Effect of FSP parameters and tool geometry on microstructure, hardness, and wear properties of AA7075 with and without reinforcing B4C ceramic particles

Tonelli, Lavinia; Morri, Alessandro; Toschi, Stefania; Shaaban, M. K.; Ammar, Hany R.; Ahmed, Mohamed M. Z.; Ramadan, R.; El-Mahallawi, I.; Ceschini, Lorella

doi:10.1007/s00170-019-03442-6

Cited by 49 publications

(15 citation statements)

References 33 publications

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“…Owing to its low fracture toughness, PCBN also has a tendency to fail during the initial plunge stage [ 25 ]. Thus, the WC material represents a cost-effective option for FSW of hard metals [ 26 ] and hard composites [ 29 , 30 ] if the tool life can be extended. An important parameter that can be considered to extend tool life is the geometry of the tool pin and the shoulder [ 31 ].…”

Section: Introductionmentioning

confidence: 99%

Friction Stir Welding of 2205 Duplex Stainless Steel: Feasibility of Butt Joint Groove Filling in Comparison to Gas Tungsten Arc Welding

et al. 2021

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This work investigates the feasibility of using friction stir welding (FSW) process as a groove filling welding technique to weld duplex stainless steel (DSS) that is extensively used by petroleum service companies and marine industries. For the FSW experiments, three different groove geometries without root gap were designed and machined in a DSS plates 6.5 mm thick. FSW were carried out to produce butt-joints at a constant tool rotation rate of 300 rpm, traverse welding speed of 25 mm/min, and tilt angle of 3o using tungsten carbide (WC) tool. For comparison, the same DSS plates were welded using gas tungsten arc welding (GTAW). The produced joints were evaluated and characterized using radiographic inspection, optical microscopy, and hardness and tensile testing. Electron back scattering diffraction (EBSD) was used to examine the grain structure and phases before and after FSW. The initial results indicate that FSW were used successfully to weld DSS joints with different groove designs with defect-free joints produced using the 60° V-shape groove with a 2 mm root face without root gap. This friction stir welded (FSWed) joint was further investigated and compared with the GTAW joint. The FSWed joint microstructure mainly consists of α and γ with significant grain refining; the GTWA weld contains different austenitic-phase (γ) morphologies such as grain boundary austenite (GBA), intragranular austenite precipitates (IGA), and Widmanstätten austenite (WA) besides the ferrite phase (α) in the weld zone (WZ) due to the used high heat input and 2209 filler rod. The yield strength, ultimate tensile strength, and elongation of the FSWed joint are enhanced over the GTAW weldment by 21%, 41%, and 66% and over the BM by 65%, 33%, and 54%, respectively. EBSD investigation showed a significant grain refining after FSW with grain size average of 1.88 µm for austenite and 2.2 µm for ferrite.

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Section: Introductionmentioning

confidence: 99%

Friction Stir Welding of 2205 Duplex Stainless Steel: Feasibility of Butt Joint Groove Filling in Comparison to Gas Tungsten Arc Welding

et al. 2021

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“…Whilst the tool shoulder stimulates bulk material flow, the stirring pin during the welding process fosters a layer-by-layer material to flow [ 8 ]. Furthermore, the heat generation during the FSW has a strong effect on the weld quality, and it comes from specific tool surfaces, designed tool shoulder, and pin geometry [ 9 , 10 ].The geometry of the tool pin affects the flow of plasticized material and the joint efficiency [ 10 , 11 ]. In fact, the pin geometry is an important parameter in the friction stir welding (FSW) process for temperature history, material flow, and grain size, as well as the quality of the FSW joints [ 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

Bobbin Tool Friction Stir Welding of Aluminum Thick Lap Joints: Effect of Process Parameters on Temperature Distribution and Joints’ Properties

et al. 2021

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Bobbin tool friction stir welding (BT-FSW) is characterized by a fully penetrated pin and double-sided shoulder that promote symmetrical solid-state joints. However, control of the processing parameters to obtain defect-free thick lap joints is still difficult and needs more effort. In this study, the BT-FSW process was used to produce 10 mm AA1050-H14 similar lap joints. A newly designed bobbin tool (BT) with three different pin geometries (cylindrical, square, and triangular) and concave shoulders profile was designed, manufactured, and applied to produce the Al alloy lap joints. The experiments were carried out at a constant tool rotation speed of 600 rpm and a wide range of various welding travel speeds of 200, 400, 600, 800, and 1000 mm/min. The generated temperature during the BT-FSW process was recorded and analyzed at the joints’ center line, and at both advancing and retreating sides. Visual inspection, macrostructures, hardness, and tensile properties were investigated. The fracture surfaces after tensile testing were also examined. The results showed that the pin geometry and travel speed are considered the most important controlling parameters in BT-FSW thick lap joints. The square (Sq) pin geometry gives the highest BT-FSW stir zone temperature compared to the other two pins, cylindrical (Cy) and triangular (Tr), whereas the Tr pin gives the lowest stir zone temperature at all applied travel speeds from 200 to 1000 mm/min. Furthermore, the temperature along the lap joints decreased with increasing the welding speed, and the maximum temperature of 380 °C was obtained at the lowest travel speed of 200 mm/min with applying Sq pin geometry. The temperature at the advancing side (AS) was higher than that at the retreating side (RS) by around 20 °C. Defect-free welds were produced using a bobbin tool with Cy and Sq pin geometries at all the travel welding speeds investigated. BT-FSW at a travel speed of 200 mm/min leads to the highest tensile shear properties, in the case of using the Sq pin. The hardness profiles showed a significant effect for both the tool pin geometry and the welding speed, whereas the width of the softened region is reduced dramatically with increasing the welding speed and using the triangular pin.

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“…In most recent studies, it has been called additive friction stir deposition (AFSD) [13]. AFSD, as a thermomechanical process, is typically similar to friction stir processing [11,[14][15][16], and welding [17][18][19] in heat generation, heat dissipation, and heat transfer mechanisms in the stir zone. The thermal stresses in the additive manufactured part (AMP) produced by the AFSD process are likely to be minimal, owing to a lower temperature gradient when compared to additive processes involving melting stir zone.…”

Section: Introductionmentioning

confidence: 99%

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

et al. 2021

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In the current investigation, additive friction stir-deposition (AFS-D) of as-cast hypoeutectic A356 Al alloy was conducted. The effect of feeding speeds of 3, 4, and 5 mm/min at a constant rotational speed of 1200 rpm on the macrostructure, microstructure, and hardness of the additive manufacturing parts (AMPs) was investigated. Various techniques (OM, SEM, and XRD) were used to evaluate grain microstructure, presence phases, and intermetallics for the as-cast material and the AMPs. The results showed that the friction stir deposition technique successfully produced sound additive manufactured parts at all the applied feeding speeds. The friction stir deposition process significantly improved the microstructure of the as-cast alloy by eliminating porosity and refining the dendritic α-Al grains, eutectic Si phase, and the primary Si plates in addition to intermetallic fragmentation. The mean values of the grain size of the produced AMPs at the feeding speeds of 3, 4, and 5 mm/min were 0.62 ± 0.1, 1.54 ± 0.2, and 2.40 ± 0.15 µm, respectively, compared to the grain size value of 30.85 ± 2 for the as-cast alloy. The AMPs exhibited higher hardness values than the as-cast A356 alloy. The as-cast A356 alloy showed highly scattered hardness values between 55 and 75.8 VHN. The AMP fabricated at a 3 mm/min feeding speed exhibited the maximum hardness values between 88 and 98.1 VHN.

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Effect of FSP parameters and tool geometry on microstructure, hardness, and wear properties of AA7075 with and without reinforcing B4C ceramic particles

Cited by 49 publications

References 33 publications

Friction Stir Welding of 2205 Duplex Stainless Steel: Feasibility of Butt Joint Groove Filling in Comparison to Gas Tungsten Arc Welding

Friction Stir Welding of 2205 Duplex Stainless Steel: Feasibility of Butt Joint Groove Filling in Comparison to Gas Tungsten Arc Welding

Bobbin Tool Friction Stir Welding of Aluminum Thick Lap Joints: Effect of Process Parameters on Temperature Distribution and Joints’ Properties

The Applicability of Die Cast A356 Alloy to Additive Friction Stir Deposition at Various Feeding Speeds

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