Abstract
Friction stir welding (FSW), a promising solid state joining process invented at TWI in 1991, was used to join 9 mm thick 7475 aluminum alloy which is considered essentially unweldable by fusion processes. In the present work, the process parameters such as tool rotational speed were varied from 300 to 1000 rpm for a travel speed of 50 mm/min and the influence of process parameters in terms of energy input on microstructure, hardness, tensile strength, and the corrosion property of 7475 aluminum joints was evaluated and analyzed. The maximum tensile strength of FSW joints was obtained at rotational speed of 400 rpm and traverse speed of 50 mm/min (59.2 kJ) which attributed maximum stirred zone area and maximum hardness. The maximum corrosion resistance properties of weld in 3.5% NaCl solution, however, were obtained at rotational speed of 1000 rpm and traverse speed of 50 mm/min. Furthermore, for a given weld, stirred zone showed improved corrosion properties than TMAZ.
Similar content being viewed by others
References
M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Temple-Smith, and C.J. Dawes, Friction Welding, The Welding Institute, United States Patent, 460,317, Cambridge, GB, 1995
J.Q. Su, T.W. Nelson, R. Mishra, and M. Mahoney, Microstructural Investigation of Friction Stir Welded 7050-T651 alloy, Acta Mater., 2003, 51, p 713–729
C.G. Rhodes, M.W. Mahoney, W.H. Bingel, R.A. Spurling, and C.C. Bampton, Effects of Friction Stir Welding on Microstructure of 7075 Aluminum, Scripta Mater., 1997, 36, p 69–75
K.V. Jata, K.K. Sankaran, and J.J. Ruschau, Metall. Mater. Trans. A, 2000, 31A, p 2181–2192
G. Liu, L.E. Murr, C.-S. Niou, J.C. McClure, and F.R. Vega, Microstructural Aspects of the Friction Stir Welding of 6061-T6 Aluminum, Scripta Mater., 1997, 37, p 355–361
Y.S. Sato, H. Kokawa, M. Enomoto, S. Jogan, and T. Hashimoto, Precipitation Sequence in Friction Stir Weld of 6063 Aluminum During Aging, Metall. Mater. Trans. A, 1999, 30A, p 3125–3130
Y.S. Sato, H. Kokawa, M. Enomoto, and S. Jogan, Metall. Mater. Trans. A, 1999, 30A, p 2429–2437
K.V. Jata and S.L. Semiatin, Continuous Dynamic Recrystallization During Friction Stir Welding of High Strength Aluminium Alloys, Scripta Mater., 2000, 43, p 743–749
S. Benavides, Y. Li, L.E. Murr, D. Brown, and J.C. McClure, Low-Temperature Friction-Stir Welding of 2024 Aluminum, Scripta Mater., 1999, 41, p 809–815
M. Peel, A. Steuwer, M. Preuss, and P.J. Withers, Microstructure, Mechanical Properties and Residual Stresses as a Function of Welding Speed in Aluminium AA5083 Friction Stir Welds, Acta Mater., 2003, 51, p 4791–4801
A.P. Reynolds, W.D. Lockwood, and T.U. Seidel, Processing-Property Correlation in Friction Stir Welds, Mater. Sci. Forum, 2000, 331–337, p 1719–1724
H.J. Liu, H. Fujii, M. Maeda, and K. Nogi, Tensile Properties and Fracture Locations of Friction-Stir-Welded Joints of 2017-T351 Aluminum Alloy, J. Mater. Process. Technol., 2003, 142, p 692–696
B. Yang, J. Yan, M.A. Sutton, and A.P. Reynolds, Banded Microstructure in AA2024-T351 and AA2524-T351 Aluminum Friction Stir Welds Part I. Metallurgical Studies, Mater. Sci. Eng. A, 2004, 364, p 55–65
K.A.A. Hassan, A.F. Norman, and P.B. Prangnell, Mater. Sci. Forum, 2002, 396–402, p 1549–1554
K.V. Jata, Friction Stir Welding of High Strength Aluminium Alloys, Mater. Sci. Forum, 2000, 331–337, p 1701–1712
K.A.A. Hassan, A.F. Norman, D.A. Price, and P.B. Prangnell, Acta Mater., 2003, 51, p 1923–1936
K. Elangovan and V. Balasubramanian, Influences of Pin Profile and Rotational Speed of the Tool on the Formation of Friction Stir Processing Zone in AA2219 Aluminium Alloy, Mater. Sci. Eng. A, 2007, 459, p 7–18
J.B. Lumsden, M.W. Mahoney, C.G. Rhodes, and G.A. Pollock, Corrosion Behavior of FSW 7050-T7651, Corrosion, 2003, 59, p 212–219
J.B. Lumsden, M.W. Mahoney, G. Pollock, and C.G. Rhodes, Intergrannular Corrosion Following Friction Stir Welding of Aluminium Alloy 7075-T651, Corrosion, 1999, 55, p 1127–1135
C.S. Paglia, M.C. Carroll, B.C. Pitts, A.P. Reynolds, and R.G. Buchheit, Mater. Sci. Forum, 2002, 396–402, p 1677–1684
W. Hu and E.I. Meletis, Corrosion and Environment-Assisted Cracking Behavior of Friction Stir Welded Al2195 and Al2219 Alloys, Mater. Sci. Forum, 2000, 331–337, p 1683–1688
G.S. Frankel and Z. Xia, Localized Corrosion and Stress Corrosion Cracking Resistance of Friction Stir Welded Al Alloy 5454, Corrosion, 1999, 55, p 139–150
J. Corral, E.A. Trillo, Y. Li, and L.E. Murr, Corrosion of Friction-Stir Welded Aluminum Alloys 2024 and 2195, J. Mater. Sci. Lett., 2000, 19, p 2117–2122
F. Zucchi, G. Trabanelli, and V. Grassi, Pitting and Stress Corrosion Cracking Resistance of Friction Stir Welded AA 5083, Mater. Corros., 2001, 52, p 853–859
A. Squillace, A.D. Fenzo, G. Giorleo, and F. Bellucci, A Comparison Between FSW and TIG Welding Techniques: Modifications of Microstructure and Pitting Corrosion Resistance in AA 2024-T3 Butt Joints, J. Mater. Process. Technol., 2004, 152, p 97–105
S. Williams, R. Ambat, D. Price, M. Jariyaboon, A. Davenport, and A. Wescott, Mater. Sci. Forum, 2003, 426–432, p 2855–2860
M.J. Pee, A. Steuwer, P.J. Withers, T. Dickerson, Q. Shi, and H. Shercliff, Metall. Mater. Trans. A, 2006, 37A, p 2183–2193
Z. Sandra, L. Laurent, L. Julien, and B. Régis, Experimental Investigation of the Influence of the FSW Plunge Processing Parameters on the Maximum Generated Force and Torque, Int. J. Adv. Manuf. Technol., 2010, 47, p 201–215
M.W. Mahoney, C.G. Rhodes, J.G. Flintoff, R.A. Spurling, and W.H. Bingel, Metall. Mater. Trans. A, 1998, 29, p 1955
Z.Y. Ma, R.S. Mishra, and M.W. Mahoney, Friction Stir Welding and Processing II, K.V. Jata, M.W. Mahoney, R.S. Mishra, S.L. Semiatin, and T. Lienert, Ed., TMS, San Diego, 2003, p 221–230
T.H. North, G.J. Bendzsak, and C. Smith, Material Properties Relevant to FSW Modellimg, 2nd International Conference on Friction Stir Welding, Gothenburg, Sweden, 2000
B.L. Bjornklett, O. Frigaard, O. Grong, O.R. Myhr, and O.T. Midling, Modelling of Local Melting During Friction Stir Welding of Al-Zn-Mg alloys, ICAA-6:6th International Conference on Aluminium Alloys, Japan, 1998
O. Frigaard, O. Grong, B. Bjornklett, and O.T. Midling, Modeling of the Thermal and Microstructure Fields During Friction Stir Welding of Aluminium Alloys, 1st International Symposium on Friction Stir Welding, Thousand Oaks, CA, June 1999
V.F. Olga, Microstructural Issues in a Friction-Stir-Welded Aluminum Alloy, Scripta Mater., 1998, 38(5), p 8–703
H. Liang, S.L. Chen, and Y.A. Chang, A Thermodynamic Description of the Al-Mg-Zn System, Metall. Mater.Trans. A, 1997, 28A, p 1725–1734
M. Jayaraman, R. Sivasubramanian, and V. Balasubramanian, Establishing Relationship Between the Base Metal Properties and Friction Stir Welding Process Parameters of Cast Aluminium Alloys, Mater. Des., 2010, 31, p 4567–4576
H.J. Liu, H. Fujii, M. Maeda, and K. Nogi, Tensile Properties and Fracture Locations of Friction-Stir-Welded Joints of 2017-T351 Aluminum Alloy, J. Mater. Process. Technol., 2003, 142, p 692–696
H.-C. Shih, N.-J. Ho, and J.C. Huang, Kinetic Study of Precipitation Behavior in Al-Cu-Mg and 2024 Aluminum Alloys, Metall. Mater. Trans. A, 1996, 27A, p 2479–2494
C.R. Brooks, Heat Treatment, Structure and Properties of Nonferrous Alloys, ASM, Metal Park, OH, 1982
M. Rosen, E. Horowitz, L. Swartzendruber, S. Fick, and R. Mehrabian, Mater. Sci. Eng., 1982, 53, p 191–198
S.G. Mazzini and J.C. Caretti, Scripta Metall. Mater., 1991, 25, p 1987–1990
J.M. Silcock, J. Inst. Met., (1960–1961), 89, p 203–210.
R.E. Reed-Hill, Physical Metallurgy Principles, D, Van Nostrand Company Inc., Toronto, 1964
M. Van Lancker, Metallurgy of Aluminium Alloys, Chapman & Hall, London, 1967
K.A.A. Hassan, P.B. Prangnell, A.F. Norman, D.A. Price, and S.W. Williams, Sci. Technol. Weld. Join., 2003, 8, p 257–268
T. Venugopal, K. Srinivasa Rao, and K. Prasad Rao, Studies on Friction Stir Welded AA 7075 Aluminum Alloy, Trans. Indian Inst. Met., 2004, 57(6), p 659–663
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Gupta, R.K., Das, H. & Pal, T.K. Influence of Processing Parameters on Induced Energy, Mechanical and Corrosion Properties of FSW Butt Joint of 7475 AA. J. of Materi Eng and Perform 21, 1645–1654 (2012). https://doi.org/10.1007/s11665-011-0074-2
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-011-0074-2