Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

Sabry, Nicholas; Stroh, Joshua; Sediako, Dimitry

doi:10.1016/j.cirpj.2022.11.021

Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

Journal Article · Wed Jan 11 04:00:00 EST 2023 · CIRP Journal of Manufacturing Science and Technology

DOI:https://doi.org/10.1016/j.cirpj.2022.11.021· OSTI ID:2423995

Sabry, Nicholas ^[1]; Stroh, Joshua ^[1]; Sediako, Dimitry ^[1]

Univ. of British Columbia, Kelowna, BC (Canada). High-Performance Powertrain Materials Laboratory

Friction-stir-welding (FSW) has gained importance as an effective way to join dissimilar materials due to its solid-state nature. However, FSW produces substantial residual stresses in aluminum welding, often deteriorating the component's structural performance and reliability. In the current study, the d-spacing (inter-atomic distance) of several locations on a battery tray and stress-free reference samples are measured with neutron diffraction to calculate the residual stresses in a lap 6061 to A365 dissimilar friction-stir-weld. Furthermore, the present study connects the measured residual stress to microstructure properties through electron backscatter diffraction (EBSD) and optical microscopy analyses. The EBSD results indicate that the FSW operation affects the grains’ orientation, thereby producing location-specific directionally varying elasticity across the weldment. Further, this varied elasticity creates unique d-spacing profiles even in the stress-free material. Additionally, the resulting stressed and stress-free d-spacing profiles show dependencies on the FSW tool geometry, traverse direction, and rotational direction. Lastly, this study suggests that the final component residual stress can be influenced by the sequence of multi-pass welds contributing to a rise in temperature in the presence of a completed weld relaxing its residual stress.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). High Flux Isotope Reactor (HFIR)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2423995

Journal Information:: CIRP Journal of Manufacturing Science and Technology, Journal Name: CIRP Journal of Manufacturing Science and Technology Journal Issue: C Vol. 41; ISSN 1755-5817

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Related Subjects

36 MATERIALS SCIENCE
Aluminum Alloy
EBSD
Friction Stir Welding (FSW)
Neutron Diffraction
Residual Stress
Solid State Welding

Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

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