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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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.

Abstract Image

增强异种铝合金接头使用0.1毫米偏移在填充摩擦搅拌点焊
5A06-O和2219-T87铝合金是很有前途的推进剂储罐候选材料。在本研究中,采用0.1 mm偏移量的填充搅拌摩擦点焊(填充FSSW)来生产无缺陷的5A06-O/2219-T87焊缝。通过确定焊接参数对搭接抗剪强度(LSS)的影响,采用Box-Behnken法和统计分析对工艺参数进行优化。陷深是影响LSS最大的参数。所有接头都通过焊缝失效,包括在- 55°C下测试的接头。显微硬度测量显示,随着时间的推移,5A06片材的硬度略有增加,而2219片材的硬度则显著降低。显微组织分析揭示了补料FSSW的典型特征,包括热影响区、热机械影响区、搅拌区、钩和连接线残余。新的发现包括在焊缝中发现洋葱结构,其特征是细小的等轴晶粒和纳米沉淀物有助于焊缝的硬度。这种独特的微观结构是在FSSW工艺的热和机械条件下形成的,增强了材料的强度并提高了其机械性能。停止作用试验提供了对焊接过程中材料流动和微观组织演变的深入了解。虽然传统的填充FSSW不能产生无缺陷的焊缝,但研究结果强调了0.1 mm偏移填充FSSW在提高焊接质量方面的潜力,支持其在极端温度范围内要求高机械完整性的航空航天部件中的应用。
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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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