Multimodal analysis of spatially heterogeneous microstructural refinement and softening mechanisms in three-pass friction stir processed Al-4Si alloy

Escobar, Julián; Gwalani, Bharat; Olszta, Matthew J.; Silverstein, Joshua; Overman, Nicole; Bergmann, Luciano; Santos, J.F. dos; Staron, Peter; Maawad, Emad; Klusemann, Benjamin; Mathaudhu, Suveen; Devaraj, Arun

doi:10.1016/j.jallcom.2021.161351

Cited by 10 publications

(3 citation statements)

References 55 publications

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“…Through such microstructural modifications, FSP has been shown to improve ductility [4]- [6], fatigue resistance [7], yield stress [8], wearability [9], and corrosion resistance [10]. In some cases, the property enhancement is greater with more passes of FSP [11].…”

Section: Introductionmentioning

confidence: 99%

On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

Balusu

Choi

Das

et al. 2023

Int J Adv Manuf Technol

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This paper investigates the thermal-pseudo mechanical (TPM) model's residual stress prediction capability for its utility in developing friction stir processing (FSP). Specifically, two FSP tests under different processing conditions were conducted, and the corresponding simulations were carried out to verify if the TPM model can predict residual stresses for various tool radii and workpiece materials. The model was successful in predicting residual stresses for one of the tests but failed to work for the other test. Further simulations under different FSP conditions prove that the TPM model works for cast aluminum alloys in addition to wrought aluminum alloys. However, there is only a range of tool radii for which the TPM model is applicable, and the large FSP tool used is the reason for the model's failure on one of the tests. As a solution, this paper suggests modifications to the TPM model based on calibration to the FSP test temperatures. The calibrated TPM model still cannot predict the effect of the tool radii on the residual stresses; however, the effect on residual stresses due to changes in the process parameters, such as the tool traverse & rotation speeds and the clamping conditions, can be predicted.

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Section: Introductionmentioning

confidence: 99%

On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

Balusu

Choi

Das

et al. 2023

Int J Adv Manuf Technol

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show abstract

“…Despite many years of research, welding of VPDC castings is still a challenge because the welding defects such as porosity or slag inclusions are prone to form [14,15]. An alternative to these joining techniques that is more environmentally friendly and has demonstrated to be a promising technology to weld various kind of wrought and cast aluminum alloys is Friction Stir Welding (FSW) [16][17][18][19][20][21][22][23].…”

Section: Introductionmentioning

confidence: 99%

Friction Stir Weldability at High Welding Speed of Two Structural High Pressure Die Casting Aluminum Alloys

Vivas

Fernández-Calvo

Aldanondo

et al. 2022

JMMP

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In this work, the friction stir weldability of two structural high-pressure die casting aluminum alloys designed to manufacture thin-walled automotive components is investigated and compared. AlSi10MnMg and AlMg4Fe2 alloys were friction stir welded at a high welding speed (from 500 to 2000 mm/min) for a fixed rotation speed of 1500 RPM. The investigation was performed by studying the material flow influence on defect formation and microstructure, the mechanical properties of the welds and the forces that act during the friction stir welding process. The AlSi10MnMg alloy shows a lower incidence of defects than the AlMg4Fe2 alloy at all welding speeds investigated. Both materials present a great friction stir welding performance at 500 mm/min with a high joint efficiency in terms of ultimate tensile strength: 92% in AlSi10MnMg alloy and 99% in AlMg4Fe2 alloy.

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“…The authors discovered a regionally heterogeneous link between microstructure and softening process whereas microhardness achieved is 29 ± 1 HV in the stir zone. 20 Nasiri et al analysed the effect of single pass, 1500 rpm rotational speed, 25 mm/min travel speed and 2° tilt angle on Mg-7Al alloy adding Ca/Al as reinforcement using FSP. The grain refinement is obtained which is responsible for improving the ultimate tensile strength from 157 to 267.2 MPa.…”

Section: Introductionmentioning

confidence: 99%

Animal waste powder utilization for Al6061/SiC composite using friction stir processing with scroll shoulder hexagonal tool

Gupta

Singh

Kumar³

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Nowadays, a lot of animal waste is available in the world. To reduce the number of animal waste particles, it is used as reinforcement, reducing the cost of reinforcement without affecting the present qualities. In this research, AA6061 is used because of its lower weight-to-strength ratio whereas to reduce the cost of reinforcement, chicken bone powder (CBP) with varying percentages (2%, 4%, and 6%) and 2% SiC is used. A hexagonal tool with a scroll shoulder is used for the fabrication of AA6061/SiC/CBP hybrid composite. Microstructural analysis, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), fractography analysis, tool analysis, tensile strength, and hardness are used for the analysis of AA6061/SiC/CBP hybrid composite. Microstructural analysis shows that the grain size of SiC and CBP particles is reduced from 40 to 4.6 μm. Homogenous distribution of the reinforcement with no agglomeration is observed in SEM analysis. Fractography shows the presence of dimples and micro-dimples which indicates that tensile strength increases whereas XRD analysis investigates that there are no unwanted contaminants present in the AA6061/SiC/CBP hybrid composite which can be harmful during machining. Tensile strength and hardness of AA6061/SiC/CBP hybrid composite increase up to 29.28% and 18.22%, respectively, on increasing the percentage of chicken bone powder in reinforcement.

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Multimodal analysis of spatially heterogeneous microstructural refinement and softening mechanisms in three-pass friction stir processed Al-4Si alloy

Cited by 10 publications

References 55 publications

On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

On the Utility of the Thermal-Pseudo Mechanical Model’s Residual Stress Prediction Capability for the Development of Friction Stir Processing

Friction Stir Weldability at High Welding Speed of Two Structural High Pressure Die Casting Aluminum Alloys

Animal waste powder utilization for Al6061/SiC composite using friction stir processing with scroll shoulder hexagonal tool

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