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Effect of welding parameters on the strain rate and microstructure of friction stir spot welded 2024 aluminum alloy

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Abstract

The stir zone microstructure, crystallographic texture, temperature and strain rate in the stir zones produced during Al 2024 spot welding using different tool rotational speed settings are investigated. The calculated strain rate during spot welding decreases from 1600 to 0.6 s−1 when the tool rotational speed increases from 750 to 3000 rpm. The low strain rate values are associated with tool slippage resulting from spontaneous melting of S phase particles at temperatures ≥490 °C. However, the calculated strain rate is 1600 s−1 in Al 2024 spot welds made using tool rotational speed of 750 rpm since the temperature never reaches 490 °C. Material transfers downwards via that pin thread during the dwell period in Al 2024 spot welding. It is proposed that this downward transfer of material provides a continuous supply of undissolved S phase particles, which melt spontaneously when the welding parameter settings produce stir zone temperatures ≥490 °C. A weak crystallographic texture where the {100} planes are oriented at about 45° to the θ-direction exists in the stir zones of spot welds made using different tool rotational speeds (from 750 to 3000 rpm). Another crystallographic texture where the {100} planes are parallel to the Z-direction (to the tool axis) is stronger in spot welds made using higher tool rotational speed settings. Also, material located at the root of the pin thread has a quite different crystallographic texture from that in the bulk of the stir zone.

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Acknowledgements

The authors wish to acknowledge financial support from the Natural Sciences and Engineering Research Council of Canada during this project.

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Authors and Affiliations

  1. Department of Materials Science & Engineering, University of Toronto, 184 College St., Rm. 140, Toronto, ON, Canada, M5S 3E4

    Adrian Gerlich, Peter Su, Motomichi Yamamoto & Tom H. North

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  1. Adrian Gerlich
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Correspondence to Adrian Gerlich.

Appendix

Appendix

Dissolution of liquid droplets

The Al–Al2CuMg quasi-binary section in the Al–Mg–Cu ternary phase diagram is shown below:

The driving force for diffusion and dissolution of Al2CuMg is determined by the relation:

$$ k = 2\left[ {\frac{{C_{T_2 }^{\alpha /liq} - C_{T_1 }^{\alpha /\beta } }} {{C_{T_2 }^{liq/\alpha } - C_{T_2 }^{\alpha /liq} }}} \right] = 2\left[ {\frac{{5.9 - 5.7}} {{39.4 - 5.9}}} \right]\, = \,0.0119 $$

where, \( C_{T_1 }^{\alpha /\beta } \)= 5.7%, \( C_{T_2 }^{\alpha /liq} = \)5.9%, \( C_{T_2 }^{liq/\alpha } \)= 39.4%, at T 2 = 508 °C [68]. The dissolution of Al2CuMg is calculated at 490 °C since this temperature was attained in spot welds using >1500 rpm and is the reported melting temperature of this phase [61]. The diffusion coefficient of Mg in Al depends on the relation [69]:

$$ D = D_o \,\,\exp \left[ { - \frac{Q} {{RT}}} \right] $$

where, D o = 2.1 × 107 μm2/s, Q = 116 kJ/mol, R = 8.314 J/mol K, T = 763°K (490 °C), and thus D Mg in Al = 0.24 μm2/s.

The relation between the initial radius of the liquid droplet R o and the time t available for dissolution at 490 °C is determined by the relation:

$$ R_o = \sqrt {kD_{{\hbox{Mg in Al}}} \cdot t{\hbox{ }}} $$

Dissolution when the Spot Weld Cools to Room Temperature

Figure 5 shows the thermal cycle when the Al 2024 spot weld cools to room temperature. A 9th power polynomial regression analysis was used to extrapolate the temperature output to that conforming with the stir zone temperature (490 °C), see below.

The calculation method employed during the cooling period following spot welding is illustrated below:

The cooling curve obtained from the regression was divided into about 10 °C increments and the diffusion rate (Dn) at each temperature (Tn) was obtained. The mass loss by particles in the stir zone during cooling was calculated from the diffused radius during each time increment, see the above figure.

During the first time interval (from t1s to t1e) the diffused radius is calculated using D 1:

$$ R_1 = R_0 \sqrt {1 - \frac{{kD_1 }} {{R_0 ^2 }}t_{1e} } $$
$$ t_1 = t_{1e} - t_{1s} $$

In each successive time interval, the diffusion radius was obtained by taking account of the previous interval effect. For example, the second time interval (from t2s to t2e) was calculated using D 2:

$$ t_{2s} = \frac{{R_0 ^2 - R_1 ^2 }} {{kD_2 }} $$
$$ R_2 = R_0 \sqrt {1 - \frac{{kD_2 }} {{R_0 ^2 }}t_{2e} } $$
$$ t_2 = t_1 + \left( {t_{2e} - t_{2s} } \right) $$

The radius after cooling (R n ) was calculated during the final nth time interval.

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Gerlich, A., Su, P., Yamamoto, M. et al. Effect of welding parameters on the strain rate and microstructure of friction stir spot welded 2024 aluminum alloy. J Mater Sci 42, 5589–5601 (2007). https://doi.org/10.1007/s10853-006-1103-7

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