Home Refill Friction Stir Spot Welding of Dissimilar 6061/7075 Aluminum Alloy
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Refill Friction Stir Spot Welding of Dissimilar 6061/7075 Aluminum Alloy

  • Zhenlei Liu EMAIL logo , Kang Yang and Dejun Yan
Published/Copyright: July 27, 2018

Abstract

Refill friction stir spot welding (RFSSW) was used to join 6061-T6 and 7075-T6 aluminum alloys in this work. Different sheet configurations and welding parameters were used to optimize joint strength. The effect of sleeve plunge depth on the microstructure and mechanical properties of the joints were investigated. The results showed that no defects were obtained when 6061-T6 aluminum alloy was placed as the upper sheet. The lap shear failure load of the joint using 6061-T6 aluminum alloy as the upper sheet was higher than that using 7075-T6 as the upper sheet. The maximum failure load of 12,892 N was attained when using the sleeve plunge depth of 3.6 mm. The joint failed at the upward flowing 7075 near the hook.

Introduction

In the twenty-first century, the global energy crisis causes light-weight materials to be extensively used in automobile industries [1, 2]. Aluminum alloys, which own low densities, high specific strengths and good corrosion resistance, are of great potential in industries. 7075 Al is one of the high-strength alloys and is always used as structural components such as aircraft fuselage panels and airplane wings [3]. 6061 Al is one of the middle-strength alloys and is always used on high-speed trains. It is of great significance to obtain 7075/6061 joint with satisfied mechanical properties.

As is well-known, it was always unsuccessful to join aluminum alloys using fusion welding technologies because defects such as cracks, porosities and high residual stresses easily appeared [4]. Friction stir welding (FSW) was invented in the 1990s to join aluminum alloys. During FSW, peak temperature is commonly lower than the melting points of base materials (BMs). Therefore, a plenty of the fusion defects can be avoided [5]. Till now, a lot of works have been done to investigate the microstructure and mechanical properties of FSW joints [4, 5, 6, 7, 8, 9, 10, 11, 12]. Yan et al. [4] butt welded dissimilar Al–Mg–Si/Al–Zn–Mg aluminum alloys using different configuration and reported that tensile strengths of the dissimilar Al–Mg–Si/Al–Zn–Mg joints using both configurations were higher than that of the Al–Mg–Si FSW joint. Guo et al. [12] reported that better material mixing was obtained when 6061 served as the advancing side. In recent years, FSW has been used to join some new materials such as Ti alloys [6, 7, 8], Cu alloys [9], steels [10] and even composite materials [11].

Refill friction stir spot welding (RFSSW) is a new variant of FSW, which was invented in 2002 by GKSS-GmbH [13]. The most significant feature of RFSSW was that it can eliminate the keyholes. RFSSW showed great potential among spot joining technologies and is now considered as a promising technology to replace riveting and resistance spot joining [14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28]. The tool used in RFSSW is more complicated, which consists of a clamping ring, whose main function is to keep the plates tightly and avoid plastic material from escaping, and a pin and a sleeve, which are the main components to stir the material. By adopting different movements to the three components, plastic material can be refilled back into joint after RFSSW and spot joint without keyhole can be obtained. Zhao et al. [14] studied the effect of plunge depth on microstructure and mechanical properties of 7B04 Al RFSSW joints and found that the position of bonding ligament gradually migrated downwards with increasing the plunge depth. Shen et al. [15] reported that the thermal-mechanically affected zone/stir zone (TMAZ/SZ) interface and the original lap interface were the weak regions for RFSSW joint. Similar conclusion was obtained by Li et al. [16] and the fracture mechanism of RFSSW joint was detailed discussed in that work. Suhuddin et al. [17, 18] reported that the intermetallic compounds of Al12Mg17 and Al3Mg2 formed in dissimilar Al/Mg joints and they significantly affected joint strength. Campanelli et al. [19] reported that high joint strength was obtained by increasing the material mixing and simultaneously minimizing the hook height. Cao et al. [27, 28] found that the hook in 6061 RFSSW joint was closely associated to sleeve plunge depth and higher hook resulted into lower joint strength.

In this work, RFSSW was used to join 6061/7075 aluminum alloys. The optimum joint strength was obtained by changing different welding parameters. The microstructure and mechanical properties of RFSSW joint were studied.

Experiment

Three mm-thick 6061-T6 and 7075-T6 aluminum alloys were chosen as the BM in this work. The sheets were cut into dimensions of 140 mm×40 mm. Before welding, the surfaces of the sheets were polished using 500 # emery papers and cleaned in acetone. During welding, two sheets were lap combined using a width of 50 mm. The schematic of the joint is shown in Figure 1.

Figure 1: Schematic of the joint (unit mm).
Figure 1:

Schematic of the joint (unit mm).

The RFSSW machine used during experiment was RPS100SK10. The outer diameters of the clamping ring, sleeve and pin were 14.5 mm, 9 mm and 5 mm. The inner diameters of the clamping ring and the sleeve was 9.2 mm and 5.2 mm. The welding speed was chosen as 1600 rpm. Different sleeve plunge depths were 3.4 mm, 3.5 mm, 3.6 mm and 3.7 mm. The sleeve plunge and retract speeds were both 50 mm/min. After welding, metallographic samples were cut through joint centers and then were polished using standard polishing procedure. After etched using Keller’s reagent for 20 s, the cross sections of joints were taken using an optical microscopy (OM VHX-1000E). The microstructure was then observed using a scanning electron microscope (SEM, SU3500 made by Hitachi, Japan). Room temperature lap shear tests were performed using a constant speed of 3 mm/min. The fracture positions were observed by OM.

Results and discussion

Joint cross section morphology

Figure 2 shows the microstructure of the joint using 7075 as the upper sheet. The sleeve plunge depth was 3.4 mm. The joint cross section presented a basin-like morphology. Defects such as un-bonded interface, voids and incomplete refilling were observed (Figure 2(a)). Un-bonded interface was observed at the joint center. This was attributed to relative weak material flow behavior at the joint center. Shen et al. [15] reported that the grain size at the pin affected zone was bigger than that at the sleeve affected zone. Besides, Li et al. [29] reported that void was observed at the joint center. Therefore, increasing the material flow behavior at the joint center was an effective method to avoid the un-bonded interface.

Figure 2: Microstructure of the joint using 7075 as the upper sheet (a) cross section, (b) un-bonded interface (c) void and (d) incomplete refilling.
Figure 2:

Microstructure of the joint using 7075 as the upper sheet (a) cross section, (b) un-bonded interface (c) void and (d) incomplete refilling.

At the TMAZ/SZ interface near the maximum plunge depth, small voids were observed. For FSW butt joint, void is commonly considered as insufficient material flow behavior. In this work, the authors believed that the void was formed because of both material loss and the bad material flow-ability of 7075 alloy. During welding, a part of plastic material, which was extruded into the gap between the tool components, cannot be refilled back after welding. The material loss led to void. Besides, the heat input was not sufficient to soften the material to be a good plasticity, leading to voids.

At the TMAZ/SZ interface near joint upper surface, incomplete refilling was observed (Figure 2(d)). Incomplete refilling has been reported in the works of Shen et al. [15], Li et al. [30] and Xu et al. [31]. Shen et al. [15] attributed this defect to different slip conditions of the material at the TMAZ/SZ interface. Xu et al. [29] used a small plunge of the tool to eliminate this defect. Li et al. [16, 30] thought this defect was formed because of the weak diffusion bonding effect and residual stress.

Figure 3 shows the hook of the RFSSW joints using different sheet configurations. As shown in Figure 3(a), the interface presented an upward bending morphology on the joint using 6061 as upper sheet. There existed a partially bonded region and it has a width of about 110 μm. From the partially bonded region to the sleeve retraction path, a fully bonded region with a width of about 150 μm was observed. Figure 3(b) shows the hook of the joint using 7075 as the upper sheet. From the un-bonded lap interface to the SZ, the partially bonded region had a width of about 90 μm and the fully bonded region has a width of about 50 μm. When 6061 was placed as the upper sheet, better flowability of SZ was obtained compared with that using 7075 as the upper sheet. Under this condition, the lap interface was more completely broken (Figure 3(a)). On the contrary, when using 7075 as the upper sheet, relative weaker material flowability was attained and the smaller bonding width was obtained.

Figure 3: Microstructure of hook region using (a) 6061 and (b) 7075 as the upper sheets.
Figure 3:

Microstructure of hook region using (a) 6061 and (b) 7075 as the upper sheets.

For lap joints, effective lap width (ELW) is an important variable. It clearly reflects the effect of hook on joint quality. In the present work, the ELW on the joint using 6061 as the upper sheet was much bigger than that using 7075 as the upper sheet. In the following section, the microstructure and mechanical properties of the joints using 6061 as the upper sheet were mainly discussed.

Figure 4 shows the cross sections of joints using 6061 as the upper sheets. Similar to the joint using 7075 as the upper sheet, the cross sections presented basin-like morphologies. When using the plunge depth of 3.4 mm, a portion of the 7075 Al stayed at the joint center. The detailed microstructure was discussed in the following part. With increasing the plunge depth, adequate material mixing happened. No un-bonded interface was observed (Figure 4(b–d)). As shown in Figure 4(a), near the hook, a part of 7075 Al showed an upward flowing trend. The height of the upward flowing 7075 Al increased with increasing the plunge depth (Figure 4(b)). As shown in Figure 4, well bonding was formed at the TMAZ/SZ interfaces. So bigger height of the 7075 Al meant more adequate mixing between the BMs.

Figure 4: Joint cross sections using (a) 3.4 mm, (b) 3.5 mm, (c) 3.6 mm and (d) 3.7 mm.
Figure 4:

Joint cross sections using (a) 3.4 mm, (b) 3.5 mm, (c) 3.6 mm and (d) 3.7 mm.

Figure 5 shows the microstructure of the joint center using 3.4 mm. Lamellar structures were observed at the joint center. The relative light structure was 6061 Al and the relative dark structure was 7075 Al. The bedded structures were formed due to the retraction and rotation of the sleeve. Its formation was very much like that of the onion ring [32]. Figure 5(b) shows the SEM image of the lamellar structures. Figure 5(c–g) shows the element distributions at this region. As Figure 5(c) and 5(d) show, Cu and Zn elements were much obvious. They showed similar morphologies like the lamellar structures in Figure 5(b). The distributions of Cu and Zn elements showed that rather weak element diffusion happened inside this region. This conclusion proved that FSW was a solid state joining process during which element distribution was rather weak. However, the elements of Fe, Mg and Si showed rather even distribution in this region.

Figure 5: Microstructure of the joint using 3.4 mm: (a) joint center, (b) SEM image, (c) Cu, (d) Zn, (e) Fe, (f) Mg and (g) Si.
Figure 5:

Microstructure of the joint using 3.4 mm: (a) joint center, (b) SEM image, (c) Cu, (d) Zn, (e) Fe, (f) Mg and (g) Si.

Figure 6 shows the microstructure at lap interface in the joint center using the sleeve plunge depth of 3.8 mm. No lamellar structures were observed. This can be attributed to more adequate material flow behavior when using bigger sleeve plunge depth. No any cracks or voids were observed. Figure 6(b–f) shows the element distribution in this area. Similar to Figure 5, Cu and Zn elements were clearly recognized, while the other three elements presented even distribution. Again, judging from the Cu and Zn element which owned higher content in 7075 Al, it was concluded that diffusion effect in FSW was rather weak.

Figure 6: Microstructure of the joint using 3.8 mm: (a) SEM image of joint center, (b) Cu, (c) Zn, (d) Fe, (e) Mg and (f) Si.
Figure 6:

Microstructure of the joint using 3.8 mm: (a) SEM image of joint center, (b) Cu, (c) Zn, (d) Fe, (e) Mg and (f) Si.

Shen et al. [13] reported that for 7075 RFSSW joint, defect such as void easily appeared at the maximum sleeve plunge depth region. Figure 7 shows the microstructure of this region using the sleeve plunge depth of 3.8 mm. No defects were observed in Figure 7(a). Due to different etching rates, different regions of the joint were clearly recognized. Commonly, the microstructure of the joint was divided in BM, TMAZ, heat affected zone (HAZ) and SZ. 7075 is one of the typical precipitation-hardening aluminum alloys. The mechanical properties of joint were significantly affected by the secondary phase particles. Figure 7(b–e) shows the secondary phase particles at different regions. As shown in Figure 7(b), some secondary phases with different sizes were observed at the BM. At the HAZ in Figure 7(c), the secondary phases showed similar morphology like that in Figure 7(b). The TMAZ underwent both mechanical stirring and thermal effect. Thus less secondary phases with smaller sizes were observed (Figure 7(d)). As shown in Figure 7(e), in the SZ, due to the intense mechanical stirring, almost no secondary phases were seen.

Figure 7: Secondary phases near the maximum plunge depth region: (a) the general view, (b) BM, (c) HAZ, (d) TMAZ and (e) SZ.
Figure 7:

Secondary phases near the maximum plunge depth region: (a) the general view, (b) BM, (c) HAZ, (d) TMAZ and (e) SZ.

Figure 8 shows the lap shear failure loads of joints. As shown in Figure 8, when using the sleeve plunge depth of 3.4 mm, the joint using 6061 as upper owned much higher failure load (10,816 N) than the joint using 7075 as the upper sheet (7,258 N). This can be attributed to the defects in Figure 2 when using 7075 as the upper sheet. For the joints using 6061 Al as the upper sheet, with increasing the sleeve plunge depth, lap shear failure load firstly increased and then decreased. The maximum failure load of 12,892 N was attained when using the sleeve plunge depth of 3.6 mm.

Figure 8: Lap shear failure loads of the joints.
Figure 8:

Lap shear failure loads of the joints.

Figure 9(a) shows the fracture position of the joint. The joint failed at the 7075 Al which flowed upwards. Therefore, there existed one optimum upward flow height of the 7075 Al. When using small plunge depth, the material mixing between the two BMs was weak. With increasing the plunge depth, material mixing became better and therefore lap shear failure load increased. With further increasing the sleeve plunge depth, more heat input may soften the upward flow 7075 Al. Therefore, joint strength showed a decrease.

Figure 9: Fracture position of the joint: (a) general view, (b) and (c) magnified views of the fracture positions.
Figure 9:

Fracture position of the joint: (a) general view, (b) and (c) magnified views of the fracture positions.

Conclusions

  1. Defects such as void, unbonded interface and incomplete refilling are observed when using 7075 Al as the upper sheet. No defects are observed when using 6061 Al as the upper sheet.

  2. With increasing the sleeve plunge depth, better material mixing happens between the upper and lower sheets.

  3. Joint using 6061 as the upper sheet shows much high lap shear failure load than joint using 7075 as the upper sheet.

  4. With increasing the sleeve plunge depth, the lap shear failure load of joint firstly increases and then decreases. The maximum failure load of 12,892 N was obtained when using the sleeve plunge depth of 3.6 mm.

Acknowledgements

This work is supported by the China Postdoctoral Science Foundation (No.2016M590821), the Guangdong Key Laboratory of Enterprise Advanced Welding Technology for Ships (2017B030302010).

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Received: 2017-10-11
Accepted: 2018-05-03
Published Online: 2018-07-27
Published in Print: 2019-02-25

© 2019 Walter de Gruyter GmbH, Berlin/Boston

This work is licensed under the Creative Commons Attribution 4.0 Public License.

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  66. Cellular Automaton Modeling of Phase Transformation of U-Nb Alloys during Solidification and Consequent Cooling Process
  67. The effect of MgTiO3Adding on Inclusion Characteristics
  68. Cutting performance of a functionally graded cemented carbide tool prepared by microwave heating and nitriding sintering
  69. Creep behaviour and life assessment of a cast nickel – base superalloy MAR – M247
  70. Failure mechanism and acoustic emission signal characteristics of coatings under the condition of impact indentation
  71. Reducing Surface Cracks and Improving Cleanliness of H-Beam Blanks in Continuous Casting — Improving continuous casting of H-beam blanks
  72. Rhodium influence on the microstructure and oxidation behaviour of aluminide coatings deposited on pure nickel and nickel based superalloy
  73. The effect of Nb content on precipitates, microstructure and texture of grain oriented silicon steel
  74. Effect of Arc Power on the Wear and High-temperature Oxidation Resistances of Plasma-Sprayed Fe-based Amorphous Coatings
  75. Short Communication
  76. Novel Combined Feeding Approach to Produce Quality Al6061 Composites for Heat Sinks
  77. Research Article
  78. Micromorphology change and microstructure of Cu-P based amorphous filler during heating process
  79. Controlling residual stress and distortion of friction stir welding joint by external stationary shoulder
  80. Research on the ingot shrinkage in the electroslag remelting withdrawal process for 9Cr3Mo roller
  81. Production of Mo2NiB2 Based Hard Alloys by Self-Propagating High-Temperature Synthesis
  82. The Morphology Analysis of Plasma-Sprayed Cast Iron Splats at Different Substrate Temperatures via Fractal Dimension and Circularity Methods
  83. A Comparative Study on Johnson–Cook, Modified Johnson–Cook, Modified Zerilli–Armstrong and Arrhenius-Type Constitutive Models to Predict Hot Deformation Behavior of TA2
  84. Dynamic absorption efficiency of paracetamol powder in microwave drying
  85. Preparation and Properties of Blast Furnace Slag Glass Ceramics Containing Cr2O3
  86. Influence of unburned pulverized coal on gasification reaction of coke in blast furnace
  87. Effect of PWHT Conditions on Toughness and Creep Rupture Strength in Modified 9Cr-1Mo Steel Welds
  88. Role of B2O3 on structure and shear-thinning property in CaO–SiO2–Na2O-based mold fluxes
  89. Effect of Acid Slag Treatment on the Inclusions in GCr15 Bearing Steel
  90. Recovery of Iron and Zinc from Blast Furnace Dust Using Iron-Bath Reduction
  91. Phase Analysis and Microstructural Investigations of Ce2Zr2O7 for High-Temperature Coatings on Ni-Base Superalloy Substrates
  92. Combustion Characteristics and Kinetics Study of Pulverized Coal and Semi-Coke
  93. Mechanical and Electrochemical Characterization of Supersolidus Sintered Austenitic Stainless Steel (316 L)
  94. Synthesis and characterization of Cu doped chromium oxide (Cr2O3) thin films
  95. Ladle Nozzle Clogging during casting of Silicon-Steel
  96. Thermodynamics and Industrial Trial on Increasing the Carbon Content at the BOF Endpoint to Produce Ultra-Low Carbon IF Steel by BOF-RH-CSP Process
  97. Research Article
  98. Effect of Boundary Conditions on Residual Stresses and Distortion in 316 Stainless Steel Butt Welded Plate
  99. Numerical Analysis on Effect of Additional Gas Injection on Characteristics around Raceway in Melter Gasifier
  100. Variation on thermal damage rate of granite specimen with thermal cycle treatment
  101. Effects of Fluoride and Sulphate Mineralizers on the Properties of Reconstructed Steel Slag
  102. Effect of Basicity on Precipitation of Spinel Crystals in a CaO-SiO2-MgO-Cr2O3-FeO System
  103. Review Article
  104. Exploitation of Mold Flux for the Ti-bearing Welding Wire Steel ER80-G
  105. Research Article
  106. Furnace heat prediction and control model and its application to large blast furnace
  107. Effects of Different Solid Solution Temperatures on Microstructure and Mechanical Properties of the AA7075 Alloy After T6 Heat Treatment
  108. Study of the Viscosity of a La2O3-SiO2-FeO Slag System
  109. Tensile Deformation and Work Hardening Behaviour of AISI 431 Martensitic Stainless Steel at Elevated Temperatures
  110. The Effectiveness of Reinforcement and Processing on Mechanical Properties, Wear Behavior and Damping Response of Aluminum Matrix Composites
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