties of friction-stir-welded AA 5083-O. The welded joints were analyzed by metallography, tensile, and bending tests. Furthermore, the surface fracture of the best joint was evaluated by scanning electron microscopy (SEM) for verifying the major fracture mechanism. It was found that the ultimate tensile strength (UTS) of the welds was similar to that of the base material. Moreover, the microhardness profiles were comparable along the regions considered. Also, the failures of both bending and tensile tests tend to occur on the advancing side.
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