Influence of increased processing speed on the microstructure evolution and mechanical property relationship in friction stir welding of AA5182-H111 (T500)
- Authors: Bernard, Dreyer
- Date: 2016
- Subjects: Friction stir welding , Aluminum alloys -- Welding
- Language: English
- Type: Thesis , Doctoral , PhD
- Identifier: http://hdl.handle.net/10948/7322 , vital:21319
- Description: Friction stir welding of 5xxx series aluminium is generally carried out at low travel speeds, which limits the commercial applications of this process. This manuscript discusses the dynamic eformation characteristics of AA5182-H111 (T500), which allowed a travel speed of 1500 mm/min to be realised. This was achieved by using a spindle speed of 500 rev/min; the same as that required to make a weld of 200 mm/min. The thermal cycles, microstructural evolution due to tool / work-piece interaction, and the local microstructural and mechanical properties of the completed weld are discussed for a travel speed for 200 mm/min and 1500 mm/min. At a rate of 200 mm/min, heat generated due to contact between the shoulder and work-piece surface was transferred ahead of the tool, driving dynamic recrystallization which lowered the flow stress. Hereafter the material entered the stir zone where it was extruded around the pin during a process of continuous dynamic crystallization. At a travel speed of 1500 mm/min, the rate of heat conduction ahead of the tool was not rapid enough, and the material was deformed at low temperatures. A low weld pitch rotations per unit length travelled) was required to ensure that the material was sufficiently strained, to allow the formation of geometric necessary boundaries, which resulted in grain subdivision. The number of high angle grain boundaries was increased through subdivision, thus, increasing the nucleation sites for dynamically recrystallized necklace grains to form. In the absence of heat conduction from the shoulder, the high plastic strain ahead of the tool provided the energy required to drive dynamic recrystallization. Heat was generated from the high plastic strain and during recrystallization, where the stored plastic energy was adiabatically released. Once the material entered the stir zone, the high strain rates associated with the tool rotation which drove dynamic recrystallization that allowed the material to reach high levels of strain, resulted significant grain refinement. The weld zone of the 200 mm/min displayed weld a slight increase in yield strength, with respect to the parent material, due to grain refinement to 10 μm, while the yield strength of the 1500 mm/min weld was significantly increased due to grain refinement to 5 μm. The high weld speed did, however, generate high tensile residual stresses. This work is not only significant for the field of friction stir welding, but also in terms of material processing. The dynamic deformation characteristics associated with Al-5Mg-Mn, alloys which was observed ahead of the tool, is of high value in processes where plastic deformation is applied to improve the mechanical properties of these alloys.
- Full Text:
- Date Issued: 2016
- Authors: Bernard, Dreyer
- Date: 2016
- Subjects: Friction stir welding , Aluminum alloys -- Welding
- Language: English
- Type: Thesis , Doctoral , PhD
- Identifier: http://hdl.handle.net/10948/7322 , vital:21319
- Description: Friction stir welding of 5xxx series aluminium is generally carried out at low travel speeds, which limits the commercial applications of this process. This manuscript discusses the dynamic eformation characteristics of AA5182-H111 (T500), which allowed a travel speed of 1500 mm/min to be realised. This was achieved by using a spindle speed of 500 rev/min; the same as that required to make a weld of 200 mm/min. The thermal cycles, microstructural evolution due to tool / work-piece interaction, and the local microstructural and mechanical properties of the completed weld are discussed for a travel speed for 200 mm/min and 1500 mm/min. At a rate of 200 mm/min, heat generated due to contact between the shoulder and work-piece surface was transferred ahead of the tool, driving dynamic recrystallization which lowered the flow stress. Hereafter the material entered the stir zone where it was extruded around the pin during a process of continuous dynamic crystallization. At a travel speed of 1500 mm/min, the rate of heat conduction ahead of the tool was not rapid enough, and the material was deformed at low temperatures. A low weld pitch rotations per unit length travelled) was required to ensure that the material was sufficiently strained, to allow the formation of geometric necessary boundaries, which resulted in grain subdivision. The number of high angle grain boundaries was increased through subdivision, thus, increasing the nucleation sites for dynamically recrystallized necklace grains to form. In the absence of heat conduction from the shoulder, the high plastic strain ahead of the tool provided the energy required to drive dynamic recrystallization. Heat was generated from the high plastic strain and during recrystallization, where the stored plastic energy was adiabatically released. Once the material entered the stir zone, the high strain rates associated with the tool rotation which drove dynamic recrystallization that allowed the material to reach high levels of strain, resulted significant grain refinement. The weld zone of the 200 mm/min displayed weld a slight increase in yield strength, with respect to the parent material, due to grain refinement to 10 μm, while the yield strength of the 1500 mm/min weld was significantly increased due to grain refinement to 5 μm. The high weld speed did, however, generate high tensile residual stresses. This work is not only significant for the field of friction stir welding, but also in terms of material processing. The dynamic deformation characteristics associated with Al-5Mg-Mn, alloys which was observed ahead of the tool, is of high value in processes where plastic deformation is applied to improve the mechanical properties of these alloys.
- Full Text:
- Date Issued: 2016
Characterisation of dissimilar friction stir welds between 5754 Aluminium alloy and C11000 copper
- Authors: Akinlabi, Esther Titilayo
- Date: 2010
- Subjects: Friction stir welding , Aluminum alloys , Copper alloys
- Language: English
- Type: Thesis , Doctoral , DTech
- Identifier: vital:9629 , http://hdl.handle.net/10948/1536 , Friction stir welding , Aluminum alloys , Copper alloys
- Description: Friction Stir Welding (FSW) is a solid state welding process invented and patented by The Welding Institute (TWI) in 1991, for joining ferrous and non-ferrous materials1. The FSW of Aluminium and its alloys has been commercialised; and recent interest is focused on joining dissimilar materials. However, in order to commercialise the process, research studies are required to characterise and establish process windows. This research work through material characterisation of the welded joints establishes a process window for the Friction Stir welding of 5754 Aluminium Alloy and C11000 Copper. Furthermore, preliminary studies83,85 on the FSW of aluminium and copper have revealed the presence of intermetallic compounds which are detrimental to the weld qualities. This research work is also aimed at establishing process parameters that will result in limited or no intermetallic formation in the weld. The joint integrity of the resulting welds will also be correlated with the input process parameters. Based on the preliminary investigations conducted, a final weld matrix consisting of twenty seven welds was produced by varying the rotational speed between 600 and 1200 rpm, and the feed rate between 50 and 300 mm/min using three different shoulder diameter tools – 15, 18 and 25 mm to compare the heat input into the welds and to achieve the best results. The welds were characterised through microstructural evaluation, tensile testing, microhardness profiling, X-Ray Diffraction analysis, electrical resistivity and statistical analysis – in order to establish the interrelationship between the process parameters and the weld qualities. viii Microstructural evaluation of the weld samples revealed that the interfacial regions are characterised by mixture layers of aluminium and copper; while 33 percent of the tensile samples are within the acceptable range (> 75 percent joint efficiency). High Vickers microhardness values were measured at the joint interfaces, which corresponded with the intermetallic compounds. The Energy Dispersive Spectroscopy analysis revealed the presence of thin layers of intermetallics in nanoscale at the interfacial regions. The diffractograms of the X-Ray Diffraction analysis showed small peaks for intermetallics in some of the welds. Low electrical resistivities were measured at the joint interfaces. The statistical analysis showed that the downward vertical force, (Fz) can significantly influence the resulting weld qualities. An overall summary of the analysis of the weld qualities - with respect to the shoulder diameter tools employed showed that the 18 mm shoulder diameter tool is most appropriate among the three shoulder diameters considered, and a process window of medium spindle speed of 950 rpm and low-to-medium feed rate between 50 and 150 mm/min is established for FSW of Aluminium and Copper. Welds produced at 1200 rpm and 300 mm/min with low heat input did not have intermetallics formed at the joint interface.
- Full Text:
- Date Issued: 2010
- Authors: Akinlabi, Esther Titilayo
- Date: 2010
- Subjects: Friction stir welding , Aluminum alloys , Copper alloys
- Language: English
- Type: Thesis , Doctoral , DTech
- Identifier: vital:9629 , http://hdl.handle.net/10948/1536 , Friction stir welding , Aluminum alloys , Copper alloys
- Description: Friction Stir Welding (FSW) is a solid state welding process invented and patented by The Welding Institute (TWI) in 1991, for joining ferrous and non-ferrous materials1. The FSW of Aluminium and its alloys has been commercialised; and recent interest is focused on joining dissimilar materials. However, in order to commercialise the process, research studies are required to characterise and establish process windows. This research work through material characterisation of the welded joints establishes a process window for the Friction Stir welding of 5754 Aluminium Alloy and C11000 Copper. Furthermore, preliminary studies83,85 on the FSW of aluminium and copper have revealed the presence of intermetallic compounds which are detrimental to the weld qualities. This research work is also aimed at establishing process parameters that will result in limited or no intermetallic formation in the weld. The joint integrity of the resulting welds will also be correlated with the input process parameters. Based on the preliminary investigations conducted, a final weld matrix consisting of twenty seven welds was produced by varying the rotational speed between 600 and 1200 rpm, and the feed rate between 50 and 300 mm/min using three different shoulder diameter tools – 15, 18 and 25 mm to compare the heat input into the welds and to achieve the best results. The welds were characterised through microstructural evaluation, tensile testing, microhardness profiling, X-Ray Diffraction analysis, electrical resistivity and statistical analysis – in order to establish the interrelationship between the process parameters and the weld qualities. viii Microstructural evaluation of the weld samples revealed that the interfacial regions are characterised by mixture layers of aluminium and copper; while 33 percent of the tensile samples are within the acceptable range (> 75 percent joint efficiency). High Vickers microhardness values were measured at the joint interfaces, which corresponded with the intermetallic compounds. The Energy Dispersive Spectroscopy analysis revealed the presence of thin layers of intermetallics in nanoscale at the interfacial regions. The diffractograms of the X-Ray Diffraction analysis showed small peaks for intermetallics in some of the welds. Low electrical resistivities were measured at the joint interfaces. The statistical analysis showed that the downward vertical force, (Fz) can significantly influence the resulting weld qualities. An overall summary of the analysis of the weld qualities - with respect to the shoulder diameter tools employed showed that the 18 mm shoulder diameter tool is most appropriate among the three shoulder diameters considered, and a process window of medium spindle speed of 950 rpm and low-to-medium feed rate between 50 and 150 mm/min is established for FSW of Aluminium and Copper. Welds produced at 1200 rpm and 300 mm/min with low heat input did not have intermetallics formed at the joint interface.
- Full Text:
- Date Issued: 2010
- «
- ‹
- 1
- ›
- »