Multi-Track Friction Stir Lap Welding of 2024 Aluminum Alloy: Processing, Microstructure and Mechanical Properties
Abstract
:1. Introduction
2. Experimental Procedures
2.1. Experimental Setup and Manufacturing Process
2.2. Microstructural Characterization and Mechanical Testing
3. Results and Discussion
3.1. Single-Track Friction Stir Lap Welding
3.1.1. Single-Track FSLW with One-Pass Processing
3.1.2. Single-Track FSLW with Two-Pass Processing
3.2. Multi-Track Friction Stir Lap Welding
3.3. Microstructure and Mechanical Properties
4. Conclusions
- (1)
- Defects generated during FSLW are very sensitive to the variation of parameters. Systematic studies were carried out to determine the suitable processing parameters. The rotational speed and traverse speed are found to play an important role in hole generation.
- (2)
- Tilt angle has a certain positive effect on defect elimination, but significantly increases equipment cost. Alternatively, two-pass processing is found to be able to replace the tilt angle and ensure defect-free forming. Under two-pass processing with welding speed 300 mm/min, rotation rate 1000 rpm and plunge depth 0.2 mm, defect-free samples were successfully fabricated.
- (3)
- Hook-shaped defects are an inherent feature of FSLW, which combine to become crack-like unbonded defects in the overlapping zone during multi-track processing. The overlapping rate of 20% is found to be enough to eliminate these unbonded defects, and obtain full density multi-track samples.
- (4)
- Ultrafine equiaxed grains with the diameter about 9.4 μm are obtained in FSLW samples, because of the dynamic recrystallization during FSLW. Accordingly, the strength of the multi-track FSLW samples is much higher than that of the rolled 2024-O substrate. Meanwhile, it exhibits a high ductility of the elongation about 31.05%, which is about two times that of the rolled 2024-O substrate.
Acknowledgments
Author Contributions
Conflicts of Interest
References
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Parameters | No. | Welding Speed, ν (mm/min) | Rotation Speed, ω (rpm) | Plunge Depth, h (mm) |
---|---|---|---|---|
Constant ν | a1 | 300 | 500 | 0.2 |
a2 | 300 | 750 | 0.2 | |
a3 | 300 | 1000 | 0.2 | |
a4 | 300 | 1250 | 0.2 | |
a5 | 300 | 1500 | 0.2 | |
a6 | 300 | 1750 | 0.2 | |
a7 | 300 | 2000 | 0.2 | |
Constant ω | b1 | 100 | 1000 | 0.2 |
b2 | 150 | 1000 | 0.2 | |
b3 | 200 | 1000 | 0.2 | |
b4 | 250 | 1000 | 0.2 | |
b5 | 300 | 1000 | 0.3 | |
b6 | 350 | 1000 | 0.2 | |
b7 | 400 | 1000 | 0.2 | |
b8 | 450 | 1000 | 0.2 | |
b9 | 500 | 1000 | 0.2 | |
b10 | 550 | 1000 | 0.2 | |
Constant ω/ν | c1 | 150 | 500 | 0.2 |
c2 | 225 | 750 | 0.2 | |
c3 | 300 | 1000 | 0.4 | |
c4 | 375 | 1250 | 0.2 | |
c5 | 450 | 1500 | 0.2 | |
c6 | 525 | 1750 | 0.2 | |
c7 | 600 | 2000 | 0.2 |
FSLW Parameters | Values |
---|---|
Rotation speed | 1000 rpm |
Traverse speed | 300 mm/min |
Plunge depth | 0.2 mm |
Tilt angle | 0 |
Overlapping rate | 20% |
Tool path pattern | Same direction |
Special process | Two-pass processing |
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Zou, S.; Ma, S.; Liu, C.; Chen, C.; Ma, L.; Lu, J.; Guo, J. Multi-Track Friction Stir Lap Welding of 2024 Aluminum Alloy: Processing, Microstructure and Mechanical Properties. Metals 2017, 7, 1. https://doi.org/10.3390/met7010001
Zou S, Ma S, Liu C, Chen C, Ma L, Lu J, Guo J. Multi-Track Friction Stir Lap Welding of 2024 Aluminum Alloy: Processing, Microstructure and Mechanical Properties. Metals. 2017; 7(1):1. https://doi.org/10.3390/met7010001
Chicago/Turabian StyleZou, Shengke, Shuyuan Ma, Changmeng Liu, Cheng Chen, Limin Ma, Jiping Lu, and Jing Guo. 2017. "Multi-Track Friction Stir Lap Welding of 2024 Aluminum Alloy: Processing, Microstructure and Mechanical Properties" Metals 7, no. 1: 1. https://doi.org/10.3390/met7010001