Datong Zhang

Dissimilar friction stir welding between 5052 aluminum alloy and AZ31 magnesium alloy

Abstract Dissimilar friction stir welding between 5052 Al alloy and AZ31 Mg alloy with the plate thickness of 6 mm was investigated. Sound weld was obtained at rotation speed of 600 r/min and welding speed of 40 mm/min. Compared with the base materials, the microstructure of the stir zone is greatly refined. Complex flow pattern characterized by intercalation lamellae is formed in the stir zone. Microhardness measurement of the dissimilar welds presents an uneven distribution due to the complicated microstructure of the weld, and the maximum value of microhardness in the stir zone is twice higher than that of the base materials. The tensile fracture position locates at the advancing side (aluminum side), where the hardness distribution of weld shows a sharp decrease from the stir zone to 5052 base material.

Microstructure and mechanical properties of dissimilar pure copper/1350 aluminum alloy butt joints by friction stir welding

The dissimilar friction stir welding of pure copper/1350 aluminum alloy sheet with a thickness of 3 mm was investigated. Most of the rotating pin was inserted into the aluminum alloy side through a pin-off technique, and sound welds were obtained at a rotation speed of 1000 r/min and a welding speed of 80 mm/min. Complicated microstructure was formed in the nugget, in which vortex-like pattern and lamella structure could be found. No intermetallic compounds were found in the nugget. The hardness distribution indicates that the hardness at the copper side of the nugget is higher than that at the aluminum alloy side, and the hardness at the bottom of the nugget is generally higher than that in other regions. The ultimate tensile strength and elongation of the dissimilar welds are 152 MPa and 6.3%, respectively. The fracture surface observation shows that the dissimilar joints fail with a ductile-brittle mixed fracture mode during tensile test.

Effect of pressure on microstructures and mechanical properties of Al-Cu-based alloy prepared by squeeze casting

A new high-strength aluminum alloy with better fluidity than that of ZL205A was developed. The effect of applied pressure during squeeze casting on microstructures and properties of the alloy was studied. The results show that the fluidity of the alloy is 16% and 21% higher than that of ZL205A at the pouring temperature of 993 K and 1 013 K, respectively. Compared with permanent-mold casting, mechanical properties of the alloy prepared by squeeze casting are much higher. The tensile strength and elongation of the alloy are 520 MPa and 7.9% in squeeze casting under an applied pressure of 75 MPa, followed by solution treatment at 763 K for 1 h and at 773 K for 8 h, quenching in water at normal temperature and aging at 463 K for 5 h. The improvement of mechanical properties is attributed to the remarkable decreasing of the secondary dendrite arm spacing(SDAS) and eliminating of micro-porosity in the alloy caused by applied pressure.

Superplasticity of AZ31 magnesium alloy prepared by friction stir processing

Microstructure and tensile behaviors of AZ31 magnesium alloy prepared by friction stir processing (FSP) were investigated. The results show that microstructure of the AZ31 hot-rolled plate with an average grain size of 92.0 μm is refined to 11.4 μm after FSP. The FSP AZ31 alloy exhibits excellent plasticity at elevated temperature, with an elongation to failure of 1050% at 723 K and a strain rate of 5×10−4 s−1. The elongation of the FSP material is 268% at 723 K and 1×10−2 s−1, indicating that high strain rate superplasticity could be achieved. On the other hand, the hot-rolled base material, which has a coarse grain structure, possesses no superplasticity under the experimental conditions.

Effect of Thermal History on Microstructures and Mechanical Properties of AZ31 Magnesium Alloy Prepared by Friction Stir Processing

Hot-rolled AZ31 (Mg-2.57Al-0.84Zn-0.32Mn, in mass percentage) magnesium alloy is subjected to friction stir processing in air (normal friction stir processing, NFSP) and under water (submerged friction stir processing, SFSP). Thermal history of the two FSP procedures is measured, and its effect on microstructures and mechanical properties of the experimental materials is investigated. Compared with NFSP, the peak temperature during SFSP is lower and the duration time at a high temperature is shorter due to the enhanced cooling effect of water. Consequently, SFSP results in further grain refinement, and the average grain size of the NFSP and SFSP specimens in the stir zone (SZ) are 2.9 μm and 1.3 μm, respectively. Transmission electron microscopy (TEM) examinations confirm that grain refinement is attributed to continuous dynamic recrystallization both for NFSP and SFSP. The average Vickers hardness in the SZ of the NFSP and SFSP AZ31 magnesium alloy are 76 HV and 87 HV. Furthermore, the ultimate tensile strength and the elongation of the SFSP specimen increase from 191 MPa and 31.3% in the NFSP specimen to 210 MPa and 50.5%, respectively. Both the NFSP and SFSP alloys fail through ductile fracture, but the dimples are much more obvious in the SFSP alloy.

Production of Mg-Al-Zn magnesium alloy sheets with ultrafine-grain microstructure by accumulative roll-bonding

Accumulative roll-bonding (ARB) was applied to Mg-Al-Zn magnesium alloy sheets to prepare ultrafine-grain microstructure. Significant grain refinement is achieved after three cycles of ARB with average grain size of about 1.3 μm. The microstructure is characterized by nearly uniform ultrafine equiaxed microstructure without twins. The evolution of the misorientation distribution during ARB was measured by EBSD. Grain refinement can be contributed to the grain subdivision induced by severe accumulated strain, the accumulated strain enhanced concurrent dynamic recovery and recrystallization as well as the complicated distribution of interface and shear strain during ARB.

Effects of Mn content on microstructures and mechanical properties of Al-5.0Cu-0.5Fe alloys prepared by squeeze casting

The effects of Mn content on the microstructures and mechanical properties of squeeze cast Al-5.0Cu-0.5Fe alloys at different applied pressures were examined by tensile test, optical microscopy, scanning electron microscopy and image analysis. The results show that the needle-like β-Fe phase (Al7Cu2Fe) is completely converted to the Chinese script α-Fe phase (Al15(FeMn)3(CuSi)2) when the applied pressure is 0 MPa and the Mn/Fe mass ratio reaches 1.6. As to squeeze casting, the Mn/Fe mass ratio of 0.8 is demanded for the complete conversion of β-Fe phase to α-Fe phase at the applied pressure of 75 MPa. The lower Mn content, i.e., the less Mn/Fe mass ratio, for squeeze cast alloy is due to the small size and less content of the Fe-rich phases. Excessive amount of Mn, however, deteriorates the mechanical properties because of the increase in the total amount of α-Fe and the porosity that associates with the excessive brittle phases.

In Vitro Corrosion Study of Friction Stir Processed WE43 Magnesium Alloy in a Simulated Body Fluid

Corrosion behavior of friction stir processing (FSP) WE43 alloy in a simulated body fluid (SBF) was investigated. Micro-galvanic corrosion was the dominated corrosion behavior, and the corrosion resistance of FSP WE43 alloy was improved compared to the cast counterpart. Furthermore, due to the fine-grained and homogeneous microstructure, uniform corrosion morphology was observed on FSP WE43 alloy. According to the tensile properties of specimens with different immersion time intervals, FSP WE43 alloy shows better performance to maintain the mechanical integrity in SBF as compared to the as-cast alloy.

Improving the Mechanical Properties of Cu-15Ni-8Sn Alloys by Addition of Titanium

The effect of Ti addition on the microstructure and mechanical properties of Cu-15Ni-8Sn alloys was investigated. Optical microscopy (OM), scanning electronic microscopy (SEM), and transmission electron microscopy (TEM) were used to determine grain size and distribution of the second phases in the alloys. The results indicate that the tensile properties of Cu-15Ni-8Sn alloys are improved significantly with Ti addition. Tensile elongation increased from 2.7% for the alloy without Ti to 17.9% for the alloy with 0.3% Ti, while tensile strength was maintained and even increased from 935 MPa to 1024 MPa. The improvement of the mechanical properties of Cu-15Ni-8Sn alloys by the addition of Ti is attributed to the grain refinement and suppression of discontinuous precipitation during heat treatment.

Ductility Improvement of an AZ61 Magnesium Alloy through Two-Pass Submerged Friction Stir Processing

Friction stir processing (FSP) has been considered as a novel technique to refine the grain size and homogenize the microstructure of metallic materials. In this study, two-pass FSP was conducted under water to enhance the cooling rate during processing, and an AZ61 magnesium alloy with fine-grained and homogeneous microstructure was prepared through this method. Compared to the as-cast material, one-pass FSP resulted in grain refinement and the β-Mg17Al12 phase was broken into small particles. Using a smaller stirring tool and an overlapping ratio of 100%, a finer and more uniform microstructure with an average grain size of 4.6 μm was obtained through two-pass FSP. The two-pass FSP resulted in a significant improvement in elongation of 37.2% ± 4.3%, but a slight decrease in strength compared with one-pass FSP alloy. Besides the microstructure refinement, the texture evolution in the stir zone is also considered responsible for the ductility improvement.