Reinforcing the exit hole from friction stir welding and processing

Wang, Tianhao; Liu, Tingkun; Roosendaal, Timothy; Upadhyay, Piyush

doi:10.1016/j.mtla.2022.101611

Reinforcing the exit hole from friction stir welding and processing

Journal Article · Wed Nov 02 00:00:00 EDT 2022 · Materialia

DOI:https://doi.org/10.1016/j.mtla.2022.101611· OSTI ID:1906347

^[1]; ^[1]; Roosendaal, Timothy ^[1]; Upadhyay, Piyush ^[1]

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

After friction stir welding/processing (FSW/P), an exit hole remains at the end of the run, which can be the weakest region of the welded/processed workpiece. In addition, tensile residual stress around the exit hole resulting from heating during FSW/P facilitates incipient crack initiating from the exit hole under external loading. Current solutions include removing or repairing the exit hole, which are time-consuming and costly. Here, we propose a novel method to reinforce the exit hole by applying an additional FSW/P pass around it, in a way that replaces preexisting tensile residual stress with compressive residual stress. Under external loading, there is no evident strain accumulation around the exit hole, and the workpiece ultimately fails along the FSW/P heat affected zone. This method provides a more convenient way to reinforce the exit hole than the current exit-hole repair or removal methods for industrial applications.

View Accepted Manuscript (DOE)

Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 1906347

Alternate ID(s):: OSTI ID: 1905352

Report Number(s):: PNNL-SA-175228

Journal Information:: Materialia, Journal Name: Materialia Vol. 26; ISSN 2589-1529

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
Exit hole
Friction stir processing
Friction stir welding
Residual stress
Synchrotron x-ray technique

Reinforcing the exit hole from friction stir welding and processing

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