Enhanced dissimilar aluminum alloy joints using 0.1 mm offset in refill friction stir spot welding

IF 6.2 2区 材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY
José Francisco Caldeira Maranho , Fan Cui , Huawei Tang , Xiaosong Feng , Hao Luan , Junjun Shen , Witor Wolf , Brenda Juliet Martins Freitas , Wenya Li , Nelson Guedes de Alcântara , Jorge Fernandez dos Santos , Benjamin Klusemann , Guilherme Yuuki Koga
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引用次数: 0

Abstract

5A06-O and 2219-T87 aluminum alloys are promising candidates for propellant tanks. In this study, refill friction stir spot welding (refill FSSW) with a 0.1 mm offset was applied to produce defect-free 5A06-O/2219-T87 welds. A Box-Behnken method and statistical analysis were used to optimize the processing parameters, by determining the influence of welding parameters on lap shear strength (LSS). Plunge depth was the most influential parameter on LSS. All joints failed through the weld seam, including those tested at −55 °C. Microhardness measurements showed a slight increase in the 5A06 sheet over time, while the 2219 sheet exhibited significant hardness reduction. Microstructural analysis revealed typical features of refill FSSW, including a heat-affected zone, thermo-mechanically affected zone, stir zone, hook, and joint-line remnants. Novel findings include the identification of an onion structure in the welds, characterized by fine equiaxed grains and nanoprecipitates that contribute to weld's hardness. This unique microstructure, formed under the thermal and mechanical conditions of the FSSW process, strengthens the material and enhances its mechanical performance. Stop-action tests provided insights into material flow and microstructural evolution during welding. While conventional refill FSSW could not produce defect-free welds, the findings highlight the potential of the 0.1 mm offset refill FSSW to enhance weld quality, supporting its application in aerospace components requiring high mechanical integrity across extreme temperature ranges.

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来源期刊
Journal of Materials Research and Technology-Jmr&t
Journal of Materials Research and Technology-Jmr&t Materials Science-Metals and Alloys
CiteScore
8.80
自引率
9.40%
发文量
1877
审稿时长
35 days
期刊介绍: The Journal of Materials Research and Technology is a publication of ABM - Brazilian Metallurgical, Materials and Mining Association - and publishes four issues per year also with a free version online (www.jmrt.com.br). The journal provides an international medium for the publication of theoretical and experimental studies related to Metallurgy, Materials and Minerals research and technology. Appropriate submissions to the Journal of Materials Research and Technology should include scientific and/or engineering factors which affect processes and products in the Metallurgy, Materials and Mining areas.
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