Effect of tool design and pass strategy on defect elimination and uniform, enhanced tensile properties of friction stir processed high-pressure die-cast A380 alloy

Samanta, Avik; Das, Hrishikesh; Grant, Glenn J.; Jana, Saumyadeep

doi:10.1016/j.msea.2022.144388

Effect of tool design and pass strategy on defect elimination and uniform, enhanced tensile properties of friction stir processed high-pressure die-cast A380 alloy

Journal Article · Thu Nov 24 00:00:00 EST 2022 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing

DOI:https://doi.org/10.1016/j.msea.2022.144388· OSTI ID:1909782

^[1]; Das, Hrishikesh ^[1]; ^[1]; Jana, Saumyadeep ^[1]

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

This work reports implementation of friction stir processing (FSP) to locally modify microstructure and create a defect-free processing zone with the aid of different tool designs and altering the passing strategy for two different process parameter combinations. Here, FSP is applied on high pressure die-cast (HPDC) A380 alloy, a widely used Al-Si alloy fabricated in the die casting sector for automotive and aerospace applications. However, the presence of gas and shrinkage porosity, brittle needle-shaped Fe-containing ß-FeSiAl₅ intermetallic compounds, Al-dendrites, coarse and acicular silicon particles, and large second-phase particulates have a detrimental influence on the uniformity of tensile properties across the thickness direction of an HPDC plate. FSP is able to eliminate porosity, refine microstructure and improve tensile properties. An FSP tool design and a passing strategy are identified for the best microstructure consolidation and uniform enhanced tensile properties. This study noted the importance of tool features such as scroll design and flats on tool pin and multiple pass orientation strategy to find best combination of defect-free refined microstructure and uniform tensile strength and ductility across the processing zone of HPDC Al alloys.

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:: 1909782

Report Number(s):: PNNL-SA-177217

Journal Information:: Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing, Journal Name: Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing Vol. 861; ISSN 0921-5093

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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