Residual Stress Measurements Using Neutron Diffraction in Magnesium Alloy Laser Welded Joints

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1 Residual Stress Measurements Using Neutron Diffraction in Magnesium Alloy Laser Welded Joints A. Fabre 1, J.-É. Masse 1, M. Ceretti 2 and L. Barrallier 1 1 MécaSurf Team, ENSAM - 2, cours des Arts et Métiers Aix en Provence - France 2 LLB (CEA-CNRS) CE Saclay Gif sur Yvette - France Keywords: Residual Stress, Neutron Diffraction, Welded Joint, Magnesium Alloy Abstract. Magnesium alloys are widely used in automotive or aeronautic industries in order to reduce weight of structures. Laser welding is, nowadays, competing with the classical processes (MIG, TIG, electron beam) because of the increasing of productivity, welding components size. Fatigue life of these parts depends on joint behavior, which is conditioned by its microstructural state and its residual stress field. In our study 5 kw CO 2 Laser was used to weld WE43 magnesium alloy under neutral gas. Welding was performed on 3 mm thin plate samples. Determination of residual stresses has performed using neutron diffraction technique. With this approach it was possible to determine complete stress tensor field (in-depth and lateral) in the welded joint, the heat affected zone and the base metal without matter removal. By modeling neutron spectrometer, corrections were made to take in account parasitic shift of diffraction peak near the surface of specimen and to improve spatial resolution of stress profiles. Attenuation coefficient of WE43 magnesium alloy for wavelength used (0,35 nm) has been deduced from experiment. Introduction Low density metal alloys can be considered the most interesting materials in areonautics, car and railway industries because they decrease enourmosly the effects of mass in mouvment. In this context, magnesium alloys are nowadays very interesting. In aeronautic field, these alloys are used for machining copter gearbox case, for parts on civil planes, for car and transport transmission case, clutch case, and pats of seat [1, 2]. Most of actual European and world research is oriented in developing new magnesium alloys in order to improve their mechanical resistance as well as their manufacturing and casting processes. In the last ten years some studies in aeronautical field have been done on conventional treatment of these alloys. But very few laboratories or technical centers are studing the increasing of resistance properties and assembly using these materials. In weldability, high risk of porosity defect and weld cracking are important for these alloys. Today the TIG and MIG welding technics are the most used. Laser welding is developping because it is faster than other technics and it allows to limit the thermal effects and the microstructural transformation in the welded joints [3]. As in all the welding technics with fusion, the residual mechanical state of the welded joints strongly depends on the material and on the operating conditions. In order to dimensioning structures under mechanical sollicitations it is essential to know the residual mechanical state. X-rays diffraction doesn't allow the complete in depth stress determination in welded joint without matter removal. In this case, the stress field could be modified and matter removal corrections have to performed.. However, stress evaluation with correction in welded joint is not possible due to the presence of complex stress gradients and only neutron diffraction allows stress determination avoiding the joint destruction. Material and experiment Samples. Welded joint was performed on WE43 magnesium alloy plates [4]. This type of alloy is used in aeronautics to make molded parts. The alloy composition is given in the table 1. Alloying

2 element are chosen to improve corrosion resistance. Specimen were machining from molded plates to obtain 3 mm thickness plates. Welding was performed on 5 kw CO 2 Trumpf laser. Plates were hold jump-jointed in order to minimize positive allowance during welding operation and to reduce the final deformations. Feed speed was chosen to 33 mm.s -1 and helium was used as protection gas. The geometry of welded sample is given in the figure 1. The width of welded joint is about 1.6 mm. The figure 2 shows the microstructure of the welded joint. Grain size in welded joint is 4-6 time higher than base metal. No morphological texture was found. Gradient transition between welded joint and base metal is important, thickness of heat affected zone (HAZ) seems to be tight. element Nd Y Zr Pr Mg wt.% balance Table 1: WE43 magnesium alloy composition (weight percent). lattice parameters hcp structure a = nm c = nm diffracting planes {xxx} wavelength 0.35 nm diffracting angle 91 2q y angles -30, 0, 60, 90 acquisition time 2400 seconds by peak _ S 2{hkl} MPa -1 Z range [mm] with 0.4 step X range [mm] 0, 0.5, 1, 1.5, 2 probe volume size 0.3 x 0.5 x 36 mm 3 Table 2: Experimental parameters of neutron diffraction. Neutron diffraction. Neutron diffraction strain measurements were performed using G5.2 instrument of the Laboratory Léon Brillouin (LLB) facility (CEA Saclay France). Diffraction parameters are given in the table 2. Wavelength and lattice planes were chosen in order to optimize diffracting angles close to 90 and high intensity of diffraction peaks. For strain scanning, the smallest primary slit and detector slit available were chosen. Parallelepiped probe volume has been oriented following the longitudinal direction of welded joint. The sin 2 y method has been used to evaluate the stresses. These measurements have been carried out in w mode with several independent y incidence angles. Results of residual stress analysis using neutron diffraction have shown that it is necessary to take into account, near the surface of sample, some instrumental aberrations. In fact, parasitic diffraction peak shifts appear because the neutron probe is not completely immersed in the analyzed sample, the wavelength distribution in probe volume is not homogeneous and the material absorption is critical. This effect can be much greater than the peak shifts induced by residual stress state. Laser Beam 3 mm thickness 3 mm O X Z X 100 mm Z welded joint analysis directions probe volume 50 mm Fig. 1 : Specimen geometry. Position of neutron probe in welded joint.

3 1 mm Fig. 2 : Microstructure of laser welded joint. Effect Fig. 3 : View of G5.2 diffractometer (CEA-LLB) with welded joint specimen. of grow up of grains in welded joint. A modeling of two-axis spectrometers, based on Monte Carlo calculation method, has been developed to take into account this effect [5, 6]. The correction model used the whole elements of neutron instrument: guide, monochromator, primary and secondary slits, detector and sample. With this approach, it is possible to optimize experimental conditions and to define the true volume of the neutron gauge. Data simulation and analysis require knowledge of the attenuation coefficient of WE43 magnesium alloy. No bibliographic data were found for chosen wavelength. Attenuation coefficient was determined using several in-depth simulations of the diffraction peak intensity evolution. The figure 4 shows the variation of simulated peak intensity profile as a function of the attenuation coefficient with mm-1 range value. The simulation results were compared to the experimental values obtained for in-depth scanning at y = 0 outside the welded joint. The best fit of experimental data was found for 0.2 mm-1 attenuation value, as it is show in the figure 5. With this attenuation coefficient it was possible to simulate the whole conditions of diffraction in order to correct instrumental aberrations of experimental data. The corrected results allowed to determine with more accuracy stress gradient near welded joint. Due to the shape of neutron probe, only transversal stresses were evaluated (X direction). Longitudinal stress gradient along the joint was supposed to be negligible. Longitudinal stresses could not be determined because the probe volume must be smallest in order to have a neutron gauge size compatible with stress gradient (thickness of welded joint is about 3 mm). Results and discussion The figure 6 shows residual stress map in the welded joint and in the HAZ. The average stress is in tension around 400 MPa in the joint and decrease to the core of specimen. Dispersion of assessment is about ± 100 MPa.

4 Intensity ,01 0,02 0,05 0,1 0,2 0,3 0, ,5 1 1,5 2 2,5 3 3,5 4 Depth (mm) Fig. 4: In-depth simulated intensity of diffraction peaks as function of attenuation coefficient for y = 0. Fig. 5: Best fitting of in-depth diffraction peak intensity profile by polynomial fitted curve of simulated intensity for 0.2 mm -1 attenuation coefficient.

5 Fig.6: Residual stress of laser welded joint. In-depth vs half lateral evolution, for several lateral positions. In our study, corrections of instrumental effects have been taken into account only for depth direction. To improve the results near the surface, it is also necessary to adjust lateral position X due to the absorption phenomena. Near the surface, precision of results decreases in the same way than the diffracting volume even instrumental corrections are made. In the treatment of diffracting peaks, the texture effects have not be introduce to calculate stress state. Welded joint seems to be textured because some measured intensity peak profiles are no well fitted by the simulation approach. Texture analysis will be performed to complete microstructural characterization. Summary Attenuation coefficient of WE43 magnesium alloy, equal to 0.2 nm -1, has been determined for neutron wavelength equal to 0.35 nm. Stress state of welded joint has been evaluated for the transversal direction. Tension stresses were found along welding joint.

6 Acknowledgments The work described in this paper was carried out as a part of a french government (Ministère de l Éducation Nationale de la Recherche et de la Technologie) project entitled PRESTIGE decision n 00K0529 between Honsel Fonderie Messier S.A., PMA, GAER Systemes, CLAIRE, Université de Dijon, École Centrale de Lyon, Université Aix-Marseille II and École Nationale Supérieure d Arts et Métiers. References [1] BRITE-EURAM III. Project, Magnesium in industrial application by manufacturing a complete car door with a Mg door inner shell. 4 rd PCRD ( ). [2] K. Wiemer, TWI report, 644, (1998). [3] M. Dhahri, J.-É. Masse, J.-F. Mathieu, G. Barreau and M. Autric, Advanced Engineering Materials, vol. 3, n 7, (2001), p [4] L. Billaud, Référentiel Dunod, 11 (1998), p [5] A. Carradó, J.-M. Sprauel, L. Barrallier and A. Lodini, Journal of Neutron research, in press MECA-SENS 2000, Reims, France, 12 (2000). [6] E. Pluyette, J.-M. Sprauel, A. Lodin, M. Perrin and P. Todeschini. ECRS4, Cluny, France, (1996), p

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