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1 Aville online t ScienceDirect Procedi Mterils Science 8 (2015 ) Interntionl Congress of Science nd Technology of Metllurgy nd Mterils, SAM - CONAMET 2013 Effect of Het Input on AA5052 Friction Stir Welds Chrcteristics Leonrdo N. Tufro, Iván Mnzoni, Hernán G. Svood c,d, * Instituto Ncionl de Tecnologí Industril, Centro de Investigción y Desrrollo en Mecánic, Av. Grl Pz 5445, B1650KNA, Sn Mrtín, Buenos Aires, Argentin Instituto Sto, UNSAM-CNEA, Av. Grl Pz 1499, B1650KNA, Sn Mrtín, Buenos Aires, Argentin c Lortorio de Mteriles y Estructurs, Fcultd de Ingenierí, INTECIN, Universidd de Buenos Aires, Av. Ls Hers 2214, C1127AAR, Ciudd Autónom de Buenos Aires, Argentin d Consejo Ncionl de Investigciones Científics y Técnics (CONICET), Av. Rivdvi 1917, C1033AAJ, Ciudd Autónom de Buenos Aires, Argentin Astrct Friction Stir Welding (FSW) is reltively novel solid stte welding process tht strong enhnced the welding of luminum lloys for structurl pplictions. In this process, the het necessry for the required plstic flow of mteril is produced t the interfse tool-work piece, eing ffected y fctors such s rottionl speed, xil lod nd tool shoulder dimeter, mong others. The ojective of this work ws to study the effect of tool shoulder dimeter on het input during FSW of AA5052-H32 lloy nd the resulting chrcteristics of the produced welded joints. Tools of 10, 12, 14 nd 16 mm shoulder dimeter were constructed nd used to utt weld pltes of 3 mm thick of AA5052-H32 luminum lloy. Welds were mde with 514 rpm of rottionl speed nd 98 mm/min of welding speed. Therml cycles were cquired during welding using thermocouples. Mcrostructurl chrcteriztion nd Vickers microhrdness profiles were done on ech welded smple. It ws oserved n increse in power with shoulder dimeter, s well s lower level of defects in the stirred zone, relted with n improved plstic flow. Hrdness lso decresed with tool dimeter, due to higher therml effect on the microstructure The Authors. Pulished y Elsevier Ltd. This is n open ccess rticle under the CC BY-NC-ND license 2014 L. N. Tufro, I. Mnzoni, H. G. Svood. Pulished y Elsevier Ltd. ( Selection Selection nd nd peer-review peer-review under under responsiility responsiility of the of scientific the scientific committee committee of SAM of - CONAMET SAM - CONAMET Keywords: Friction Stir Welding (FSW); Aluminum; Het Input; Tool Shoulder * Corresponding uthor. Tel.: ; fx: E-mil ddress: hsvood@fi.u.r The Authors. Pulished y Elsevier Ltd. This is n open ccess rticle under the CC BY-NC-ND license ( Selection nd peer-review under responsiility of the scientific committee of SAM - CONAMET 2013 doi: /j.mspro

2 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) Introduction Friction Stir Welding (FSW) is reltively novel solid stte welding process, which hs proved to hve gret potentil for different mterils, prticulrly luminum lloys. FSW is sed on the plstic flow of mteril produced y non-consumle rotting tool inserted into the joint to e welded. The het necessry to produce the required plstic flow for the conformtion of the joint is minly produced t the interfce tool-work piece, eing ffected y fctors such s rottionl speed, welding speed, xil lod nd tool shoulder dimeter (D), mong others. Schmidt nd Httel (2008) developed n nlyticl model for the het genertion in FSW. The most importnt difference etween this model nd previous ones is tht it considers the contct condition t this interfce y prmeter clled slip rte ( ), which vries from 0 to 1. If the slip rte is 0, the contct condition is sliding, nd if it is 1, the contct condition is sticking. Moreover, lthough it hs een reported tht the het input (HI) generted y the tool pin cn ecome 20% of the totl het input, in this work the terms ssocited with the tool pin re omitted to simplify the nlysis (Mishr nd M, (2005); Mishr nd Mhoney, (2007)). Therefore, sed on tht model, Eqution 1 expresses power (Q) generted during FSW depending on the rottionl speed ( ) nd the tool shoulder dimeter (D), considering tht the sher yield stress ( y ), the friction coefficient ( ), the contct pressure (p) nd the slip rte ( ) re uniform throughout the interfce. (1) As shown in Eqution 1, n increse of the D would produce lrge increse in generted Q, if the remining fctors were kept constnt. However, s mny of the fctors tht pper in Eqution 1 re temperture dependent, nd this depends on the power, it is not esy to descrie the effect of the increse of the D on the HI. In the recent yers, studies hve een crried out out the influence of the tool shoulder dimeter on the defect genertion nd mechnicl properties of friction stir welds of AA6061 nd AA 7075-T6 (Elngovn nd Blsurmnin (2008); Rjkumr et l. (2011)). In these works, the increse of the D ws only ssocited with n increse of HI, ut it is not quntified nor explined the reltionship etween oth fctors. In this sense, more work is needed on this mtter. In FSW there re different types of defects relted to the lck of HI, which genertes n insufficient plstic flow. Therefore, the tunnel defect, the kissing ond nd/or zigzg line, my e ssocited with lck of plstic flow nd/or het input (Mishr nd Mhoney (2007); Oosterkmp et l. (2004)). In turn, the HI defines the volume of recrystllized mteril in the welding nugget (WN), the finl grin size in this zone nd metllurgicl spects s the microstructure degrdtion in the het ffected zone (HAZ) (Mishr nd M (2005); Nndn et l. (2008)). Finlly, the defect density nd microstructurl evolution, oth ssocited with the therml cycle during FSW, control the finl properties of the joint (Mishr nd Mhoney (2007)). The ojective of this work ws to study the effect of D on HI during FSW of AA5052-H32 lloy nd the chrcteristics of the joints otined. Nomenclture Slip Rte TC Thermocouple D Tool Shoulder Dimeter WN Welding Nugget FEM Finite Element Method WNA Welding Nugget Are FSW Friction Stir Welding y Sher Yield Stress HAZ Het Affected Zone HI Het Input HV Vickers Hrdness P Men Pressure PT Pek Temperture Q Power

3 916 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) Experimentl procedure In order to chieve the proposed ojectives, pltes of 150x75x3 mm of AA5052-H32 were utt welded y FSW using four tools with different shoulder dimeters (10, 12, 14 nd 16 mm). FSW tools were mde of H13 tool steel nd hve of concve shoulder with smooth tpered pin with three mchined flts t 120 to the xis of symmetry, s shown in Figure 1.. For ll cses, the pin length ws 2.8 mm, with se dimeter of 3 mm. An imge of the experimentl set up used for FSW cn e seen in Figure 1.. Fig. 1. () Scheme of FSW tools; () FSW experimentl set up. During welding, therml cycles were cquired using two K-type thermocouples. The thermocouples were positioned t 1 nd 2 mm from the edge of the weld ed (TC1 nd TC2, respectively) on the dvncing side of the joint nd ner of the hlf length of the specimen, with distnce etween them of 5 mm, s cn e seen in Figure 1.. The thermocouples were plced in mchined holes of 1 mm in dimeter nd 1.5 mm in deep. Tle 1 shows the welding prmeters used nd the identifiction of the smples. Tle 1. FSW prmeters Identifiction D10 10 D12 12 D14 14 D16 16 Shoulder Dimeter (mm) Rottionl Speed (rpm) Welding Speed (mm/min) ,5 Tool Tilt Angle (º) Het trnsfer during the welding process ws modeled y finite elements method (FEM) to get the vlue of the net power (Q) from cquired therml cycling. The het trnsfer in the pltes ws considered two-dimensionl, trnsient nd considering only conduction. Furthermore, sptil distriution of the het source ws used, proportionl to the distnce from the center of the source. Het losses to the environment were tken into ccount, y conduction to the cking plte nd convection in the remining oundry surfces. The finl result ws the net power (Q) necessry to otin clculted pek temperture in the position of TC1 equl to the pek temperture mesured y the sme thermocouple (Tufro nd Svood (2012)). A strin gge ttched in the hed of the mchine ws used to mesure xil lod during welding, y mens of clirtion curve strin-xil lod, otined previously (Fernndez (2009)). This strin is mesured using Strin Indictor P-3500, Vishy-Mesurement Group. From the welded smples cross sections were extrcted from ech specimen, which were prepred for mcrogrphic oservtion nd Vickers microhrdness (HV) mesurements. The different zones of the welded joints

4 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) nd the presence of discontinuities ssocited with FSW were nlyzed. Also, the welding nugget re ws mesured in ech cse. Microhrdness profiles were otined on the cross section long line on the hlf thickness, with lod of 500 gf. 3. Results nd discussion 3.1. Visul Inspection Figure 2 shows the surfce ppernce of the welded smples otined with different D. c Fig. 2. Surfce ppernce of FSW welded smples with different D: () D10; () D12; (c) D14; (d) D16. It cn e seen tht ll of them hd stisfctory surfce ppernce, without the presence of detectle surfce defects. It is lso noted tht the width of the weld ed ws incresed ccording to the used D Therml cycles As mentioned in the previous section, the thermocouples were locted t 1 nd 2 mm from the edge of the weld ed in ech cse. Thus, s it cn e seen in Tle 2, the distnce etween the TC nd the joint centerline ws different for ech D. Also, it cn e seen the pek temperture (PT) reched y TC1 nd the clculted power (Q) from this mesured PT, for ech cse. d

5 918 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) Tle 2. Thermocouples position nd results from cquired therml cycles Designtion Distnce etween the TC nd the Center Line (mm) TC1 Pek Temperture for TC1 (ºC) D D D D TC2 Power (W) Figure 3 shows the therml cycles cquired y oth thermocouples for the four D studied. It cn e seen tht the pek temperture corresponding to the TC1 rech mximum for D=12mm. Although the PT ws expected to increse continuously with D, the trend otined is lnce etween higher HI nd higher distnce to the centerline, due to the chnge in the position of the TC. In turn, Q incresed with the employed D. c Fig. 3. Acquired therml cycles of FSW welded specimens: () D10; () D12; (c) D14; (d) D16. d In Figure 4. re plotted the pek tempertures profiles clculted y FEM for the different D such tht the PT mesured with TC1 (indicted in the figure with filled lue mrker) were equl to the clculted PT in the position of this TC. Thus, it cn e clerly seen tht if the TCs were positioned t the sme distnce from the centreline, PTs would e ever incresing. For exmple, this ehvior cn e oserved y the dshed line plotted to 9 mm from the centreline in Figure 4.. However, this is not convenient to perform in prctice ecuse for smller shoulder dimeters the TCs should e positioned wy from the het source, mgnifying the error relted with simplifying ssumptions of the models (Tufro nd Svood, (2012)). It cn lso e oserved tht s D increse, the clculted PT profiles ecome more uniform, which imply smller increse in clculted PTs. This ehvior is relted to the incresed re covered y the het source s D increses, resulting in more uniform het source density.

6 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) Moreover, in Figure 4. re plotted the net power Q vlues clculted from the PTs corresponding to the TC1 from different D. It cn e seen tht Q incresed linerly with D. An experimentl expression ws otined to quntify this reltionship, with good degree of correltion. Fig. 4. Pek temperture profiles () nd het input () clculted y FEM from the pek temperture corresponding to the TC1 for different D Anlyzing the nlyticl model for het genertion in FSW expressed in Eqution 1, Q increses with the cue of the D, if the remining prmeters re constnt. Therefore, this set of prmeters (, y,, p) should decrese with incresing the shoulder dimeter in such wy tht reltionship etween oth prmeters remins liner. For exmple, incresing D, increses Q nd T, which implies decrese in y, ssocited with the het genertion for the sticking contct condition. Finlly, it should e clrified tht the PT profile shown in Figure 4. for the dimeter D12 nd the clculted Q exceeded the generl trend (Figure 4.), which could e relted to the dispersion in the control of the set of vriles ssocited with the mesurements done Axil Lod Tle 3 shows the results from the xil lod mesurement. In ech cse, the men pressure ws clculted s the rtio etween the xil lod nd the projected re of the tool shoulder, corresponding to the re of circle with dimeter equl to the shoulder dimeter. Tle 3. Results from xil lod mesuring Designtion Shoulder Dimeter (mm) Axil Lod (kn) Projected Are (mm 2 ) D D D D Men Pressure (MP) In Figure 5., the xil lod vlues mesured for ech D re plotted. It cn e seen tht the xil lod incresed linerly with this prmeter. Moreover, Figure 5. shows the evolution of the men pressure (P) with D. In this cse, it is noted tht the P decresed linerly with D. For oth vriles, experimentl expressions were otined to model the nlyzed reltionships, with good degree of correltion. These P vlues re representtive of the contct pressure ppering in the nlyticl model for the het genertion in FSW presented in Eqution 1. Thus, continuing the nlysis of previous susection, this decrese in contct pressure with the shoulder dimeter implies decrese of het genertion for the sliding contct condition.

7 920 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) Fig. 5. Axil lod () nd men pressure () vs. tool shoulder dimeter. Therefore, for oth contct conditions, it my e explined why the power not incresed with the cue of the shoulder dimeter s it seems in the het genertion model of Eqution 1. From these considertions emerge the need to tke into ccount the temperture dependence of the other prmeters (, y,, p) Mcrostructurl chrcteriztion Figure 6 shows the mcrogrphs of cross sections of the four FSW welded specimens, for different D. c d Fig. 6. Mcrogrph of FSW welded specimens: () D10; () D12; (c) D14; (d) D16. It cn e oserved the different chrcteristics zones of FSW welded joints, showing full penetrtion in the root, in ll cses. The dvncing side is lwys locted on the right side of the imge. The lck line tht is shown in the

8 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) figure ws used to clculte the welding nugget re. For D10 cn e seen tunnel defect relted with the low HI introduced during the weld. Although the WN shpe ws similr for ll the welding conditions, it cn e oserved n increse in its size with D. For this reson, in Figure 7. is nlyzed the evolution of the welding nugget re (WNA) vs. D. Fig. 7. Welding nugget re vs tool shoulder dimeter () nd power (). As it ws oserved with PTs profiles nd clculted Q vlues, the WNA of the welded specimen D12 ws found ove of the generl trend. As it is known, n increse in Q involves n increse in temperture nd in the plstic flow of mteril, so it is expected to otin etter correltion etween WNA nd Q (Mishr nd M, (2005)). Becuse of this, in Figure 7., WNA vs. Q is plotted, showing liner trend with etter degree of correltion. In mcrogrphs of Figure 6 cn e seen some discontinuities in the welding nugget of the specimen D10. Figure 8 shows welding nugget detil of the four welding conditions. c Fig. 8. Welding nugget detil of FSW welded specimens: () D10; () D12; (c) D14; (d) D16. d

9 922 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) In the WN of the welded specimen D10, Figure 8., it cn seen defect ner the root, which is generted due to lcking plstic flow of mteril, ssocited with reltively low het input. The mteril stirred y the tool should e le to fill the volume produced y the trnsltion of the pin. If the generted het is not sufficient, the deformed mteril is cooled efore filling the region ehind the tool, generting this type of defect (Mishr nd Mhoney, (2007)). Furthermore, is clerly oserved zigzg line in the WN of ll welded specimens, which is nother chrcteristic discontinuity of this process tht cn ffect the mechnicl properties of the joint, depending on its continuity. This zigzg line is the oxide lyer remnnt of the originl surfces to e joined. It is known tht the seprtion nd rupture of such lyers depends on the plstic flow of mteril nd het input (Mishr nd Mhoney, (2007)). However, it is oserved in this figure tht the vrition of the shoulder dimeter pprently do not hve gret effect on the shpe of this zigzg line. Finlly, esides the zigzg line corresponding to the oxide lyers of the initil surfces to e joined, other lines cn e oserved ner the root in the WN of the welded specimen D10, Figure 8.. These lines might e ssocited with the contct of the successive mteril lyers deposited ehind pin in ech revolution of the tool. The low HI limits the plstic flow nd complictes the forging of the mteril for the formtion of the metlurgicl joint. In this wy, oxides interfces re present etween mteril lyers nd my e ssocited to the kissing ond defect (Oosterkmp et l., (2004)) Microhrdness profiles Figure 9 shows the Vickers microhrdness (HV) profiles otined for the four welded specimens, where the vlues corresponding to mesurements otined in the WN re unfilled, in ech cse. It cn e seen reduction in hrdness from the BM (78 HV) towrds the HAZ nd WN, for ll welding conditions. The dvncing side shows slightly lower HV vlues, locting in this zone the minimum HV vlue, for the different D. Considering tht the se mteril hs een hrdened y cold working, the oserved hrdness decrese would e ssocited with the recovery nd recristlizción in these zones during the welding process. This effect hs een reported for strin-hrdened lloys (Mishr nd Mhoney, 2007). Furthermore, it cn e seen tht the hrdness in the WN tended to decrese with the shoulder dimeter, while the size of the zone where the hrdness decreses incresed with this prmeter. For higher D (D14 nd D16) the hrdness ws the lowest reching HV. Fig. 9. Vickers microhrdness profiles for different tool shoulder dimeters. These phenomen re relted to the increse of the therml field with D, which ws previously nlyzed nd cn e represented with PT profiles plotted in Figure 3.. The higher HI llows chieving the recrystlliztion temperture in higher volume of mteril, ssocited with the criticl strin. Regrding the hrdness of the WN, n increse in HI produces n increse in grin size, resulting in hrdness decrese.

10 Leonrdo N. Tufro et l. / Procedi Mterils Science 8 ( 2015 ) Finlly, it hs een oserved tht the hrdness in the HAZ is slightly lower in the dvncing side for ll hrdness profiles. This ehvior cn e ssocited with the symmetry of the FSW process, since it is generlly understood tht the HI is slightly higher on this side (Nndn et l. (2008)). 4. Conclusions FSWelds of AA5052-H32 on pltes of 3 mm otined with different tool shoulder dimeters were nlyzed. Net power vlues clculted y the FEM model from the cquired therml cycles incresed linerly with the tool shoulder dimeter. This increse in power is much less thn predicted y the nlyzed nlyticl model for het genertion in FSW, considering tht its prmeters re constnt. This demonstrte the need of introduced the temperture dependence of these prmeters. In this wy, the liner reltionship etween these two fctors could e explined for oth contct conditions (sticking nd sliding), considering the decrese in the sher yield stress nd the men pressure with the shoulder dimeter. The effect of the shoulder dimeter nd the resulting het generted were relted with different chrcteristics of welded joints. First, the size of the welding nugget incresed linerly with power, which is ssocited with n increse in temperture nd plstic flow of mteril. This plstic flow ws lower for the smllest tool shoulder dimeter, generting defect in the se of the welding nugget. There ws not oserved n effect of shoulder dimeter on the zigzg oxide line. The hrdness in the welding nugget tended to decrese with shoulder dimeter, which would e ssocited with n increse of grin size. Furthermore, the size of the zone where the hrdness decreses incresed with the shoulder dimeter, which is relted to the increse in temperture field. Therefore, the incresing of the shoulder dimeter incresed the therml field nd plstic flow, limiting the defects genertion nd decresing the hrdness. The est lnce etween these effects ws otined for the shoulder dimeter of 12 mm. Acknowledgements The uthors wnt to cknowledge to the University of Buenos Aires nd INTI for the finncil support for this work nd to the personnel of the Mterils nd Structures Lortory of FIUBA nd of the Centre of Mechnics of INTI for its collortion. References Elngovn, K., Blsurmnin, V., Influences of tool pin profile nd tool shoulder dimeter on the formtion of friction stir processing zone in AA6061 luminium lloy. Mterils nd Design 29, Fernández, G., Solddur por Fricción Agitción (FSW), Fcultd de Ingenierí, Universidd de Buenos Aires. Mishr, R. S., M, Z. Y., Friction stir welding nd processing. Mterils Science nd Engineering R 50, Mishr, R. S., Mhoney, M. W., Friction Stir Welding nd Processing. ASM Interncionl. Nndn, R., DeRoy, T., Bhdeshi, H. K. D. H., Recent dvnces in friction-stir welding - Process, weldment structure nd properties. Progress in Mterils Science 53, Oosterkmp, A., Oosterkmp, L. D., Nordeide, A., Kissing Bond Phenomen in Solid-Stte Welds of Aluminum Alloys. Welding Journl 83, 225s 231s. Rjkumr, S., Murlidhrn, C., Blsurmnin, V., Influence of friction stir welding process nd tool prmeters on strength properties of AA7075-T6 luminium lloy joints. Mterils nd Design 32, Schmidt, H. B., Httel, J. H., Therml modelling of friction stir welding. Script Mterili 58, Tufro, L. N., Svood, H. G., Estudio de los Ciclos Térmicos Adquiridos durnte FSW medinte Modelos Anlíticos y Numéricos. Anis 37th Congresso Ncionl de Soldgem, Ouro Preto, Brsil, CT29.

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