Strength and microstructure of friction stir welded additively manufactured Scalmalloy® in as-welded and heat-treated conditions

Mirandola, Pietro; Lunetto, Vincenzo; Novel, David; Barozzi, M.; Bellutti, P.; Maddis, Manuela De; Spena, Pasquale Russo

doi:10.1016/j.jmapro.2023.04.051

Cited by 5 publications

(1 citation statement)

References 31 publications

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“…Of all the solid-state welding processes evaluated, FSW is by far the most widely used process for joining AM-manufactured Al alloys [37,[55][56][57][58][59][60][61][62][63][64][65][66][67][68][69][70]. For this process, only studies were found evaluating the weldability of parts produced by the PBF-LB process.…”

Section: Solid State Welding Processesmentioning

confidence: 99%

A Review on the Weldability of Additively Manufactured Aluminium Parts by Fusion and Solid-State Welding Processes

Nunes,

Faes,

De Waele

et al. 2023

Metals

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Additive manufacturing (AM) processes are playing a significant role in several industrial sectors such as construction and machine building industries, involving a wide variety of metallic materials. Among these, the AM of aluminium alloys has developed significantly over the last decade, mainly through Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) processes. Despite the many advantages of AM technology, some large or complex products cannot be produced entirely without the use of conventional manufacturing and joining processes, generally for financial or operational reasons. In this way, the ability to join conventionally and additively manufactured components or parts represents a crucial step towards their future use and the consolidation of conventional and additive manufacturing technologies. Despite the growing interest in AM technologies, there is still a significant lack of information on the joining of conventionally and additively manufactured components. The present work proposes a first review of the literature evaluating the weldability of AM aluminium alloys. The focus is on the use of fusion and solid-state welding processes and analysing the achieved microstructural evolution and mechanical properties. A clear relationship is observed between the AM technology used to produce the part, and the physical principles of the joining process. In addition, the gaps in the literature are highlighted to enable focused future work.

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Section: Solid State Welding Processesmentioning

confidence: 99%

A Review on the Weldability of Additively Manufactured Aluminium Parts by Fusion and Solid-State Welding Processes

Nunes,

Faes,

De Waele

et al. 2023

Metals

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Non-destructive detection and analysis of weld defects in dissimilar pulsed GMAW and FSW joints of aluminium castings and plates through 3D X-ray computed tomography

Orlando,

De Maddis,

Razza

et al. 2024

Int J Adv Manuf Technol

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This work focuses on porosity formation during the welding of dissimilar aluminium alloys (cast and sheet) by pulsed gas metal arc welding (GMAW) with different travel speeds (12–14 mm/s) and by friction stir welding (FSW). The case study concerns the assembling of a battery-pack enclosure prototype. The welded specimens were scanned by 3D X-ray computed tomography. The cast base material (BM) shows a porosity percentage of 1.45%, and it is characterized by pores with a strong hyperbolic relationship between equivalent diameter and sphericity. Considering the GMAW beads, porosity rises with the travel speed (from 1.80 to 5.12%), due to the reduction of the opening window in which pores can escape. Pores with volume higher than 0.10 mm3 rise with the travel speed, representing from 9.75 to 32.98% of the total porosity. These pores are responsible for the weaker hyperbolic connection for sphericity found for the GMAW beads. On the other hand, FSW mixes and homogenizes the pores in the cast BM. The novelty of the paper lays in proving the strong potentialities of FSW for weld porosity reduction. A re-designing of the battery-pack enclosures is necessary to limit arc welding in marginal areas, which are not crucial for sealing but necessary to create a stable platform to be subsequently sealed with FSW.

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Microstructures and mechanical properties of friction stir welded additively manufactured Scalmalloy®

Mirandola,

Novel,

Perini

et al. 2024

Int J Adv Manuf Technol

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The development of high-strength advanced additively manufactured (AM) aluminum alloys is driven by the need for weight reduction in complex-shaped structural applications. In this context, heat-treatable aluminum-scandium alloy, known commercially as Scalmalloy®, offers high strength and lightness, also at high temperatures, due to solution strengthening Al3(Sc, Zr) particles. A widespread diffusion of such AM alloy is also related to welding technologies that could preserve its engineered microstructure. This study investigates the microstructural and mechanical properties of butt friction stir welding (FSW) joints of LPBF Scalmalloy® plates under different welding settings. Joint performance was evaluated under quasi-static and cyclic loading conditions. Porosity in Scalmalloy® and welds was assessed using 3D X-ray computed tomography. An aging heat treatment assessed the extent of precipitation hardening in the FSW joints. Results show that metal stirring during FSW notably reduced the intrinsic porosity of Scalmalloy®, decreasing the equivalent pore diameter from about 200 μm to 60 μm in the welded joints. Under quasi-static loading, welded specimens failed at the interface between the thermo-mechanically affected and the stir zones on the advancing side. The aging heat treatment improved the mechanical strength of Scalmalloy® from approximately 400 to 480 MPa, albeit at the expense of ductility (elongation at fracture decreased from 16 to 4%). The higher heat input and stirring developed at a low welding speed reduced lazy S defects but limited the effectiveness of subsequent aging. In fatigue testing, welded joints consistently failed within the aged base material due to the intrinsic porosity of Scalmalloy®.

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Strength and microstructure of friction stir welded additively manufactured Scalmalloy® in as-welded and heat-treated conditions

Cited by 5 publications

References 31 publications

A Review on the Weldability of Additively Manufactured Aluminium Parts by Fusion and Solid-State Welding Processes

A Review on the Weldability of Additively Manufactured Aluminium Parts by Fusion and Solid-State Welding Processes

Non-destructive detection and analysis of weld defects in dissimilar pulsed GMAW and FSW joints of aluminium castings and plates through 3D X-ray computed tomography

Microstructures and mechanical properties of friction stir welded additively manufactured Scalmalloy®

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