High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History

doi:https://doi.org/10.1007/s11661-017-4411-4

Title: High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History

Abstract

Friction-stir-welding (FSW) is a cost-effective and high quality joining process for aluminum alloys (especially heat-treatable allo ys) that has been applied successfully in the aerospace industry. However, the full potential of FSW on more cost-sensitive applications is still limited by the production rate, namely the welding speed of the process. The majority of literature evaluating FSW of aluminum alloys is based on welds made in the range of welding speeds around hundreds of millimeters per minute, and only a handful are at a moderate speed of 1 m/min. In this study we present a microstructural analysis of friction stir welded AA7075-T6 blanks with welding speeds up to 3 m/min. Textures, microstructures, mechanical properties, and weld quality are analyzed using TEM, EBSD, metallographic imaging, and Vickers hardness. Results are coupled with welding parameters to aid in the understanding of the complex material flow and texture gradients within the welds in an effort to optimize welding parameters for high speed processing.

Authors:: Zhang, Jingyi; Upadhyay, Piyush; Hovanski, Yuri; Field, David P.

Publication Date:: 2017-11-20

Research Org.:: Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1422298

Report Number(s):: PNNL-SA-128971
Journal ID: ISSN 1073-5623; VT0505000

DOE Contract Number:: AC05-76RL01830

Resource Type:: Journal Article

Journal Name:: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science

Additional Journal Information:: Journal Volume: 49; Journal Issue: 1; Journal ID: ISSN 1073-5623

Publisher:: ASM International

Country of Publication:: United States

Language:: English

Citation Formats


                    Zhang, Jingyi, Upadhyay, Piyush, Hovanski, Yuri, and Field, David P. High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History.  United States: N. p., 2017. 
        Web.  doi:10.1007/s11661-017-4411-4.

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                    Zhang, Jingyi, Upadhyay, Piyush, Hovanski, Yuri, & Field, David P. High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History.  United States.  https://doi.org/10.1007/s11661-017-4411-4

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                    Zhang, Jingyi, Upadhyay, Piyush, Hovanski, Yuri, and Field, David P. Mon .  
        "High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History".  United States.  https://doi.org/10.1007/s11661-017-4411-4.

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@article{osti_1422298,

  title        = {High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History},

  author       = {Zhang, Jingyi and Upadhyay, Piyush and Hovanski, Yuri and Field, David P.},

  abstractNote = {Friction-stir-welding (FSW) is a cost-effective and high quality joining process for aluminum alloys (especially heat-treatable allo ys) that has been applied successfully in the aerospace industry. However, the full potential of FSW on more cost-sensitive applications is still limited by the production rate, namely the welding speed of the process. The majority of literature evaluating FSW of aluminum alloys is based on welds made in the range of welding speeds around hundreds of millimeters per minute, and only a handful are at a moderate speed of 1 m/min. In this study we present a microstructural analysis of friction stir welded AA7075-T6 blanks with welding speeds up to 3 m/min. Textures, microstructures, mechanical properties, and weld quality are analyzed using TEM, EBSD, metallographic imaging, and Vickers hardness. Results are coupled with welding parameters to aid in the understanding of the complex material flow and texture gradients within the welds in an effort to optimize welding parameters for high speed processing.},

  doi          = {10.1007/s11661-017-4411-4},

  url          = {https://www.osti.gov/biblio/1422298},
  journal      = {Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science},

  issn         = {1073-5623},

  number       = 1,

  volume       = 49,

  place        = {United States},

  year         = {2017},

  month        = {11}

}

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Material Flow Modification in a FSW Through Introduction of Flats
journal, November 2015

Schneider, Judy; Brooke, Shane; Nunes, Arthur C.
Metallurgical and Materials Transactions B, Vol. 47, Issue 1
https://doi.org/10.1007/s11663-015-0523-7

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Title: High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History

Abstract

Citation Formats

Relationships between weld parameters, hardness distribution and temperature history in alloy 7050 friction stir welds journal, April 2005

On experimental optimization of friction stir welding of aluminum 6061: understanding processing-microstructure-property relations journal, March 2015

Development of grain structure during friction stir welding journal, August 2004

The influence of artificial aging on the microstructure, mechanical properties, corrosion, and environmental cracking susceptibility of a 7075 friction-stir-weld journal, October 2007

Friction stir welding characteristics of 2017-T351 aluminum alloy sheet journal, June 2005

Influence of welding speed on the fatigue of friction stir welds, and comparison with MIG and TIG journal, December 2003

Effects of tool–workpiece interface temperature on weld quality and quality improvements through temperature control in friction stir welding journal, November 2013

Microstructural Characteristics and Mechanical Properties of 7050-T7451 Aluminum Alloy Friction Stir-Welded Joints journal, May 2016

Effect of tool rotational speed on residual stress, microstructure, and tensile properties of friction stir welded 6061-T6 aluminum alloy thick plate journal, September 2015

Thermal Management in Friction-Stir Welding of Precipitation-Hardened Aluminum Alloys journal, March 2015

Microstructural investigation of friction stir welded 7050-T651 aluminium journal, February 2003

Effects of Friction Stir Welding Speed on AA2195 alloy journal, January 2016

Microstructure, crystallographic texture and mechanical properties of friction stir welded AA2017A journal, February 2012

Effects of forge axis force and backing plate thermal diffusivity on FSW of AA6056 journal, December 2012

Microtexture in the friction-stir weld of an aluminum alloy journal, April 2001

Temperature measurement and control of bobbin tool friction stir welding journal, December 2015

Friction Stir Processing Technology: A Review journal, February 2008

Dynamic Recrystallization of Al Alloy 7075 in Turning journal, March 2016

Friction stir welding and processing journal, August 2005

High-Speed Friction-Stir Welding to Enable Aluminum Tailor-Welded Blanks journal, April 2015

In-process heat treatments to improve FS-welded butt joints journal, September 2008

Effect of post-weld heat treatment on the mechanical properties of 2219-O friction stir welded joints journal, January 2006

Effect of Strain Rate Upon Plastic Flow of Steel journal, January 1944

Friction stir weld nugget temperature asymmetry journal, January 2010

Residual stress in friction stir-welded Al sheets journal, July 2004

Optimization of process parameters of aluminum alloy AA 2014-T6 friction stir welds by response surface methodology journal, September 2015

A study of texture patterns in friction stir welds journal, April 2008

Investigation of precipitation in an Al–Zn–Mg alloy after two-step ageing treatment at 100° and 150°C journal, September 1999

Microstructural evolution ahead of the tool in aluminum friction stir welds journal, March 2008

Recrystallization mechanisms during friction stir welding/processing of aluminum alloys journal, March 2008

Microstructural evolution and mechanical properties of friction-stir-welded Al–Mg–Si joint journal, February 2014

Microstructural Evolution in Friction Stir Welded 1050 Aluminum and 6061 Aluminum Alloy journal, January 2004

Effect of cooling media on residual stresses induced by a solid-state welding: underwater FSW journal, August 2015

High Rotation Speed Friction Stir Welding for 2014 Aluminum Alloy Thin Sheets journal, February 2017

Friction stir welding characteristics of different heat-treated-state 2219 aluminum alloy plates journal, March 2006

Optimization of friction stir welding parameters for improved corrosion resistance of AA2219 aluminum alloy joints journal, December 2015

Finite element simulation of material flow in friction stir welding journal, June 2001

The adjustment strategy of welding parameters for spray formed 7055 aluminum alloy underwater friction stir welding joint journal, December 2015

Enhancing mechanical properties of friction stir welded 2219Al-T6 joints at high welding speed through water cooling and post-welding artificial ageing journal, August 2015

Fine-grain evolution in friction-stir processed 7050 aluminum journal, May 2003

Hot deformation behavior and microstructural evolution of homogenized 7050 aluminum alloy during compression at elevated temperature journal, January 2011

Friction-stir welding effects on microstructure and fatigue of aluminum alloy 7050-T7451 journal, September 2000

Effect of grain size refinement and precipitation reactions on strengthening in friction stir processed Al–Cu alloys journal, December 2011

Finite element modeling of friction stir welding—thermal and thermomechanical analysis journal, October 2003

Optimization of processing-microstructure-properties relationship in friction-stir welded 6061-T6 aluminum alloy journal, April 2016

Friction Stir Welding of 7075-T651 Aluminium Alloy journal, January 2016

Constitutive Description of 7075 Aluminum Alloy During Hot Deformation by Apparent and Physically-Based Approaches journal, January 2015

Friction stir welding of lap joints: Influence of process parameters on the metallurgical and mechanical properties journal, August 2009

Ultimate tensile strength optimization of different FSW aluminium alloy joints journal, February 2015

The strength of friction stir welded and friction stir processed aluminium alloys journal, March 2008

Mechanical properties and their relations to microstructural characteristics of high-speed friction stir-welded AA6005A-T6 aluminum hollow extrusions journal, June 2016

Continuous dynamic recrystallization during friction stir welding of high strength aluminum alloys journal, September 2000

High speed friction stir welding of aluminium alloys journal, November 2010

Softening mechanism and microstructure evolution of as-extruded 7075 aluminum alloy during hot deformation journal, April 2014

Residual stress distribution and microstructure in the friction stir weld of 7075 aluminum alloy journal, August 2015

Internal defect and process parameter analysis during friction stir welding of Al 6061 sheets journal, June 2012

Effect of friction stir processing on microstructure and mechanical properties of aluminium journal, March 2012

EBSD Analysis of Friction Stir Weld Textures journal, November 2013

High strain rate superplasticity in a commercial 2024 Al alloy via friction stir processing journal, October 2003

Mechanical response of 2024-7075 aluminium alloys joined by Friction Stir Welding journal, July 2005

Microstructural evolution of 6063 aluminum during friction-stir welding journal, September 1999

Quantitative evaluation of precipitates in an Al–Zn–Mg–Cu alloy after isothermal aging journal, March 2006

Grain refinement process in commercial 7075-T6 aluminum alloy under friction stir welding and superplasticity journal, April 2008

Material flow in butt friction stir welds in AA2024-T3 journal, February 2006

Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds journal, June 2009

Stationary shoulder FSW for joining high strength aluminum alloys journal, July 2015

Quantifying crystallographic texture in the probe-dominated region of thick-section friction-stir-welded aluminium journal, September 2008

Material flow in FSW of AA7075–T6 butt joints: numerical simulations and experimental verifications journal, July 2006

Thermal modeling of friction stir welding in a moving coordinate system and its validation journal, May 2003

Comparative hot workability of 7012 and 7075 alloys after different pretreatments journal, July 1995

Effects of microstructural heterogeneity on very high cycle fatigue properties of 7050-T7451 aluminum alloy friction stir butt welds journal, February 2016

Texture variation and its influence on the tensile behavior of a friction-stir processed magnesium alloy journal, June 2006

Determination of strain rate in Friction Stir Welding by three-dimensional visualization of material flow using X-ray radiography journal, September 2015

Tensile properties and fracture locations of friction-stir-welded joints of 2017-T351 aluminum alloy journal, December 2003

Analysis of AA 6082-T6 welds strength mismatch: stress versus hardness relationships journal, February 2015

Relationship between grain size and Zener–Holloman parameter during friction stir processing in AZ31 Mg alloys journal, September 2004

Banded microstructure in AA2024-T351 and AA2524-T351 aluminum friction stir welds journal, January 2004

Relationships between weld parameters, hardness distribution and temperature history in alloy 7050 friction stir welds
journal, April 2005

On experimental optimization of friction stir welding of aluminum 6061: understanding processing-microstructure-property relations
journal, March 2015

Development of grain structure during friction stir welding
journal, August 2004

The influence of artificial aging on the microstructure, mechanical properties, corrosion, and environmental cracking susceptibility of a 7075 friction-stir-weld
journal, October 2007

Friction stir welding characteristics of 2017-T351 aluminum alloy sheet
journal, June 2005

Influence of welding speed on the fatigue of friction stir welds, and comparison with MIG and TIG
journal, December 2003

Effects of tool–workpiece interface temperature on weld quality and quality improvements through temperature control in friction stir welding
journal, November 2013

Microstructural Characteristics and Mechanical Properties of 7050-T7451 Aluminum Alloy Friction Stir-Welded Joints
journal, May 2016

Effect of tool rotational speed on residual stress, microstructure, and tensile properties of friction stir welded 6061-T6 aluminum alloy thick plate
journal, September 2015

Thermal Management in Friction-Stir Welding of Precipitation-Hardened Aluminum Alloys
journal, March 2015

Microstructural investigation of friction stir welded 7050-T651 aluminium
journal, February 2003

Effects of Friction Stir Welding Speed on AA2195 alloy
journal, January 2016

Microstructure, crystallographic texture and mechanical properties of friction stir welded AA2017A
journal, February 2012

Effects of forge axis force and backing plate thermal diffusivity on FSW of AA6056
journal, December 2012

Microtexture in the friction-stir weld of an aluminum alloy
journal, April 2001

Temperature measurement and control of bobbin tool friction stir welding
journal, December 2015

Friction Stir Processing Technology: A Review
journal, February 2008

Dynamic Recrystallization of Al Alloy 7075 in Turning
journal, March 2016

Friction stir welding and processing
journal, August 2005

High-Speed Friction-Stir Welding to Enable Aluminum Tailor-Welded Blanks
journal, April 2015

In-process heat treatments to improve FS-welded butt joints
journal, September 2008

Effect of post-weld heat treatment on the mechanical properties of 2219-O friction stir welded joints
journal, January 2006

Effect of Strain Rate Upon Plastic Flow of Steel
journal, January 1944

Friction stir weld nugget temperature asymmetry
journal, January 2010

Residual stress in friction stir-welded Al sheets
journal, July 2004

Optimization of process parameters of aluminum alloy AA 2014-T6 friction stir welds by response surface methodology
journal, September 2015

A study of texture patterns in friction stir welds
journal, April 2008

Investigation of precipitation in an Al–Zn–Mg alloy after two-step ageing treatment at 100° and 150°C
journal, September 1999

Microstructural evolution ahead of the tool in aluminum friction stir welds
journal, March 2008

Recrystallization mechanisms during friction stir welding/processing of aluminum alloys
journal, March 2008

Microstructural evolution and mechanical properties of friction-stir-welded Al–Mg–Si joint
journal, February 2014

Microstructural Evolution in Friction Stir Welded 1050 Aluminum and 6061 Aluminum Alloy
journal, January 2004

Effect of cooling media on residual stresses induced by a solid-state welding: underwater FSW
journal, August 2015

High Rotation Speed Friction Stir Welding for 2014 Aluminum Alloy Thin Sheets
journal, February 2017

Friction stir welding characteristics of different heat-treated-state 2219 aluminum alloy plates
journal, March 2006

Optimization of friction stir welding parameters for improved corrosion resistance of AA2219 aluminum alloy joints
journal, December 2015

Finite element simulation of material flow in friction stir welding
journal, June 2001

The adjustment strategy of welding parameters for spray formed 7055 aluminum alloy underwater friction stir welding joint
journal, December 2015

Enhancing mechanical properties of friction stir welded 2219Al-T6 joints at high welding speed through water cooling and post-welding artificial ageing
journal, August 2015

Fine-grain evolution in friction-stir processed 7050 aluminum
journal, May 2003

Hot deformation behavior and microstructural evolution of homogenized 7050 aluminum alloy during compression at elevated temperature
journal, January 2011

Friction-stir welding effects on microstructure and fatigue of aluminum alloy 7050-T7451
journal, September 2000

Effect of grain size refinement and precipitation reactions on strengthening in friction stir processed Al–Cu alloys
journal, December 2011

Finite element modeling of friction stir welding—thermal and thermomechanical analysis
journal, October 2003

Optimization of processing-microstructure-properties relationship in friction-stir welded 6061-T6 aluminum alloy
journal, April 2016

Friction Stir Welding of 7075-T651 Aluminium Alloy
journal, January 2016

Constitutive Description of 7075 Aluminum Alloy During Hot Deformation by Apparent and Physically-Based Approaches
journal, January 2015

Friction stir welding of lap joints: Influence of process parameters on the metallurgical and mechanical properties
journal, August 2009

Ultimate tensile strength optimization of different FSW aluminium alloy joints
journal, February 2015

The strength of friction stir welded and friction stir processed aluminium alloys
journal, March 2008

Mechanical properties and their relations to microstructural characteristics of high-speed friction stir-welded AA6005A-T6 aluminum hollow extrusions
journal, June 2016

Continuous dynamic recrystallization during friction stir welding of high strength aluminum alloys
journal, September 2000

High speed friction stir welding of aluminium alloys
journal, November 2010

Softening mechanism and microstructure evolution of as-extruded 7075 aluminum alloy during hot deformation
journal, April 2014

Residual stress distribution and microstructure in the friction stir weld of 7075 aluminum alloy
journal, August 2015

Internal defect and process parameter analysis during friction stir welding of Al 6061 sheets
journal, June 2012

Effect of friction stir processing on microstructure and mechanical properties of aluminium
journal, March 2012

EBSD Analysis of Friction Stir Weld Textures
journal, November 2013

High strain rate superplasticity in a commercial 2024 Al alloy via friction stir processing
journal, October 2003

Mechanical response of 2024-7075 aluminium alloys joined by Friction Stir Welding
journal, July 2005

Microstructural evolution of 6063 aluminum during friction-stir welding
journal, September 1999

Quantitative evaluation of precipitates in an Al–Zn–Mg–Cu alloy after isothermal aging
journal, March 2006

Grain refinement process in commercial 7075-T6 aluminum alloy under friction stir welding and superplasticity
journal, April 2008

Material flow in butt friction stir welds in AA2024-T3
journal, February 2006

Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds
journal, June 2009

Stationary shoulder FSW for joining high strength aluminum alloys
journal, July 2015

Quantifying crystallographic texture in the probe-dominated region of thick-section friction-stir-welded aluminium
journal, September 2008

Material flow in FSW of AA7075–T6 butt joints: numerical simulations and experimental verifications
journal, July 2006

Thermal modeling of friction stir welding in a moving coordinate system and its validation
journal, May 2003

Comparative hot workability of 7012 and 7075 alloys after different pretreatments
journal, July 1995

Effects of microstructural heterogeneity on very high cycle fatigue properties of 7050-T7451 aluminum alloy friction stir butt welds
journal, February 2016

Texture variation and its influence on the tensile behavior of a friction-stir processed magnesium alloy
journal, June 2006

Determination of strain rate in Friction Stir Welding by three-dimensional visualization of material flow using X-ray radiography
journal, September 2015

Tensile properties and fracture locations of friction-stir-welded joints of 2017-T351 aluminum alloy
journal, December 2003

Analysis of AA 6082-T6 welds strength mismatch: stress versus hardness relationships
journal, February 2015

Relationship between grain size and Zener–Holloman parameter during friction stir processing in AZ31 Mg alloys
journal, September 2004

Banded microstructure in AA2024-T351 and AA2524-T351 aluminum friction stir welds
journal, January 2004

Flow visualization and residual microstructures associated with the friction-stir welding of 2024 aluminum to 6061 aluminum
journal, November 1999

Effect of Rotation Speed to Welding Speed Ratio on Microstructure and Mechanical Behavior of Friction Stir Welded Aluminum-Lithium Alloy Joints: Microstructure and Mechanical Behavior of Friction Stir Welded Al-Li Alloy
journal, August 2013

Heterogeneity of crystallographic texture in friction stir welds of aluminum
journal, November 2001