Influence of SiC microparticles and multi-pass FSW on weld quality of the AA6082 and AA5083 dissimilar joints

doi:10.21203/rs.3.rs-2568962/v1

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Influence of SiC microparticles and multi-pass FSW on weld quality of the AA6082 and AA5083 dissimilar joints

https://doi.org/10.21203/rs.3.rs-2568962/v1

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published 13 May, 2023

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In the current research, the influence of multi-pass (one, two and three passes) of friction stir welding and SiC microparticles on the tensile strength, microhardness and %strain of dissimilar reinforced joints of AA6082 and AA5083 was examined. Tool rotating speed of 900 rpm, transverse speed of 45 mm/min, tool tilt angle of 2º and 8% volume percentage of SiC microparticles were considered as constant parameters for multi-pass FSW. The finding demonstrated that increasing the number of FSW passes from one to three augmented the dispersion pattern of Sic microparticles. The grain refinement of multi-pass reinforced joints was achieved by the pinning effect of SiC microparticles and dynamic recrystallization. The three-passes FSWed reinforced joint exhibited the highest tensile strength (247.17 MPa), %stain (13.1%) and microhardness (126.6 HV) due to the higher grain refinement.

Reinforced joints

tensile strength

%strain

microhardness

SiC microparticles

The fabrication of metal matrix composites employing reinforcing particles (RPs) is a creative technique for augmenting the mechanical characteristics (stiffness, hardness and strength, etc.), corrosion, and wear resistance [1–3]. The distributed reinforcing particles, via the "pinning effect" inhibit the grain boundaries from expanding during dynamic recrystallization, resulting in equiaxed tiny grains that ameliorate the tribological and mechanical characteristics of welded or processed materials [4–6]. To enhance tribological and mechanical characteristics, micro/nanoparticles-based aluminum metal matrix composites through FSP were fabricated to produce surface and bulk composites [7–9]. The transformation from traditional materials to lightweight materials is recently developing in almost all industries for fabricating high-strength and lightweight structural components. Aluminum alloys offer exceptional mechanical characteristics like higher strength, lightweight, and good corrosion resistance. Therefore, aluminum alloys have attracted great interest for structural applications in almost all industrial domains, including aerospace, marine and automobile. Fusion welding methods find inappropriate for welding low melting point materials due to their limitations of high residual stresses, surface cracks, distortion and porosity [10–12]. Thus, friction stir welding (FSW) is solid-state in nature and seems to be the most effective method for joining dissimilar aluminum alloys.

Several researchers also employed FSW to produce aluminum metal matrix composites (AMMCs) utilizing various micro/nano-sized RPs to ameliorate the weld properties of related aluminum alloys. Recent studies have examined the viability of fabricating AMMCs with different reinforcing particles, including AA2124 with SiC particles, AA7005 with Al₂O₃ particles and AA2009 with SiC particles [13–15]. The incorporation of micro/nano particles into the stir zone helped the researchers improve the weld properties of numerous metal alloys. Compared to the FSWed samples without SiC particles, improved weld qualities of dissimilar AA7075/AA2024 were produced with different volume percentages (5, 8, and 13% ) of nano-sized SiC particles. It was found that 5% SiC nanoparticle inclusion provided the best mechanical properties [16]. The reinforcement particles of Al₂O₃ outperformed Sic reinforcement particles and a hybrid of the two in FSW of the dissimilar AA6101 and AA1350 in terms of mechanical and wear characteristics [17].

The strain-hardenable AA5083 has exceptional corrosion resistance additionally, it has superb weldability [18]. Consequently, AA5083 is often used not only in the aerospace and automotive industries but also in shipbuilding and armored vehicles [19, 20]. AA6082 is also frequently utilized in a wide range of automotive and aerospace applications. AA6082 provides an impressive combination of corrosion resistance, strength, and surface characteristics [21]. Dissimilar welding of AA6082 and AA5083 has drawn the considerable interest of almost all the industrial sectors due to their broad applications and superior weldability. The motivation behind this study to improve weld quality of these alloys which will be tremendously beneficial in a number of industrial domains. Therefore, in the present research the consequences of multi-pass FSW and SiC microparticles (SiCp) on weld quality of AA5083 and AA6082 dissimilar joint was investigated. The consequences of multi-pass FSW and SiC particles on weld quality of AA5083 and AA6082 dissimilar joint has not yet been studied, to the author's knowledge.

The materials utilized in this study to develop dissimilar FSWed joints were: AA5083 and AA6082 with dimensions 150x40x6 mm as the base and the SiC particles (SiCp) ranging from 50 to 80 µm as reinforcing material. A friction stir welding machine equipped with position controls was employed for multi-pass FSW. The Adjacent surfaces of the base plates were milled to incorporate the SiC powder. To include 8% SiCp, the depth and width of the milled slot were taken as 3 mm and 0.48 mm, respectively as depicted in Fig. 1a.. The SiCp was mixed with ethanol, and a thick slurry was made. The milled slots were cleaned with acetone before filling the SiCp slurry. The slurry of SiCp was filled manually in the milled slots. A detailed and systematic explanation of composite development utilizing the groove approach was previously published [22, 23]. The multi-pass FSW was performed at constant rotating speed, transverse speed, tool tilt angle, and volume fraction of SiCp of 900 rpm, 40 mm/min, 2 ̊, and 8%, respectively. The position of materials The FSW parameters condition and volume fraction of SiCp were chosen based on preliminary trials to obtain defect-free FSWed reinforced joints. Prior to multi-pass FSW, a pin-less tool of shoulder diameter 19.5 mm was employed (Fig. 1b) to close the groove from top at a constant rotating speed and transverse speed of 900 rpm and 40 mm/min respectively .The parametric setting of FSW and volume percentage of SiCp were chosen based on machine capability and trail runs. The profiles of tool pin significantly impact the flow of material during FSW. The cylindrical threaded-pin tool revealed defect-free FSWed joints with better material flow than the cylindrical pin tool and cylindrical tapered-pin tool [24]. Therefore, in the current research, multi-pass FSW was performed utilizing a cylindrical threaded-pin tool made of H13 tool steel. Figure 1b illustrates the dimensional characteristics and pictorial view of the FSW tool. In the case of welding dissimilar materials, positioning of materials is an essential consideration for defect-free dissimilar joints. Therefore, in the current research, plates of AA6082 were situated on the advancing side, as suggested by previous studies [25, 26]. Table 1 illustrates the parametric setting of multi-pass FSW and the reinforcing condition of SiCp. The defect free FSWed joints after multi-pass FSW are depicted in Fig. 2.

The test sample extraction plan for various tests is cited in Fig. 3. A universal testing machine (Model: UT-04-0100, BISS Pvt. Ltd., India) of a capacity of 100 kN was employed to perform tensile tests. Microhardness indentations were performed under 100gm load and separated by a 1 mm distance utilizing a Micro-Vickers hardness tester (Model: XHVT1000Z/V, Jinan victory inst. Co. Ltd.). To analyze the consequences of SiC particles and multi-pass FSW, samples were cross-sectioned and prepared for microstructural evolution. The etching of prepared samples was performed with Keller reagent. Optical-microscopy (OM) and Field-emission-scanning-electron-microscopy (FESEM) were utilized to evaluate the microstructural behavior of the stir zone. OM was performed utilizing a metallurgical inverted microscope (Model: Suxma-met, Conation Technologies), while FESEM analysis was performed using FESEM (Model: JSM-IT100, Jeol) equipped with an energy-dispersive X-ray spectroscopy (EDS) detector (Model: 51-ADD0076, Oxford Instrument).

The grain structure, FESEM photo-image and elemental composition obtained using EDS of AA5083 and AA6082 are cited in Fig. 4 (a-d). The mean grain size of AA5083 and AA6082 was found to be ~ 35 and ~ 39 µm, respectively. The FESEM photo-image and elemental composition obtained using EDS of SiCp are cited in Fig. 4 (e, f). The Due to heat input and dynamic recrystallization (DRX) resulting from severe plastic deformation, three distinct zones are identified in the weld zone of the FSWed joints: the stir zone (SZ), the thermo-mechanical affected zone (TMAZ), and heat-affected zone (HAZ) [27, 28]. Compared to the HAZ and TMAZ, the SZ exhibited higher grain refinement [29].

Table 1

Experimental condition of various FSWed joints
FSWed joints	Tool rotating speed (rpm)	Transverse speed (mm/min)	Tool angle (degree)	Number of FSW passes	Volume fraction of SiCmp (%)
One-pass FSWed unreinforced joint	900	40	2	1	0
One -pass FSWed reinforced joint	900	40	2	1	8
Two-passes FSWed reinforced joint	900	40	2	2	8
Three-passes FSWed reinforced joint	900	40	2	3	8

3.1 Microstructural characterization

To examine the influences of multi-pass FSW and SiC particles on the weld quality of AA6082 and AA5083 dissimilar joints, an investigation associated with the distribution of SiCp and grain structure of SZ was carried out. Figure 5 depicts the FESEM photo-image of the SZ of one-pass FSWed unreinforced joint and multi-pass (one, two and three) FSWed reinforced joints. The defect-free joining of AA6082 and AA5083 with the proper intermixing was observed in the one-pass FSWed unreinforced joint, as depicted in Fig. 5a. Figure 5 (b-d) depicts the FESEM photo-image of the SZ of one, two and three-passes FSWed reinforced joints and confirms the consequences of the increasing FSW passes on the dispersion pattern of particles.

The clustering of SiCp along with poor bonding with AMM was noticed in the SZ of the one-pass FSWed reinforced joint as delineated in Fig. 5b. This demonstrates that one FSW pass was not producing sufficient strain to prevent clustering of SiCp [30]. The clustering of SiCp was found absent as the FSW passes enhanced from one to two, but the dispersion pattern of SiCp was observed as non-uniform in the two-passes FSWed reinforced joint, as cited in Fig. 5c [31]. The augmented dispersion pattern of SiCp may be attributed to the repeated strain developed by the tool’s stirring action resulting in disjoining of clustering of SiCp as the FSW passes enhanced from one to two. Further improved dispersion of SiCp was found after implementing three passes of FSW. Therefore the uniform dispersion of SiCmp was observed after implementing three FSW passes, as cited in Fig. 5d. The absence of SiCp clustering revealed the excellent bonding between SiCp and surrounded AMM [32, 33]. The uniformity of SiCmp in the SZ of three-passes FSWed reinforced joints was confirmed by the EDS mapping analysis. It is evident from the Si elemental mapping (Fig. 5e) that the dispersion pattern of SiCmp is uniform after three passes of FSW. Referring to Fig. 6 (a-c), The EDS analysis of FSWed unreinforced joint and reinforced joints after one and three FSW passes also confirms the incorporation of SiCmp in FSWed reinforced joints. Considering the EDS analysis finding, the silicon percentage in the one-pass FSWed unreinforced joint was 0.56%, respectively. In contrast, the silicon percentage in the one-pass and three-passes FSWed reinforced joint was 6.98% and 7.66%, respectively. The carbon content in the one-pass and three-passes reinforced FSWed joint was 2.02% and 2.83%, respectively.

Figure 7 depicts the grain structure of the SZ of FSWed unreinforced joint and various reinforced joints. The stretched grain structure of AA6082 and AA5083 transformed into equiaxed and fined grains due to DRX [34]. The grain size of the SZ is mainly influenced by the temperature effect, DRX and RPs in the AMM. The dominating factors among these three phenomena decide the grain size. The temperature effect arises due to increased heat input at lower transverse speeds and higher rotating speeds, which induces grain growth and coarsening of grains [35]. DRX occurs at high temperature owing to severe plastic deformation resulting in the conversion of the low-angle boundaries to the high-angle boundaries and nucleates the new grains at developmental regions, which diminishes the grain size [36]. The RPs in the SZ serve as grain boundary barriers, inhibiting grain development via Zener-pinning effect [37]. Consequently, at constant rotating speed (900 rpm) and transverse speed (45 mm/min), the phenomena of DRX and the influence of SiCp dominated in diminishing the grain size. Whereas, Due to the absence of SiCp in FSWed unreinforced joint, only the DRX phenomenon dominated in diminishing the grain size. Thus, higher grain refinement was achieved in the three-passes FSW reinforced joints due to the DRX and the effect of uniformly distributed SiCp [38].

The coarse gain structure of AA 6082 and AA5083 exhibits the mean grain size of 39 and 35 µm, respectively. An abrupt reduction in the grain size was observed after implementing one-pass of FSW owing to DRX [39]. Therefore, a mean grain size of 19.4 µm (Fig. 7a) was found in the one-pass FSWed unreinforced joint, as delineated in Fig. 7a. The grain size of the one-pass FSWed reinforced joint was found to be smaller (12.6 µm) than one-pass FSWed unreinforced joint, as cited in Figs. 7a and b. This may be ascribed to the presence of SiCp in the SZ, as the same rotating speed and transverse speed were used for unreinforced and reinforced joints. As the FSW passes proceeded from one to three, it was observed that the grain size of SZ was further diminished. The further reduction in the grain size may be ascribed to the dispersion pattern of SiCp [40]. The more uniformly distributed RPs decreased the grain size by providing more obstacles to grain boundaries and restricting grain growth by the pinning effect [41]. When dislocations begin to accumulate during plastic deformation owing to RPs, the particles-induced nucleation-based DRX is feasible [42, 43]. The presence of more uniformly dispersed SiCp enhances the pinning effect, which results in higher grain refinement. Consequently, the grain size of the two-passes and three-passes FSWed reinforced joints was found to be 7.2 (Fig. 7c) and 3.4 µm (Fig. 7d), respectively. Thus, the grain structure of multi-pass FSWed reinforced joints evident that equiaxed and fine grains were developed owing to the domination of DRX and the pinning effect of uniformly dispersed SiCp [43].

3.2 Influence on tensile properties

In Fig. 8, the average tensile characteristics of the base materials and the various FSWed joints was presented. In the case of unreinforced joints, grain size is the key variable in influencing the mechanical characteristics of the FSWed joint. However, the size, quantity, dispersion pattern of RPs, and the bonding strength between the RPs and AMM also influence the mechanical characteristics of the FSWed reinforced joints [44]. It can be revealed from Fig. 8 that the tensile strength of the FSWed unreinforced and reinforced joints are lesser than that of the base materials. In contrast, the one-pass FSWed reinforced joint exhibits higher tensile strength than that of the unreinforced joint. This is ascribed to the existence of SiCp, which inhibits dislocation boundary movement and prevents grain development, resulting in reduced gain size [45]. The bonding between AMM and RPs, grain size, and dislocation density all significantly influenced the tensile strength of the FSWed reinforced joint [46]. The improved dispersion of SiCp was achieved by the increase in FSW passes. More uniform dispersion of RPs developed more barriers to grain development and further diminished grain size [47]. The tensile strength is inversely correlated with grain size, as stated by the Hall-Patch equation [48]. The grain size of FSWed reinforced joints was observed to be smaller than that of the base materials due to the pinning effect of SiCp and DRX [49]. Consequently, the three-passes FSWed reinforced joint exhibited a higher tensile strength of 247.17 MPa. Whereas the one-pass FSWed unreinforced joint exhibited the minimum tensile strength of 206.83 MPa. These observations are consistent with those of Jamalian et al. [50]. The %strain of one-pass FSWed unreinforced joint and reinforced joint was found to be higher than AA6082 but lower than AA5083. The %strain of the one-pass FSWed reinforced joint was observed lower than that of unreinforced joints and both the base alloys. But the %strain of two and three-passes FSWed reinforced joints was 12.2, and 13.1%, respectively, which is higher than the base materials.

Figure 9(a-d) depicts the fractography of the fractured tensile samples of various FSWed joints. The fracture occurred towards the AA6082 side at HAZ, where the hardness value was observed as minimal [51]. The dimple fracture, symptomatic of the ductile approach of failure, was noticed in all tensile samples. Under the tensile stress, the test samples’ edges formed a shear plane with a cup-cone shape [52]. In the FSWed reinforced joints, the ductile fracture with honeycomb dimples was identified (Fig. 9). The smaller dimple size was observed in the one-pass FSWed reinforced joint (Fig. 9b) compared to the one-pass FSWed unreinforced joint. From Fig. 9 (c, d), it can be noticed that the dimple size was further decreased as the FSW passes were enhanced from one to three. The diminished grain size was found in the three-passes FSWed reinforced joint via pinning effect of uniformly dispersed SiCp. The fractography of raptured surface (Fig. 9d) also revealed fine and equiaxed dimples developed by the micro voids’ coalescence [53, 54]. The ruptured zone was found at the HAZ towards AA6082, confirmed by hardness variation, which led to augmented %strain. Thus, it can be concluded that the embedded SiCmp ameliorated the tensile chrematistics of the FSWed joints. This may be correlated to the enhanced grain refinement by DRX and pinning effect of uniformly dispersed SiCp and excellent bonding between the SiCp and the AMM, resulting in higher resistance to fracture [55].

3.3 Influence on microhardness

The microhardness distribution in the weld zone of several FSWed joints of AA5083 and AA6082 was evaluated using a Vickers microhardness tester. The asymmetrical microhardness variation was noted in the weld zone of FSWed joints due to the irregular plastic flow in the retreating and advancing side [56]. The mean microhardness of base materials (AA6082 and AA5083) and at the center of the weld zone of FSWed joints is cited in Fig. 10a.

The one-pass FSWed unreinforced joint exhibited a microhardness of 93.2 HV, which is lower than that of AA5083 but higher than AA6082. According to the microhardness findings, one-pass FSWed unreinforced joint exhibits the lowest hardness compared to the multi-pass FSWed reinforced joints. The microhardness was enhanced by incorporating SiCp and implementing one, two and three passes of FSW. Therefore, the microhardness of one, two and three passes FSWed joints was observed as 105.8, 113.1 and 126.6.4 HV, respectively. The three-passes FSWed reinforced joint has the maximum microhardness of 126.6 HV among all the FSWed joints. The distribution of microhardness in the weld zone of the various FSWed joints is cited in Fig. 10b. The SZ indicates the higher microhardness owing to smaller grain size caused by the pinning effect of SiCp and DRX compared to the TMAZ and HAZ. In contrast, the microhardness in the HAZ was noticed lesser owing to coarsening of grains at high temperature and over-aging [57]. The microhardness of the FSWed reinforced joints was also augmented owing to the hard nature of SiCp. The three-passes FSWed reinforced joint revealed the highest microhardness due to better grain refinement than other FSWed joints.

In the current work, dissimilar FSWed reinforced joints of AA5083 and AA6082 were developed using 8% volume fraction of SiCp. The impact of SiC microparticles along with multi-pass FSW on the weld quality of AA5083 and AA6082 dissimilar FSWed joints was investigated. The following are the main finding from the obtained results:

In one-pass FSWed unreinforced joint, only DRX was involved in the grain refining. In contrast, the improved grain refinement in the multi-pass FSWed reinforced joints was accomplished by the pinning effect of SiCp and DRX.
The improved dispersion of SiCmp was found as the FSW passes enhanced from one to three. The uniformly dispersed SiCp was observed in the three-passes FSWed reinforced joint.
The multi-pass FSWed reinforced joints revealed a higher tensile strength than the unreinforced joint. Furthermore, the three-passes FSWed reinforced joint exhibited a higher tensile strength of 247.17 MPa.
The %strain of one-pass FSWed unreinforced joint and reinforced joint was found to be higher than AA6082 but lower than AA5083. The %strain of one-pass FSWed reinforced joint was to be found lower than unreinforced joints and both the base alloys. But the %strain of two and three-passes FSWed reinforced joints was 19.2, and 21.4%, respectively, which is higher than that of both the base materials.
The one-pass FSWed unreinforced joint exhibited a microhardness of 93.2 HV, which is lower than that of AA5083 and higher than AA5083. The microhardness was enhanced by incorporating SiCp and implementing one, two and three passes of FSW. Therefore, the microhardness of one, two and three passes FSWed joints was observed as 105.8, 113.1 and 129.6.4 HV, respectively.

Compliance with Ethical Standards : No

Competing Interests: No competing interests.

Consent to Participate: No objection.

Consent for Publication: No objection.

Informed consent: Not applicable.

Conflict-of-Interest: No

Availability of Data and Material: All the data and information mentioned in this article are related to this research.

Author’s Contribution: Sumit Jain and R.S. Mishra: Writing and reviewing of article.

Husain Mehdi: Drafting and reviewing.

Funding statement: Not applicable

Acknowledgements: The authors would like to express gratitude to Department at the Mechanical Engineering in DTU, Delhi.

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No competing interests reported.

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published 13 May, 2023

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Editorial decision: Major revision
26 Feb, 2023
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Influence of SiC microparticles and multi-pass FSW on weld quality of the AA6082 and AA5083 dissimilar joints

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Abstract

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1. Introduction

2. Material And Experimentation

3. Results And Discussion

3.1 Microstructural characterization

3.2 Influence on tensile properties

3.3 Influence on microhardness

4. Conclusions

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References

Additional Declarations

Status:

Journal Publication

Version 1