Review Paper: Production and Microstructural Phenomena affecting Friction Stir Welding Mechanical Behaviour and Applications.

Yıl 2020, Cilt: 4 Sayı: 4 - Rewiev Paper, 1 - 39, 23.10.2020

Oluwaseun John Dada

Öz

Friction stir welding (FSW) is the fastest evolving
joining technology and the principal prospective technique for implementing
integral fuselage structure in aircraft manufacturing. The viability of FS
welds is dependent upon mechanical properties and production turnovers, which
are dependent on welding rates and tool design. Hence this review paper border
on the effect of welding parameters, tool designs on microstructure and
mechanical behaviour of friction stir welds. The microstructure and microhardnesses which were influenced by the welding rates determined
static properties, failure locations and residual stress minima and maxima. The study reviews the nature and distribution of material flow, grain structure, and precipitates in the aluminum FS welds and their effect on mechanical properties. The advances in industrial application of
Friction Stir Welds and future prospects are critical to the review. 

Anahtar Kelimeler

Friction Stir Welding; Microstructure; Fracture Mechanism; Mechanical Behaviour; Damage Tolerance;

Kaynakça

• 1 R. S. Mishra and M. W. Mahoney, Friction Stir Welding and Processing, ASM International, 2007.
• 2 C. Zhou, X. Yang and G. Luan, Mater. Chem. Phys., 2006, 98, 285–290.
• 3 M. Ericsson and R. Sandstrom, Int. J. Fatigue, 2003, 25, 1379–1387.
• 4 C. . Chen and R. Kovacevic, Int. J. Mach. Tools Manuf., 2004, 44, 1205–1214.
• 5 W.-B. Lee, M. Schmuecker, U. A. Mercardo, G. Biallas and S.-B. Jung, Scr. Mater., 2006, 55, 355–358.
• 6 R. S. Mishra and Z. Y. Ma, Mater. Sci. Eng. R Reports, 2005, 50, 1–78.
• 7 M. Pacchione and J. Telgkamp, in 25th International Congress of the Aeronautical Sciences, pp. 1–12.
• 8 A. Lanciotti and C. Polese, Impact of Direct Water Cooling on the Quality and Performance of Friction Stir Welded Joints in a AlMgSiCu Aluminium Alloy, 2004.
• 9 H. Kafali and N. Ay, Aerosp. Sci. Aviat. Technol., 2009, ASAT-13-MS, 1–9.
• 10 R. Nandan, T. Debroy and H. Bhadeshia, Prog. Mater. Sci., 2008, 53, 980–1023.
• 11 H. . WEBSTER, About FSW.
• 12 W. M. U. Thomas, E. D. Nicholas, A. Hall and C. Cb, Mater. Des., 1998, 18, 269–273.
• 13 T. Akinlabi, Nelson Mandela Metropolitan University, 2010.
• 14 C. Genevois, a Deschamps, a Denquin and B. Doisneaucottignies, Acta Mater., 2005, 53, 2447–2458.
• 15 Y. S. Sato, M. Urata and H. Kokawa, Metall. Mater. Trans. A, 2002, 33, 625–635.
• 16 Y. S. Sato, H. Kokawa, M. Enomoto and S. Jogan, Metall. Mater. Trans. A, 1999, 30, 2429–2437.
• 17 Y. S. Sato, Weld. Int., 2003, 17, 706–709.
• 18 M. Jones, P. Heurtier, C. Desrayaud, F. Montheillet, D. Allehaux and J. Driver, Scr. Mater., 2005, 52, 693–697.
• 19 J. Q. Su, T. W. Nelson, R. Mishra and M. Mahoney, Acta Mater., 2003, 51, 713–729.
• 20 M. Mahoney, C. Rhodes and J. Flintoff, Metall. Mater. Trans. A, 1998, 29, 1955–1964.
• 21 C. G. Rhodes, M. W. Mahoney, W. H. Bingel, R. A. Spurling and C. Bampton, Scr. Mater., 1997, 36, 69–75.
• 22 O. J. Dada, C. Polese, L. A. Cornish, B. O. Adewuyi and J. O. Borode, in AMSEN, 2012.
• 23 H. Hori, S. Makita and H. Hino, in Proceedings of the First International Symposium on Friction Stir Welding, Thousand Oaks, CA, USA, June 14–16, 1999.
• 24 M. P. Miles, T. W. Nelson and B. J. Decker, Metall. Mater. Trans. A, 2004, 35, 3461–3468.
• 25 H. G. Salem, A. P. Reynolds and J. S. Lyons, Scr. Mater., 2002, 46, 337–342.
• 26 Y. J. Chao, X. Qi and W. Tang, J. Manuf. Sci. Eng., 2003, 125, 138.
• 27 T. Okada, M. Suzuki, H. Miyake, T. Nakamura, S. Machida and M. Asakawa, Int. J. Adv. Manuf. Technol., 2010, 50, 127–135.
• 28 B. Boen, NASA - A Bonding Experience: NASA Strengthens Welds, https://www.nasa.gov/topics/nasalife/friction_stir.html.
• 29 B. R. Somers and A. W. Pense, Mater. Charact., 1994, 33, 295–309.
• 30 S. Lomolino, R. Tovo and J. Dossantos, Int. J. Fatigue, 2005, 27, 305–316.
• 31 ESAB, Technical Hand Book: Friction Stir Welding.
• 32 A. Heinz, A. Haszler, C. Keidel, S. Moldenhauer, R. Benedictus and W. . Miller, Mater. Sci. Eng. A, 2000, 280, 102–107.
• 33 G. Tempus, in WERKSTOFFE FÜR TRANSPORT UND VERKEHR, ETH Zurich, 2001.
• 34 G. Pouget and A. P. Reynolds, Int. J. Fatigue, 2008, 30, 463–472.
• 35 A. Merati, MATERIALS REPLACEMENT FOR AGING AIRCRAFT.
• 36 J. M. Goetz, The Ohio State University, Columbus, OH, USA, 2005.
• 37 J. Kaufman, Properties of aluminum alloys: fatigue data and the effects of temperature, product form, and processing.
• 38 C. Zhou, X. Yang and G. Luan, Mater. Sci. Eng. A, 2006, 418, 155–160.
• 39 T. . Dickerson and J. Przydatek, Int. J. Fatigue, 2003, 25, 1399–1409.
• 40 S. W. Williams, Air Sp. Eur. Aircr. Technol., 2001, 3, 64–66.
• 41 M. M. Ratwani, in RTO AVT Lecture Series on ‘Ageing Aircraft Fleets: Structural and Other Subsystem Aspects’, 2000.
• 42 D. Burford and C. Widener, Advances in Friction Stir Welding for aerospace applications.
• 43 K. Dimitris, in AlFat Ec9 Brussels, pp. 1–8.
• 44 Aero Index UK, Aicraft Structures Design.
• 45 J. Telgkamp and H.-J. Schmidt, in Structural Health Monitoring 2003: From Diagnostics & Prognostics to Structural Health Management : Proceedings of the 4th International Workshop on Structural Health Monitoring, Stanford University, Stanford, CA, September 15-17, 2003, DEStech Publications, Inc, 2003, p. 1552.
• 46 M. Neubauer and G. Günther, AIRCRAFT LOADS.
• 47 Aviation Metals INC, Inroduction to Aluminium Alloys.
• 48 G. Mathers, The welding of aluminium and its alloys, Woodhead Publishing Limited, 2002.
• 49 J. E. Hatch, Aluminum: Properties and Physical Metallurgy, ASM International, 1984.
• 50 S. T. Amancio-Filho, S. Sheikhi, J. F. dos Santos and C. Bolfarini, J. Mater. Process. Technol., 2008, 206, 132–142.
• 51 Aalco Metals Ltd, Aluminium Alloy - Commercial Alloy - 6082 - T6~T651.
• 52 J. G. Kaufman and A. S. M. International, Introduction to Aluminum Alloys and Tempers, ASM International, 2000.
• 53 Z. Barlas and U. Ozsarac, Weld. J., 2012, 91, 16–22.
• 54 I. J. Polmear, Light alloys: metallurgy of the light metals, J. Wiley & Sons, 1995.
• 55 J.-K. Paik, Int. J. Nav. Archit. Ocean Eng., 2009, 1, 39–49.
• 56 D. Rao, J. Heerens, G. Alves Pinheiro, J. F. dos Santos and N. Huber, Mater. Sci. Eng. A, 2010, 527, 5018–5025.
• 57 P. Vilaça, N. Pepe and L. Quintino, Weld. World (ISSN 0043-2288), J. Int. Inst. Weld., 2006, 50, 55–64.
• 58 ALCOA, ALCOA MILL PRODUCTS ALLOY 2024 SHEET AND PLATE EXCELLENT FATIGUE PROPERTIES – CONSISTENT PERFORMANCE.
• 59 ALCOA, ALLOY 6061 Understanding Extruded Aluminum Alloys.
• 60 ALCOA MILL PRODUCT INC, ALCOA MILL PRODUCTS ALLOY 6013 SHEET HIGHER STRENGTH WITH IMPROVED FORMABILITY.
• 61 K. H. Hassan, P. B. Prangnell, A. F. Norman, D. A. Price and S. W. Williams, Sci. Technol. Weld. Join., 2003, 8, 257–268(12).
• 62 S. R. Ren, Z. Y. Ma and L. Q. Chen, Scr. Mater., 2007, 56, 69–72.
• 63 G. Singh, K. Singh and J. Singh, Trans. Indian Inst. Met., 2011, 64, 325–330.
• 64 R. M. Indira, R. N. Marpu and A. C. . Kumar, ARPN J. Eng. Appl. Sci., 2011, 6, 61–66.
• 65 S. Rajakumar, C. Muralidharan and V. Balasubramanian, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 2010, 224, 1175–1191.
• 66 J. Yan, M. Sutton and A. Reynolds, Welds, Sci. Technol. Weld. Joining, 10, 725–736.
• 67 A. K. Hussain, Int. J. Sci. Technol., 2010, 2, 5977–5984.
• 68 P. Cavaliere, a. De Santis, F. Panella and a. Squillace, Mater. Des., 2009, 30, 609–616.
• 69 D. Trimble, J. Monaghan and G. O’Donnell, CIRP Ann. …, 2012, 61, 9–12.
• 70 T. S. Srivatsan, S. Vasudevan and L. Park, Mater. Sci. Eng. A, 2007, 466, 235–245.
• 71 S. Kahl, in 8th International Symposium on Friction Stir Welding, Timmendorfer Strand, Germany 18-20 May, 2010, p. 458.
• 72 C. G. Derry and J. D. Robson, Mater. Sci. Eng. A, 2008, 490, 328–334.
• 73 A. Barcellona, G. Buffa, L. Fratini and D. Palmeri, J. Mater. Process. Technol., 2006, 177, 340–343.
• 74 G. Biallas, R. Braun, C. D. Donne, G. Staniek and W. A. Kaysser, Proc. First Int. Conf. Frict. Stir Weld., 1999, 2–11.
• 75 A. Von Strombeck, J. dos Santos, F. Torster, P. Laureano and M. Kocak, in First International Symposium on Friction Stir Welding, June 1999 (Thousand Oaks, CA), TWI, vol. 1999.
• 76 L. Magnusson and L. Kallman, in Second International Symposium on Friction Stir Welding, (Gothenburg, Sweden), June 26–28, 2000, (Gothenburg, Sweden)TWI, 2000.
• 77 D. Lohwasser, in Second International Symposium on Friction Stir Welding, Gothenburg,Sweden, TWI, June 26–28, 2000.
• 78 G. Bussu and P. E. Irving, in First International Symposium on Friction Stir Welding, (Thousand Oaks, CA), TWI, 1999.
• 79 J. Kristensen, C. Dalle Donne, T. Ghidini, J. Mononen, A. Norman, A. Pietras, M. Russell and S. Slater, in Fifth Int. Friction Stir Welding Conference, Metz, France,TWI,14–16, September 2004.
• 80 B. Christner, J. McCoury and S. Higgins, in International Symposium on Friction Stir Welding, (Park City, UT), TWI, May 14–16, 2003, vol. 2003.
• 81 C. Dalle Donne, G. Biallas, T. Ghidini and G. Raimbeaux, Second Int. Symp. Frict. Stir Welding, (Gothenburg, Sweden), TWI,June 26–28, 2000.
• 82 L. Karlsson, L. Svensson and H. Larsson, in Trends in Welding Research, Proc.of the Fifth International Conference , June 1–5, 1998 (Pine Mountain, GA), J. Vitek, S. David, J. Johnson, H. Smartt,and T. DebRoy, Ed., ASM International, Materials Park, OH, 1999, 1998, pp. 574–579.
• 83 Y. S. Sato, S. H. C. Park and H. Kokawa, Metall. Mater. Trans. A, 2001, 32, 3033–3042.
• 84 M. Kumagai and S. Tanaka, in First International Symposium on Friction Stir Welding, June 1999 (Thousand Oaks, CA), TWI, 1999.
• 85 K. Colligan, I. Ucok, K. McTernan, P. Konkel and J. Pickens, in Third International Symposium on Friction Stir Welding, Sept 27–28, 2001 (Kobe, Japan), TWI, 2001.
• 86 M. . James, D. . Hattingh and G. . Bradley, Int. J. Fatigue, 2003, 25, 1389–1398.
• 87 C. Juricic, C. Dalle Donne and U. Drebler, in Third International Symposium on Friction Stir Welding.
• 88 P. Hema, S. M. Gangadhar and K. Ravindranath, Int. J. Appl. Eng. Res., 2012, 7, 907–916.
• 89 H. Fujii, L. Cui, M. Maeda and K. Nogi, Mater. Sci. Eng. A, 2006, 419, 25–31.
• 90 M. Dumont, a Steuwer, a Deschamps, M. Peel and P. Withers, Acta Mater., 2006, 54, 4793–4801.
• 91 M. Cabibbo, H. J. McQueen, E. Evangelista, S. Spigarelli, M. Di Paola and a. Falchero, Mater. Sci. Eng. A, 2007, 460–461, 86–94.
• 92 E. O. Hall, in Proceedings of The Physical Society B64, 1951, pp. 747–753.
• 93 M. A. Sutton, A. P. Reynolds, D. Q. Wang and C. R. Hubbard, J. Eng. Mater. Technol., 2002, 124, 215.
• 94 A. Ali, M. W. Brown, C. A. Rodopoulos and S. Gardiner, J. Fail. Anal. Prev., 2006, 6, 83–96.
• 95 D. M. Rodrigues, C. Leitão, R. Louro, H. Gouveia and a. Loureiro, Sci. Technol. Weld. Join., 2010, 15, 676–681.
• 96 A. Tronci, R. McKenzie, R. Leal and D. Rodrigues, Sci. Technol. Weld. Join., 2011, 16, 433–439.
• 97 K. Elangovan and V. Balasubramanian, Mater. Charact., 2008, 59, 1168–1177.
• 98 D. Radaj, Int. J. Fatigue, 1996, 18, 153–170.
• 99 W. Fricke, Mar. Struct., 2003, 16, 185–200.
• 100 M. P. Kaplan, T. A. Wolff and I. Willis & Kaplan, in ASM HandBook Volume 19 Fatigue and Fracture, ASM International, 1996, pp. 557–564.
• 101 R. Stephen, A. Fatemi, R. Stephen and H. Fuchs, Metal fatigue in Engineering, John Wiley & Son Co, 2001.
• 102 S. Maddox, Int. J. Fatigue, 2003, 25, 1359–1378.
• 103 C. Zhou, X. Yang and G. Luan, Scr. Mater., 2006, 54, 1515–1520.
• 104 Bomel Limited, Comparison of Fatigue Provisions in Codes and Standards.
• 105 H. Aydin, A. Bayram, M. T. Yildirim and K. Yiğit, Mater. Sci., 2010, 16, 9–12.
• 106 T. R. Gurney, Fatigue of Welded Structures, Cambridge University Press, 2nd editio., 1979.
• 107 D. Booth and I. Sinclair, Mater. Sci. FORUM, 2002, 396, 1671–1676.
• 108 G. Bussu and P. Irving, Int. J. Fatigue, 2003, 25, 77–88.
• 109 G. Patton, C. Rinaldi, Y. Bréchet, G. Lormand and R. Fougères, Mater. Sci. Eng. A, 1998, 254, 207–218.
• 110 E. Hornbogen and E. A. Starke, Acta Metall. Mater., 1993, 41, 1–16.
• 111 A. Merati and G. Eastaugh, Eng. Fail. Anal., 2007, 14, 673–685.
• 112 A. K. Vasudévan and R. D. Doherty, Acta Metall., 1987, 35, 1193–1219.
• 113 P. Withers, Mater. Sci. Technol., 2001, 17, 366–375.
• 114 M. N. James, D. J. Hughes, Z. Chen, H. Lombard, D. G. Hattingh, D. Asquith, J. R. Yates and P. J. Webster, Eng. Fail. Anal., 2007, 14, 384–395.
• 115 E. Brinksmeier, J. T. Cammett, W. König, P. Leskovar, J. Peters and H. K. Tönshoff, CIRP Ann. - Manuf. Technol., 1982, 31, 491–510.
• 116 A. Ohta, N. Suzuki, Y. Maeda, K. Hiraoka and T. Nakamura, Int. J. Fatigue, 1999, 21, 113–118.
• 117 C. M. Chen and R. Kovacevic, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 2006, 220, 1359–1371.
• 118 R. Nandan, G. G. Roy, T. J. Lienert and T. DebRoy, Sci. Technol. Weld. Join., 2006, 11, 526–537.
• 119 K. Colligan, Weld. JOURNAL-NEW YORK-, 1999, 229–237.
• 120 H. N. B. Schmidt, T. L. Dickerson and J. H. Hattel, Acta Mater., 2006, 54, 1199–1209.
• 121 A. P. Reynolds, Sci. Technol. Weld. Join., 2000, 5, 120–124(5).
• 122 L. Fratini, G. Buffa, D. Palmeri, J. Hua and R. Shivpuri, Sci. Technol. Weld. Join., 2006, 11, 412–421(10).
• 123 A. . Norman, T. Brough and P. B. Pragnell, Mater. Sci. Forum, 2000, 331–337, 1713–1718.
• 124 D. P. P. Booth, M. J. Starink and I. Sinclair, Mater. Sci. Technol., 2007, 23, 276–284.
• 125 M. . Sutton, B. Yang, A. . Reynolds and R. Taylor, Mater. Sci. Eng. A, 2002, 323, 160–166.
• 126 T. L. Dickerson and J. Przydatek, TWI report 7387.03/98/1024.03, 2000.
• 127 Y. H. Zhao, S. B. Lin, F. X. Qu and L. Wu, Mater. Sci. Technol., 2006, 22, 45–50(6).
• 128 G. Buffa, J. Hua, R. Shivpuri and L. Fratini, Mater. Sci. Eng. A, 2006, 419, 381–388.
• 129 H. Schmidt and J. Hattel, Model. Simul. Mater. Sci. Eng., 2005, 13, 77–93.
• 130 M. Guerra, C. Schmidt, J. . McClure, L. . Murr and A. . Nunes, Mater. Charact., 2002, 49, 95–101.
• 131 W. M. Thomas, K. I. Johnson and C. S. Wiesner, Adv. Eng. Mater., 2003, 5, 485–490.
• 132 Y. Murakami, Metal Fatigue- Effects of Small Defects and Nonmetallic Inclusions, Elsevier Ltd, 2002.
• 133 M. A. Wahab and M. S. Alam, J. Mater. Process. Technol., 2004, 153–154, 931–937.
• 134 J. Hyzak, Metall. Mater. Trans. A, 1982, 13, 33–43.
• 135 D. G. Kinchen, L. Martin, M. Space, N. Orleans and E. Aldahir, NDE of Friction Stir Welds in Aerospace Applications.
• 136 M. H. Ogle, P. L. Threadgill and S. J. Maddox, Joints in Aluminium - Inalco ’98: Seventh International Conference, Woodhead Publishing, 1999.
• 137 A. . Leonard and S. . Lockyer, in 4th International Symposium on friction stir Welding, Park City Utah, USA, May 14-16, 2003.
• 138 M. M. Attallah and H. G. Salem, Mater. Sci. Eng. A, 2005, 391, 51–59.
• 139 H. Okamura, K. Aota, M. Sakamoto, M. Ezumi and K. Ikeuchi, Weld. Int., 2002, 16, 266–275.
• 140 Y. S. Sato, F. Yamashita, Y. Sugiura, S. H. C. Park and H. Kokawa, Scr. Mater., 2004, 50, 365–369.
• 141 H. S. Park, T. Kimura, T. Murakami, Y. Nagano, K. Nakata and M. Ushio, Mater. Sci. Eng. A, 2004, 371, 160–169.
• 142 A. O’Brien, C. (eds. . Guzman and American Welding Society, Welding Hand Book: Welding Processes, Part 2 Volume 3 Ninth Edition, Miami, Americal Welding Society, 2007.
• 143 NMMU Seminar, D. G. Hattingh, 2012.
• 144 M. Peel, a. Steuwer, M. Preuss and P. J. Withers, Acta Mater., 2003, 51, 4791–4801.
• 145 R. Nandan, T. Debroy, H. Bhadeshia, Progress in Materials Science, 2008, 53, 980–1023.
• 146 C. E. D. Rowe and W. Thomas, ADVANCES IN TOOLING MATERIALS FOR FRICTION.