Influence of friction stir processing on the room temperature fatigue cracking mechanisms of A356 aluminum alloy

Nelaturu, Phalgun; Jana, Saumyadeep; Mishra, Rajiv S.; Grant, Glenn; Carlson, Blair E.

doi:10.1016/j.msea.2018.01.044

Title: Influence of friction stir processing on the room temperature fatigue cracking mechanisms of A356 aluminum alloy

Journal Article · Thu Jan 11 00:00:00 EST 2018 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing

DOI:https://doi.org/10.1016/j.msea.2018.01.044· OSTI ID:1418022

Nelaturu, Phalgun ^[1]; Jana, Saumyadeep ^[2]; Mishra, Rajiv S. ^[1]; Grant, Glenn ^[2]; Carlson, Blair E. ^[3]

Univ. of North Texas, Denton, TX (United States)
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
General Motors Technical Center, Warren, MI (United States)

Here, failure by fatigue is a common problem associated with cast aluminum alloys due to defects like shrinkage porosities, non-metallic inclusions, etc. Friction stir processing (FSP) has recently emerged as an effective technique for local modification of microstructure. This study investigates the fatigue crack initiation and growth mechanisms in cast and FSPed A356 aluminum alloy. Two sets of parameters were used to friction stir the cast alloy resulting in the complete modification the cast microstructure to a wrought microstructure. Both the FSPed microstructures exhibited severe abnormal grain growth (AGG) after heat treatment leading to a multimodal grain size distribution – the grain sizes ranging from a few microns to a few millimeters. One of the FSP conditions displayed an excellent improvement in fatigue life by an order of magnitude, while the other condition displayed an unexpectedly large scatter in fatigue lives. Detailed study of the fractured fatigue specimens by electron back scattered diffraction (EBSD) revealed that both, fatigue crack initiation and propagation, were intimately tied to the grain size as well as the grain misorientations in the microstructure.

View Accepted Manuscript (DOE)

Cite

Export

Save

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

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 1418022

Report Number(s):: PNNL-SA-130375; PII: S0921509318300534; TRN: US1801235

Journal Information:: Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing, Vol. 716; ISSN 0921-5093

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

Citation Metrics:

Cited by: 37 works

Citation information provided by
Web of Science

References (59)

Light weight materials for automotive applications Cole, G. S.; Sherman, A. M. Materials Characterization, Vol. 35, Issue 1 https://doi.org/10.1016/1044-5803(95)00063-1	journal	July 1995
An Overview of the Development of Al-Si-Alloy Based Material for Engine Applications Ye, Haizhi Journal of Materials Engineering and Performance, Vol. 12, Issue 3 https://doi.org/10.1361/105994903770343132	journal	June 2003
Fatigue on engine pistons – A compendium of case studies Silva, F. S. Engineering Failure Analysis, Vol. 13, Issue 3 https://doi.org/10.1016/j.engfailanal.2004.12.023	journal	April 2006
Influence of modification, solidification conditions and heat treatment on the microstructure and mechanical properties of A356 aluminum alloy Shabestari, S. G.; Shahri, F. Journal of Materials Science, Vol. 39, Issue 6 https://doi.org/10.1023/B:JMSC.0000017764.20609.0d	journal	March 2004
Strength-Ductility Behaviour of Al-Si-Cu-Mg Casting Alloys in T6 Temper Cáceres, C. H.; Svensson, I. L.; Taylor, J. A. International Journal of Cast Metals Research, Vol. 15, Issue 5 https://doi.org/10.1080/13640461.2003.11819539	journal	May 2003
The effect of heat-treatment on aluminum-based piston alloys Zeren, Muzaffer Materials & Design, Vol. 28, Issue 9 https://doi.org/10.1016/j.matdes.2006.09.010	journal	January 2007
Cyclic plasticity at pores and inclusions in cast Al–Si alloys Fan, Jinghong; McDowell, David L.; Horstemeyer, Mark F. Engineering Fracture Mechanics, Vol. 70, Issue 10 https://doi.org/10.1016/S0013-7944(02)00097-8	journal	July 2003
Fatigue behavior of A356-T6 aluminum cast alloys. Part I. Effect of casting defects Wang, Q. G.; Apelian, D.; Lados, D. A. Journal of Light Metals, Vol. 1, Issue 1 https://doi.org/10.1016/S1471-5317(00)00008-0	journal	February 2001
Fatigue behavior of A356/357 aluminum cast alloys. Part II – Effect of microstructural constituents Wang, Q. G.; Apelian, D.; Lados, D. A. Journal of Light Metals, Vol. 1, Issue 1 https://doi.org/10.1016/S1471-5317(00)00009-2	journal	February 2001
Closure mechanisms in Al–Si–Mg cast alloys and long-crack to small-crack corrections Lados, D.; Apelian, D.; Paris, P. International Journal of Fatigue, Vol. 27, Issue 10-12 https://doi.org/10.1016/j.ijfatigue.2005.06.013	journal	October 2005
Fatigue crack growth mechanisms at the microstructure scale in Al–Si–Mg cast alloys: Mechanisms in the near-threshold regime Lados, D.; Apelian, D.; Donald, J. Acta Materialia, Vol. 54, Issue 6 https://doi.org/10.1016/j.actamat.2005.11.019	journal	April 2006
Relationships between microstructure and fatigue crack propagation paths in Al–Si–Mg cast alloys Lados, Diana A.; Apelian, Diran Engineering Fracture Mechanics, Vol. 75, Issue 3-4 https://doi.org/10.1016/j.engfracmech.2007.01.027	journal	February 2008
Microstructure-based fatigue modeling of cast A356-T6 alloy McDowell, D. L.; Gall, K.; Horstemeyer, M. F. Engineering Fracture Mechanics, Vol. 70, Issue 1 https://doi.org/10.1016/S0013-7944(02)00021-8	journal	January 2003
The debonding and fracture of Si particles during the fatigue of a cast Al-Si alloy Gall, Ken; Yang, Nancy; Horstemeyer, Mark Metallurgical and Materials Transactions A, Vol. 30, Issue 12 https://doi.org/10.1007/s11661-999-0218-2	journal	December 1999
Microstructure-based fatigue life prediction for cast A356-T6 aluminum-silicon alloys Yi, J. Z.; Gao, Y. X.; Lee, P. D. Metallurgical and Materials Transactions B, Vol. 37, Issue 2 https://doi.org/10.1007/BF02693159	journal	April 2006
Scatter in fatigue life due to effects of porosity in cast A356-T6 aluminum-silicon alloys Yi, J. Z.; Gao, Y. X.; Lee, P. D. Metallurgical and Materials Transactions A, Vol. 34, Issue 9 https://doi.org/10.1007/s11661-003-0153-6	journal	September 2003
Effect of Fe-content on fatigue crack initiation and propagation in a cast aluminum–silicon alloy (A356–T6) Yi, J.; Gao, Y.; Lee, P. Materials Science and Engineering A, Vol. 386, Issue 1-2 https://doi.org/10.1016/S0921-5093(04)00964-5	journal	November 2004
The heat treatment of Al–Si–Cu–Mg casting alloys Sjölander, Emma; Seifeddine, Salem Journal of Materials Processing Technology, Vol. 210, Issue 10 https://doi.org/10.1016/j.jmatprotec.2010.03.020	journal	July 2010
The effect of solution heat-treatment time on the fatigue properties of an Al-Si-Mg casting alloy: THE EFFECT OF SOLUTION HEAT-TREATMENT TIME ON THE CASTING ALLOY Davidson, C. J.; Griffiths, J. R.; Machin, A. S. Fatigue & Fracture of Engineering Materials & Structures, Vol. 25, Issue 2 https://doi.org/10.1046/j.8756-758x.2001.00490.x	journal	February 2002
On the silicon spheroidization in Al–Si alloys Ogris, E.; Wahlen, A.; Lüchinger, H. Journal of Light Metals, Vol. 2, Issue 4 https://doi.org/10.1016/S1471-5317(03)00010-5	journal	November 2002
Effect of cooling rate on solidified microstructure and mechanical properties of aluminium-A356 alloy Zhang, L. Y.; Jiang, Y. H.; Ma, Z. Journal of Materials Processing Technology, Vol. 207, Issue 1-3 https://doi.org/10.1016/j.jmatprotec.2007.12.059	journal	October 2008
Effect of strain rate on damage evolution in a cast Al-Si-Mg base alloy Dighe, Manish D.; Gokhale, Arun M.; Horstemeyer, Mark F. Metallurgical and Materials Transactions A, Vol. 31, Issue 7 https://doi.org/10.1007/s11661-998-0331-7	journal	July 2000
Friction stir welding and processing Mishra, R. S.; Ma, Z. Y. Materials Science and Engineering: R: Reports, Vol. 50, Issue 1-2 https://doi.org/10.1016/j.mser.2005.07.001	journal	August 2005
Visualization of the material flow in AA2195 friction-stir welds using a marker insert technique Seidel, T. U.; Reynolds, A. P. Metallurgical and Materials Transactions A, Vol. 32, Issue 11 https://doi.org/10.1007/s11661-001-1038-1	journal	November 2001
Microstructural studies of friction stir welds in 2024-T3 aluminum Sutton, M. A.; Yang, B.; Reynolds, A. P. Materials Science and Engineering: A, Vol. 323, Issue 1-2 https://doi.org/10.1016/S0921-5093(01)01358-2	journal	January 2002
Development of grain structure during friction stir welding Fonda, R. Scripta Materialia, Vol. 51, Issue 3 https://doi.org/10.1016/j.scriptamat.2004.04.017	journal	August 2004
Heterogeneity of crystallographic texture in friction stir welds of aluminum Field, David P.; Nelson, Tracy W.; Hovanski, Yuri Metallurgical and Materials Transactions A, Vol. 32, Issue 11 https://doi.org/10.1007/s11661-001-1037-2	journal	November 2001
Basal plane texture and flow pattern in friction stir weld of a magnesium alloy Park, Seung Hwan C.; Sato, Yutaka S.; Kokawa, Hiroyuki Metallurgical and Materials Transactions A, Vol. 34, Issue 4 https://doi.org/10.1007/s11661-003-0228-4	journal	April 2003
Microstructural evolution of a heat-resistant magnesium alloy due to friction stir welding Zhang, D.; Suzuki, M.; Maruyama, K. Scripta Materialia, Vol. 52, Issue 9 https://doi.org/10.1016/j.scriptamat.2005.01.003	journal	May 2005
Microstructure and properties of friction stir butt-welded AZ31 magnesium alloy Xunhong, Wang; Kuaishe, Wang Materials Science and Engineering: A, Vol. 431, Issue 1-2 https://doi.org/10.1016/j.msea.2006.05.128	journal	September 2006
Friction stir welding of precipitation strengthened aluminium alloys: scope and challenges De, P. S.; Mishra, R. S. Science and Technology of Welding and Joining, Vol. 16, Issue 4 https://doi.org/10.1179/1362171811Y.0000000020	journal	May 2011
Thermal stability of friction stir processed ultrafine grained AlMgSc alloy Kumar, N.; Mishra, R. S. Materials Characterization, Vol. 74 https://doi.org/10.1016/j.matchar.2012.09.003	journal	December 2012
Producing nanograined microstructure in Mg–Al–Zn alloy by two-step friction stir processing Chang, C.; Du, X.; Huang, J. Scripta Materialia, Vol. 59, Issue 3 https://doi.org/10.1016/j.scriptamat.2008.04.003	journal	August 2008
Development of ultrafine-grained microstructure and low temperature (0.48 Tm) superplasticity in friction stir processed Al–Mg–Zr Ma, Z. Y.; Mishra, R. S. Scripta Materialia, Vol. 53, Issue 1 https://doi.org/10.1016/j.scriptamat.2005.03.018	journal	July 2005
Friction stir processing of large-area bulk UFG aluminum alloys Su, Jian-Qing; Nelson, Tracy W.; Sterling, Colin J. Scripta Materialia, Vol. 52, Issue 2 https://doi.org/10.1016/j.scriptamat.2004.09.014	journal	January 2005
A new route to bulk nanocrystalline materials Su, Jian-Qing; Nelson, Tracy W.; Sterling, Colin J. Journal of Materials Research, Vol. 18, Issue 8 https://doi.org/10.1557/JMR.2003.0243	journal	August 2003
Grain refinement of aluminum alloys by friction stir processing Su, J. -Q.; Nelson, T. W.; Sterling, C. J. Philosophical Magazine, Vol. 86, Issue 1 https://doi.org/10.1080/14786430500267745	journal	January 2006
Effect of friction stir processing on the microstructure of cast A356 aluminum Ma, Z. Y.; Sharma, S. R.; Mishra, R. S. Materials Science and Engineering: A, Vol. 433, Issue 1-2 https://doi.org/10.1016/j.msea.2006.06.099	journal	October 2006
Microstructural modification of as-cast Al-Si-Mg alloy by friction stir processing Ma, Z. Y.; Sharma, S. R.; Mishra, R. S. Metallurgical and Materials Transactions A, Vol. 37, Issue 11 https://doi.org/10.1007/BF02586167	journal	November 2006
Effect of multiple-pass friction stir processing on microstructure and tensile properties of a cast aluminum–silicon alloy Ma, Z. Y.; Sharma, S. R.; Mishra, R. S. Scripta Materialia, Vol. 54, Issue 9 https://doi.org/10.1016/j.scriptamat.2006.01.010	journal	May 2006
Effect of friction stir processing on fatigue behavior of A356 alloy Sharma, S. Scripta Materialia, Vol. 51, Issue 3 https://doi.org/10.1016/j.scriptamat.2004.04.014	journal	August 2004
Fatigue crack growth behavior of friction stir processed aluminum alloy Sharma, S.; Mishra, R. Scripta Materialia, Vol. 59, Issue 4 https://doi.org/10.1016/j.scriptamat.2008.04.014	journal	August 2008
Effect of Friction Stir Processing on Microstructure and Tensile Properties of an Investment Cast Al-7Si-0.6Mg Alloy Jana, Saumyadeep; Mishra, Rajiv S.; Baumann, John A. Metallurgical and Materials Transactions A, Vol. 41, Issue 10 https://doi.org/10.1007/s11661-010-0324-1	journal	June 2010
Effect of friction stir processing on fatigue behavior of an investment cast Al–7Si–0.6 Mg alloy Jana, S.; Mishra, R. S.; Baumann, J. B. Acta Materialia, Vol. 58, Issue 3 https://doi.org/10.1016/j.actamat.2009.10.015	journal	February 2010
Effect of stress ratio on the fatigue behavior of a friction stir processed cast Al–Si–Mg alloy Jana, S.; Mishra, R. S.; Baumann, J. B. Scripta Materialia, Vol. 61, Issue 10 https://doi.org/10.1016/j.scriptamat.2009.08.011	journal	November 2009
Effect of process parameters on abnormal grain growth during friction stir processing of a cast Al alloy Jana, S.; Mishra, R. S.; Baumann, J. A. Materials Science and Engineering: A, Vol. 528, Issue 1 https://doi.org/10.1016/j.msea.2010.08.049	journal	November 2010
A unified theory of recovery, recrystallization and grain growth, based on the stability and growth of cellular microstructures—II. The effect of second-phase particles Humphreys, F. J. Acta Materialia, Vol. 45, Issue 12 https://doi.org/10.1016/S1359-6454(97)00173-0	journal	December 1997
Influence of fraction of high angle boundaries on the mechanical behavior of an ultrafine grained Al–Mg alloy Kapoor, R.; Kumar, N.; Mishra, R. S. Materials Science and Engineering: A, Vol. 527, Issue 20 https://doi.org/10.1016/j.msea.2010.04.086	journal	July 2010
The Deformation and Ageing of Mild Steel: III Discussion of Results Hall, E. O. Proceedings of the Physical Society. Section B, Vol. 64, Issue 9 https://doi.org/10.1088/0370-1301/64/9/303	journal	September 1951
Grain size effects on the fatigue response of nanocrystalline metals Hanlon, T. Scripta Materialia, Vol. 49, Issue 7 https://doi.org/10.1016/S1359-6462(03)00393-2	journal	October 2003
Fatigue properties and crack behavior of ultra-fine and nanocrystalline pure metals Cavaliere, P. International Journal of Fatigue, Vol. 31, Issue 10 https://doi.org/10.1016/j.ijfatigue.2009.05.004	journal	October 2009
Enhanced fatigue strength of commercially pure Ti processed by severe plastic deformation Semenova, I. P.; Salimgareeva, G. Kh.; Latysh, V. V. Materials Science and Engineering: A, Vol. 503, Issue 1-2 https://doi.org/10.1016/j.msea.2008.07.075	journal	March 2009
Fatigue crack deflection and fracture surface contact: Micromechanical models Suresh, S. Metallurgical Transactions A, Vol. 16, Issue 2 https://doi.org/10.1007/BF02816051	journal	February 1985
Probabilistic fatigue life prediction model for alloys with defects: Applied to A206 Kapoor, R.; Rao, V. Sree Hari; Mishra, R. S. Acta Materialia, Vol. 59, Issue 9 https://doi.org/10.1016/j.actamat.2011.02.019	journal	May 2011
Influence of porosity on the fatigue limit of die cast magnesium and aluminium alloys Mayer, H.; Papakyriacou, M.; Zettl, B. International Journal of Fatigue, Vol. 25, Issue 3 https://doi.org/10.1016/S0142-1123(02)00054-3	journal	March 2003
Cyclic Slip Irreversibilities and the Evolution of Fatigue Damage Mughrabi, Hael Metallurgical and Materials Transactions B, Vol. 40, Issue 4 https://doi.org/10.1007/s11663-009-9240-4	journal	April 2009
Specific features and mechanisms of fatigue in the ultrahigh-cycle regime Mughrabi, H. International Journal of Fatigue, Vol. 28, Issue 11 https://doi.org/10.1016/j.ijfatigue.2005.05.018	journal	November 2006
The fatigue limits of metals Laird, Campbell Materials Science and Engineering, Vol. 22 https://doi.org/10.1016/0025-5416(76)90159-2	journal	January 1976
A crystallographic mechanism for fatigue crack propagation through grain boundaries Zhai, T.; Wilkinson, A. J.; Martin, J. W. Acta Materialia, Vol. 48, Issue 20 https://doi.org/10.1016/S1359-6454(00)00214-7	journal	December 2000

Cited By (4)

Quasi-Static Loading Responses and Constitutive Modeling of Al–Si–Mg alloy Liang, Zhenglong; Zhang, Qi Metals, Vol. 8, Issue 10 https://doi.org/10.3390/met8100838	journal	October 2018
Process parameters optimization of friction stir processed Al 1050 aluminum alloy by response surface methodology (RSM) Abdel Ghaffar Abdel Maboud, Ahmed; El-Mahallawy, Nahed A.; Zoalfakar, Said H. Materials Research Express, Vol. 6, Issue 2 https://doi.org/10.1088/2053-1591/aaed7c	journal	November 2018
A parametric investigation on the fretting fatigue behaviour of heat treated Al 6061-T6 under rotating bending phenomena Zobaer Shah, Quazi Md.; Arefin Kowser, Md.; Asaduzzzaman Chowdhury, Mohammad Australian Journal of Mechanical Engineering https://doi.org/10.1080/14484846.2019.1703508	journal	December 2019
Effect of Partial Substitution of Mn for Ni on Mechanical Properties of Friction Stir Processed Hypoeutectic Al-Ni Alloys Yousefi, Fatemeh; Taghiabadi, Reza; Baghshahi, Saeid Metallurgical and Materials Transactions B, Vol. 49, Issue 6 https://doi.org/10.1007/s11663-018-1422-5	journal	October 2018

Similar Records

Effect of temperature on the fatigue cracking mechanisms in A356 Al alloy

Journal Article · Tue Apr 07 00:00:00 EDT 2020 · Materials Science and Engineering. A. Structural Materials: Properties, Microstructure and Processing · OSTI ID:1418022

Nelaturu, Plalgun; Jana, Saumyadeep; Mishra, Rajiv S.; +2 more

Effect of Friction Stir Processing on Microstructure and Tensile Properties of an Investment Cast Al-7Si-0.6Mg Alloy

Journal Article · Fri Oct 01 00:00:00 EDT 2010 · Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science, 41A(10):2507-2521 · OSTI ID:1418022

Jana, Saumyadeep; Mishra, Rajiv S; Baumann, John B; +1 more

Evaluation of the microstructure and mechanical properties of WC particle reinforced aluminum matrix composites fabricated by friction stir processing

Journal Article · Sun Apr 15 00:00:00 EDT 2018 · Materials Characterization · OSTI ID:1418022

Huang, Guoqiang; Hou, Wentao; Shen, Yifu

Related Subjects

36 MATERIALS SCIENCE
Fracture behavior
Fatigue
Grain boundaries
Aluminum alloys
Friction stir welding/processing
abnormal grain growth

Title: Influence of friction stir processing on the room temperature fatigue cracking mechanisms of A356 aluminum alloy

Citation Formats

References (59)

Cited By (4)

Similar Records

Related Subjects