Impact of Backing Plate and Thermal Boundary Conditions for High-Speed Friction Stir Welding of 25-mm Thick Aluminum Alloy 7175-T79

Das, Hrishikesh; Reza E Rabby, MD; Whalen, Scott A.; Upadhyay, Piyush; Grant, Glenn J.

doi:10.1007/s40684-024-00607-x

Impact of Backing Plate and Thermal Boundary Conditions for High-Speed Friction Stir Welding of 25-mm Thick Aluminum Alloy 7175-T79

Journal Article · Thu Apr 18 00:00:00 EDT 2024 · International Journal of Precision Engineering and Manufacturing Green Technology

DOI:https://doi.org/10.1007/s40684-024-00607-x· OSTI ID:2341760

Das, Hrishikesh ^[1]; ^[1]; Whalen, Scott A. ^[1]; Upadhyay, Piyush ^[1]; ^[1]

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

Here this study demonstrates high-speed (150 mm/min) single pass friction stir butt joining of 25 mm thick aluminum alloy 7175-T79. To understand the impact of quenching and cooling rate on process responses, joint strength, and grain size distributions across the weld thickness, we performed a series of friction stir welding (FSW) trials in air and with a trailing water spray using steel and composite backing plates (BP). Welds made in air and trailing water spray exhibit significantly different hardness distributions across the nugget, heat affected zone (HAZ), and HAZ minimum hardness as evidenced by detailed microhardness mapping. The effect of trailing water spray (TWS) on joint efficiency overshadows the influence of BP composition due to the vastly different contribution to quenching. TWS also resulted in a multifaceted effect on FSW such as lowering processing temperature, increasing X and Z forces while lowering Y force, and narrow heat affecting zone. Finally, digital image correlation (DIC)-based fracture mode analysis and grain size measurements correlate with the hardness distribution.

View Accepted Manuscript (DOE)

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

Sponsoring Organization:: USDOE Office of Fossil Energy and Carbon Management (FECM)

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2341760

Report Number(s):: PNNL-SA--184852

Journal Information:: International Journal of Precision Engineering and Manufacturing Green Technology, Journal Name: International Journal of Precision Engineering and Manufacturing Green Technology Vol. 11; ISSN 2288-6206

Publisher:: Springer NatureCopyright Statement

Country of Publication:: United States

Language:: English

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42 ENGINEERING
backing plate
friction stir welding
thermal boundary condition
trailing water spray

Impact of Backing Plate and Thermal Boundary Conditions for High-Speed Friction Stir Welding of 25-mm Thick Aluminum Alloy 7175-T79

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References (29)

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