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
Increasing the gap tolerance in friction stir welded joints of AA6082-T6
- Authors: Oyedemi, Kayode
- Date: 2012
- Subjects: Friction stir welding , Aluminum alloys -- Welding , Welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9628 , http://hdl.handle.net/10948/d1012325 , Friction stir welding , Aluminum alloys -- Welding , Welding
- Description: This research project was conducted to increase weld gap tolerance in Friction Stir Welding (FSW) of 8 mm thick aluminum alloy 6082 – T6. Investigation was done on I-STIR PDS platform and a Johnford milling machine. The research project involved tool-pin design with varying re-entrant features and varying parameters as a method of weld gap closing to produce successful welds. Direction of spindle rotation and dwell time were established as part of a preliminary study. Clockwise spindle rotation with 20 seconds dwell time allows sufficient plasticity and improved material flow which assisted in achieving welds with prior 30 percent weld gap of the plate thickness. Final welds were made using three rotational speeds and feed rates with sufficient plunging to prevent root defects. Analysis of the results were detailed which include vickers microhardness test, tensile test and metallographic observation to access the suitability of the weld structure. From the set of tool-pins designed, the flare tool-pin gave a well-defined weld nugget with improved stirring at the weld root. Also, with a concave shoulder, right hand threaded tool-pin and counterclockwise flutes undergoing a clockwise spindle rotation, plasticized material flow was upward which was beneficial in reducing the amount of plate thinning. The right hand thread counter clockwise flute with a flute machined in the foot exhibited superior tensile strength for welds containing 30 percent weld gap.
- Full Text:
- Date Issued: 2012
- Authors: Oyedemi, Kayode
- Date: 2012
- Subjects: Friction stir welding , Aluminum alloys -- Welding , Welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9628 , http://hdl.handle.net/10948/d1012325 , Friction stir welding , Aluminum alloys -- Welding , Welding
- Description: This research project was conducted to increase weld gap tolerance in Friction Stir Welding (FSW) of 8 mm thick aluminum alloy 6082 – T6. Investigation was done on I-STIR PDS platform and a Johnford milling machine. The research project involved tool-pin design with varying re-entrant features and varying parameters as a method of weld gap closing to produce successful welds. Direction of spindle rotation and dwell time were established as part of a preliminary study. Clockwise spindle rotation with 20 seconds dwell time allows sufficient plasticity and improved material flow which assisted in achieving welds with prior 30 percent weld gap of the plate thickness. Final welds were made using three rotational speeds and feed rates with sufficient plunging to prevent root defects. Analysis of the results were detailed which include vickers microhardness test, tensile test and metallographic observation to access the suitability of the weld structure. From the set of tool-pins designed, the flare tool-pin gave a well-defined weld nugget with improved stirring at the weld root. Also, with a concave shoulder, right hand threaded tool-pin and counterclockwise flutes undergoing a clockwise spindle rotation, plasticized material flow was upward which was beneficial in reducing the amount of plate thinning. The right hand thread counter clockwise flute with a flute machined in the foot exhibited superior tensile strength for welds containing 30 percent weld gap.
- Full Text:
- Date Issued: 2012
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
Process window for friction stir welding of 3 mm titanium (Ti-6AI-4V)
- Authors: Mashinini, Peter Madindwa
- Date: 2010
- Subjects: Friction stir welding , Titanium -- Welding , Welded joints
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9618 , http://hdl.handle.net/10948/1413 , Friction stir welding , Titanium -- Welding , Welded joints
- Description: Friction stir welding was used to join 3 mm Ti-6Al-4V alloy in a butt joint configuration. This research focused on optimization of a tool geometry and the interaction between process parameters and static performance of welded joints. The main parameters varied were tool travel speed and tool rotational speed. The results showed a relationship between heat input as a function of process parameters and static strength. Improved tensile properties correspond to high heat input. The hardness plots revealed an increase in hardness on both the stir zone and heat affected zone despite the small defects on the weld root. The weld microstructure was also evaluated, which showed a variation in microstructure on both the heat affected zone and stir zone in comparison to the parent material. It was also found that the use of MgO as a heat barrier on the backing plate was detrimental to the weld tensile properties of butt-welded plates compared to bead-on-plate welds of which MgO had no influence.
- Full Text:
- Date Issued: 2010
- Authors: Mashinini, Peter Madindwa
- Date: 2010
- Subjects: Friction stir welding , Titanium -- Welding , Welded joints
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9618 , http://hdl.handle.net/10948/1413 , Friction stir welding , Titanium -- Welding , Welded joints
- Description: Friction stir welding was used to join 3 mm Ti-6Al-4V alloy in a butt joint configuration. This research focused on optimization of a tool geometry and the interaction between process parameters and static performance of welded joints. The main parameters varied were tool travel speed and tool rotational speed. The results showed a relationship between heat input as a function of process parameters and static strength. Improved tensile properties correspond to high heat input. The hardness plots revealed an increase in hardness on both the stir zone and heat affected zone despite the small defects on the weld root. The weld microstructure was also evaluated, which showed a variation in microstructure on both the heat affected zone and stir zone in comparison to the parent material. It was also found that the use of MgO as a heat barrier on the backing plate was detrimental to the weld tensile properties of butt-welded plates compared to bead-on-plate welds of which MgO had no influence.
- Full Text:
- Date Issued: 2010
Analysing the effect of FSP on MIG-laser hybrid welded 6082-T6 AA joints
- Authors: Mjali, Kadephi Vuyolwethu
- Date: 2007
- Subjects: Friction stir welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9610 , http://hdl.handle.net/10948/563 , Friction stir welding
- Description: Friction Stir Processing (FSP) of aluminium alloys has been used to modify and improve the microstructure and relevant properties of fusion welded aluminium alloys. The effect of FSP on MIG-Laser Hybrid (MLH) welded aluminium alloy 6082-T6 mechanical and microstructural properties has been studied in this research. The FSP process was used on 6mm thick aluminium alloy plates and a tool was designed specifically for FSP, and the effect of varying speeds was analysed before the final FSP welds were made. The effect of FSP was analysed by optical microscopy, tensile, microhardness and fatigue testing. The aim of the study was to determine whether the FSP process has a beneficial influence on the mechanical properties and metallurgical integrity of MIG-Laser Hybrid welded 6082-T6 aluminium alloy with varying gap tolerances. Three welding processes were compared, namely combined Friction Stir Processing on MIG-Laser hybrid process (FSP-MLH), MLH and Friction Stir Welding (FSW) as part of the analysis. (FSP was carried out on MLH components when it was found that FSP is not an entirely complete welding process but rather a finishing process per se.) The aim of this dissertation is to investigate the effects of the FSP process on the weld quality of MLH welded joints and also to compare this to individual processes like FSW and MLH. This investigation was undertaken in order to gain an understanding of the effect of these processes on fatigue performance and microhardness distribution on aluminium alloy 6082-T6 weld joints.
- Full Text:
- Date Issued: 2007
- Authors: Mjali, Kadephi Vuyolwethu
- Date: 2007
- Subjects: Friction stir welding
- Language: English
- Type: Thesis , Masters , MTech
- Identifier: vital:9610 , http://hdl.handle.net/10948/563 , Friction stir welding
- Description: Friction Stir Processing (FSP) of aluminium alloys has been used to modify and improve the microstructure and relevant properties of fusion welded aluminium alloys. The effect of FSP on MIG-Laser Hybrid (MLH) welded aluminium alloy 6082-T6 mechanical and microstructural properties has been studied in this research. The FSP process was used on 6mm thick aluminium alloy plates and a tool was designed specifically for FSP, and the effect of varying speeds was analysed before the final FSP welds were made. The effect of FSP was analysed by optical microscopy, tensile, microhardness and fatigue testing. The aim of the study was to determine whether the FSP process has a beneficial influence on the mechanical properties and metallurgical integrity of MIG-Laser Hybrid welded 6082-T6 aluminium alloy with varying gap tolerances. Three welding processes were compared, namely combined Friction Stir Processing on MIG-Laser hybrid process (FSP-MLH), MLH and Friction Stir Welding (FSW) as part of the analysis. (FSP was carried out on MLH components when it was found that FSP is not an entirely complete welding process but rather a finishing process per se.) The aim of this dissertation is to investigate the effects of the FSP process on the weld quality of MLH welded joints and also to compare this to individual processes like FSW and MLH. This investigation was undertaken in order to gain an understanding of the effect of these processes on fatigue performance and microhardness distribution on aluminium alloy 6082-T6 weld joints.
- Full Text:
- Date Issued: 2007
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