Enhancing structural efficiency through novel dissimilar material joining techniques National Technical University of Athens School of Chemical Engineering Department of Materials Science and Engineering Laboratory Unit of Advanced, Composite, Nano-Materials and Nanotechnology National Technical University of Athens School of Naval Architecture & Marine Engineering Shipbuilding Technology Laboratory SAFEJOINT Workshop 3-4 July 2014, Athens Micro structural and mechanical study of AA 5083 and AA 6082 friction stir welds reinforced with SiC, TiC and CNTs C. Charitidis, D.A. Dragatogiannis, E. Koumoulos, D. Pantelis, P. Karakizis, N. Daniolos
CHAPTER TITLES 1 2 3 4 OVERVIEW MANUFACTURE OF METAL/ METAL JOINTS USING NANOPARTICLE FILLERS FSWed AA5083-H111/AA6082-T6 Composite Using SiC/TiC/CNTs as Reinforcing Materials Conclusions - Remarks 2
1 OVERVIEW Sufficient downward force to maintain pressure and to create friction heat Shoulder which creates friction heat and welding pressure Probe which Stir the material A. Unaffected material B. Heat affected zone (HAZ) C. Thermo-mechanically affected zone (TMAZ) D. Weld nugget (Part of thermomechanically affected zone) 3
1 OVERVIEW Friction Stir Welding-why using filler particles? (a) Locations of four horizontal hardness traverses. (b) Hardness profiles [2]. Hardness profile resulting from nanoindentation experiment conducted parallel to the surface of FSW SS [1]. Cross-sectional microhardness contourmap of μfsw joints [3]. [1]. F. Legendre, S. Poissonnet, P. Bonnaillie, L. Boulanger, L. Forest, Journal of Nuclear Materials, Volumes 386-388, Fusion Reactor Materials, 2009, Pages 537-539 [2]. D.-A. Wang, S.-C. Lee, Journal of Materials Processing Technology, Volume 186, Issues 1-3, 7 May 2007, Pages 291-297 [3]. A. Scialpi, M. De Giorgi, L.A.C. De Filippis, R. Nobile, F.W. Panella, Materials & Design, Volume 29, Issue 5, 2008, Pages 928-936 4
2 OVERVIEW, PARTICLE ENHANCEMENT IN SIMILAR AND DISSIMILAR FSW/FSP In comparison with the unreinforced aluminum alloys, aluminum matrix composites reinforced with ceramic particles exhibit higher strength and stiffness, improved tribological characteristics and increased creep and fatigue strength. Particle enhancement: Literature Yang et al. applied FSP to incorporate nano ceramic particles into aluminum alloys and to fabricate composite materials by one or multiple passes. Morisada et al. concluded that the dispersion of SiC particles into AZ31 can be successfully fabricated using FSP and the product of this treatment is grain refined and has an increased hardness related to the parent material. Morisada et al. have also fabricated fullerene/a5083 and MWCNTs/AZ31 composites using FSP with the same results in hardness and grain refinement. Zarghani et al. fabricated Al/Al 2 O 3 surface nano composites using FSP, improving the hardness and the wear resistance. They also concluded that an important parameter for the good dispersion of nano particles is the number of FSP passes, obtaining the best results after four passes. Min Y. Et al., Mater Sci Eng., 45, 4431-4438 European patent, No 06025776.3, 14.03.2007 Bulletin 2007/11; European patent, No 06125031.2, 30.0.50.2007 Bulletin 2007/22. Chang C.I. et al., 2007, Key Eng Mat., 351, 351-114; Morisada Y et al., (2006), Mater Scie Eng., 433, 50 54. Morisada Y, (2007). Composites, 38, 2097 2101.; Morisada Y, (2006). Mater Sci Eng., 419, 344 348. Shafiei-Zarghani A., (2009) Mater Sci Eng., 500, 84 91 5
2 WP1 MANUFACTURE OF METAL/ METAL JOINTS USING NANOPARTICLE FILLERS NTUA s TASK SIC,TIC, CNTs FILLERS Feedback WP3 NTUA s TASK DISSIMILAR METAL JOINTS 6
2 MANUFACTURE OF METAL/ METAL JOINTS USING NANOPARTICLE FILLERS: PARAMETERS Tool pin: SVERKER 21, hardness 61 HRC Cube corner, diagonal 6 mm, height 3 mm Shoulder 22,9mm Machine Universal Milling Machine (Cugir) FU-32). Range of transverse : 19mm/min - 1250mm/min Range of stirring rate: 32rpm - 2000rpm Tilt angle 2 7
FRICTION STIR DISSIMILAR WELDING BETWEEN AA5083-H111 AND AA6082-T6 USING SIC AS REINFORCING MATERIAL SiC Good distribution Enhanced mechanical properties AA5083-H111 AA6082-T6 Tools used for FSP: a) flat shoulder with 23mm and pin of height 3mm (Φ4), b) flat shoulder with 23mm and pin of height 3mm (Φ6). 8
FRICTION STIR DISSIMILAR WELDING BETWEEN AA5083-H111 AND AA6082-T6 USING SIC AS REINFORCING MATERIAL FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 1 1 2 2 of the same 3 o 2.55 3 1 950 85 23 3 6 4 1 1180 85 23 3 6 5 3 of the same 6 2 of the opposite 7 3 of the same 750 85 23 3 4 8 2 of the opposite 750 85 23 3 4 9
MACROSCOPIC OBSERVATION OF 5083/6082/SIC (I) FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 1 1 2 2 of the same 3 o 2.55 10
MACROSCOPIC OBSERVATION OF 5083/6082/SIC (II) FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 3 1 950 85 23 3 6 4 1 1180 85 23 3 6 11
MACROSCOPIC OBSERVATION OF 5083/6082/SIC (III) FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 5 3 of the same 6 2 of the opposite 12
DETAILED MACROSCOPIC OBSERVATION OF OPTIMUM WELDED JOINT 6082 AS 5083 RS 5083 RS ~12μm Particlefree region ~7μm Particlerich region 13
MECHANICAL PROPERTIES OF 5083/6082/SIC Longitudinal nanomechanical properties distribution with SiC addition obtained at 400 nm penetration depth (2 mm from the surface). 14
FRICTION STIR DISSIMILAR WELDING BETWEEN AA5083-H111 AND AA6082-T6 USING TIC AS REINFORCING MATERIAL TiC Good distribution Enhanced mechanical properties AA5083-H111 AA6082-T6 Tool used for FSW: a) flat shoulder with 23mm and pin of height 3mm (Φ6). 15
FRICTION STIR DISSIMILAR WELDING BETWEEN AA5083-H111 AND AA6082-T6 USING TIC AS REINFORCING MATERIAL FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 1 3 of the same 2 2 of the same 1180 85 23 3 6 3 3 of the same 1180 85 23 3 6 4 2 of the opposite 5 3 of the opposite 6 (without nanopart icles) 3 of the same 1180 85 23 3 6 16
MACROSCOPIC OBSERVATION OF 5083/6082/TIC (I) FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 1 3 of the same 2 2 of the same 1180 85 23 3 6 17
MACROSCOPIC OBSERVATION OF 5083/6082/TIC (II) FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 1 3 of the same 3 3 of the same 1180 85 23 3 6 18
DETAILED MACROSCOPIC OBSERVATION OF OPTIMUM WELDED JOINT WITH TIC AS RS ~ 4 μm 19
Elastic Modulus (GPa) H nano (GPa) Hardness (GPa) H micro(1mm) (HV 0.3 ) 3 90 80 70 60 50 40 1.5 1.4 1.3 1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 NANOMECHANICAL PROPERTIES OF 5083/6082/TIC Retreating side Base metal, AA 6082 T6 Advancing side Base metal, AA 5083 H111 0.4-30 -25-20 -15-10 -5 0 5 10 15 20 25 Retreating side Base metal, AA 6082 T6 distance from the centrer of SZ Advancing side Base metal, AA 5083 H111 120 110 100 90 80 70 60 1.4 1.2 1.0 0.8 0.6 6082 BM with TiC without TiC 5083 BM 0.5 1.0 1.5 2.0 2.5 Distance from the welding substrate with TiC (nanohardness) 6082 BM Longitudinal nanomechanical properties distribution with TiC addition obtained at 400 nm penetration depth (2 mm from the surface). 30-30 -25-20 -15-10 -5 0 5 10 15 20 25 30 distance from center of SZ 20
FRICTION STIR DISSIMILAR WELDING BETWEEN AA5083-H111 AND AA6082-T6 USING CNTS AS REINFORCING MATERIAL CNTs AA5083-H111 AA6082-T6 Tool used for FSW: a) flat shoulder with 23mm and pin of height 3mm (Φ6). 21
FRICTION STIR DISSIMILAR WELDING BETWEEN AA5083-H111 AND AA6082-T6 USING CNTS AS REINFORCING MATERIAL FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 1 3 of the same 2 2 of the opposite 3 2 of the opposite 1180 85 23 3 6 4 3 of the same 1180 85 23 3 6 5 4 of the same 6 1 7 2 of the same 8 2 of the same 1180 85 23 3 6 9 1 1180 85 23 3 6 10 (without nanotubes) 3 of the same 1180 85 23 3 6 22
MACROSCOPIC OBSERVATION OF 5083/6082/CNTS (I) 1 2 3 4 FSW tests Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height shape Tilt angle Tool pin Penetration Depth 1 3 of the same 2 2 of the opposite 3 2 of the opposite 1180 85 23 3 6 4 3 of the same 1180 85 23 3 6 23
DETAILED MACROSCOPIC OBSERVATION OF OPTIMUM WELDED JOINT WITH CNTS AS RS ~ 6 μm 24
MICROHARDNESS OF 5083/6082/CNTS 25
4 CONCLUSIONS-REMARKS Using pin resulted in the most uniform particle distribution within the stir zone, Recently, Bahrami et al applied the same technique and have the same results[*] The stir zone is rich in nanoparticles and the distribution is homogeneous for the optimum conditions The microstructure of stir zone is finer in comparison to the microstructure Of the test without nanoparticles The addition of SiC and TiC nanoparticles does not affect the yield strength, yet improves the ultimate tensile strength and the percentage of elongation. It is evidenced that the addition of nanoparticles results to enhanced elastic modulus both in local (nanoindentaion measurements) and overall (tensile measurements) level. Passes Rotational (RPM) Traverse (mm/min) Shoulder Tool Pin height Tool Pin shape Tilt angle Tool pin Penetration Depth SiC 2 of the opposite cylindric al TiC CNTs 3 of the same 3 of the same 1180 85 23 3 6 1180 85 23 3 6 cylindric al cylindric al [*] Bahrami, M., Besharati Givi, M. K., Dehghani, K., & Parvin, N. (2014). On the role of pin geometry in microstructure and mechanical properties of AA7075/SiC nanocomposite fabricated by friction stir welding technique. Materials & Design,53, 519-527. 26
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