Effect of FSW Traverse Speed on Mechanical Properties of Copper Plate Joints
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussion
3.1. Microhardness Tests and Metallographic Analysis
3.2. Monotonic Tests Results
3.3. Fatigue Test Results
4. Conclusions
- In the area of tested FSW joints, a significant decrease in microhardness was observed relative to the base material property. The microhardness profiles determined for the cross-section of the joints had a W-type shape with a sudden decrease in microhardness in the HAZ and a tendency towards a slight increase in WN which, in the qualitative sense, correlated well with the average grain sizes observed in these zones. However, the data available in the literature also indicate that opposite trends of microhardness changes are possible. Summarising the obtained results and the literature data, it may be generalised that increase of the microhardness in the region of FSW joints is observed for softer copper (microhardness below 80 HV), while the drop of hardness in the FSW zone is typical for copper with a higher degree of strain hardening.
- Tensile strength parameters of tested FSW joints were significantly lower than those of base material properties which was predominantly related to the loss of the cold-work hardening effect as a result of the recrystallisation process in the HAZ. Resulting from the FSW process, the yield stress decreased on average by more than 60%, and ultimate stress fell by about 15%. For each of considered traverse speed, the FSW joints showed considerably higher static strength properties than similar joints made by TIG welding. These properties were also higher than those of the base material after annealing. Regardless of traverse speed, the tensile strength parameters of FSW joints were higher for transversal than for longitudinal orientation. Tensile tests revealed a consistent trend of decreasing strength parameters of FSW joints (i.e., yield stress and ultimate stress) with increased traverse speed. Although this effect is moderate, it is qualitatively different from the data reported so far in the literature.
- The fatigue tests turned out to be more sensitive criteria for evaluation of the FSW joints’ qualities compared to other kind of examinations applied in this work. These tests clearly confirmed the weakness of the FSW joints produced at a speed of 80 mm/min in longitudinal orientation, which was earlier indicated only by the scatter of tensile test results, and revealed the poor quality of the joints made at a speed of 40 mm/min for the same orientation, which had not been predicted earlier by other studies. All samples from the two series of the lowest fatigue life were characterised by distinct location and morphology of the cracks. Considering all static and fatigue tests—for given plates, adopted tool geometry and specified rotary speed—the traverse speed of 60 mm/min proved to be the most advantageous. It should be noted that conclusions on the quality of the FSW joints resulting from fatigue tests would be different if they were referred separately to each of the considered joint orientations. This means that the variations of FSW parameters may have a qualitatively different effect on the properties of friction stir welds oriented longitudinally and transversely to the rolling direction of the joined plates.
Author Contributions
Funding
Conflicts of Interest
References
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Kind of Test: | Tensile | Fatigue | |||
---|---|---|---|---|---|
Specimen Orientation: | Longitudinal | Transversal | Longitudinal | Transversal | |
Specimen type | Base Cu-ETP R220 | 5 | 5 | 3 | 3 |
FSW: V = 80 mm/min | 3 | 3 | 3 | 3 | |
FSW: V = 60 mm/min | 3 | 3 | 3 | 3 | |
FSW: V = 40 mm/min | 3 | 3 | 3 | 3 | |
Annealed Cu-ETP | 3 | - | - | - |
Sample Type | Longitudinal Orientation (L) | Transversal Orientation (T) | ||||
---|---|---|---|---|---|---|
YS (MPa) | UTS (MPa) | AR (%) | YS (MPa) | UTS (MPa) | AR (%) | |
Base Cu-ETP R220 | 242 ± 1.5 | 252.7 ± 1.5 | 67.3 ± 6.7 | 232.0 ± 0.7 | 261.2 ± 0.4 | 69.2 ± 1.0 |
FSW: V = 40 mm/min | 87.7 ± 0.5 | 216.0 ± 0.8 | 69.4 ± 3.5 | 101.3 ± 0.5 | 220.7 ± 0.5 | 53.1 ± 7.2 |
FSW: V = 60 mm/min | 87.3 ± 0.5 | 215.0 ± 0.8 | 70.5 ± 1.5 | 92.7 ± 0.5 | 218.7 ± 0.5 | 60.1 ± 4.2 |
FSW: V = 80 mm/min | 82.0 ± 7.3 | 209.0 ± 8.5 | 40.3 ± 2.9 | 82.3 ± 0.9 | 216.3 ± 1.7 | 61.2 ± 2.2 |
Annealed Cu-ETP | 33.0 ± 0.8 | 215.7 ± 0.5 | 71.3 ± 1.9 | - | - | - |
TIG welded joint [16] | 53 | 168 | 5.7 | - | - | - |
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Machniewicz, T.; Nosal, P.; Korbel, A.; Hebda, M. Effect of FSW Traverse Speed on Mechanical Properties of Copper Plate Joints. Materials 2020, 13, 1937. https://doi.org/10.3390/ma13081937
Machniewicz T, Nosal P, Korbel A, Hebda M. Effect of FSW Traverse Speed on Mechanical Properties of Copper Plate Joints. Materials. 2020; 13(8):1937. https://doi.org/10.3390/ma13081937
Chicago/Turabian StyleMachniewicz, Tomasz, Przemysław Nosal, Adam Korbel, and Marek Hebda. 2020. "Effect of FSW Traverse Speed on Mechanical Properties of Copper Plate Joints" Materials 13, no. 8: 1937. https://doi.org/10.3390/ma13081937