Skip to main content
SpringerLink
Log in

High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History

  • Published:
Metallurgical and Materials Transactions A Aims and scope Submit manuscript

Abstract

Friction stir welding (FSW) is a cost-effective and high-quality joining process for aluminum alloys (especially heat-treatable alloys) that is historically operated at lower joining speeds (up to hundreds of millimeters per minute). In this study, we present a microstructural analysis of friction stir welded AA7075-T6 blanks with high welding speeds up to 3 M/min. Textures, microstructures, mechanical properties, and weld quality are analyzed using TEM, EBSD, metallographic imaging, and Vickers hardness. The higher welding speed results in narrower, stronger heat-affected zones (HAZs) and also higher hardness in the nugget zones. The material flow direction in the nugget zone is found to be leaning towards the welding direction as the welding speed increases. Results are coupled with welding parameters and thermal history to aid in the understanding of the complex material flow and texture gradients within the welds in an effort to optimize welding parameters for high-speed processing.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

References

  1. W.M. Thomas, E.D. Nicholas, J.C. Needham, M.G. Murch, P. Temple-Smith, and C.J. Dawes: 1991: US.

  2. W.M. Thomas, E.D. Nicolas, J.C. Needham, M.G. Murch, P. Temple-Smith, and C.J. Dawes: 1991: GB.

  3. Xu, S. and X. Deng, Acta Materialia, 2008. 56(6): p. 1326-1341.

    Article  Google Scholar 

  4. Y.S. Sato, H. Kokawa, K. Ikeda, M. Enomoto, T. Hashimoto, and S. Jogan: Metallurgical and Materials Transactions A, 2001, 32(4): pp. 941–948.

    Article  Google Scholar 

  5. D.P. Field, T.W. Nelson, Y. Hovanski, K.V. Jata: Metall. Mater. Trans. A, 2001. 32(11): p. 2869-2877.

    Article  Google Scholar 

  6. Buffa, G., G. Campanile, L. Fratini, and A. Prisco, Mater. Sci. Eng. A, 2009. 519(1–2): p. 19–26.

    Article  Google Scholar 

  7. Rodrigues, D.M., A. Loureiro, C. Leitao, R.M. Leal, B.M. Chaparro, and P. Vilaça, Mater. Des. 2009. 30(6): p. 1913-1921.

    Article  Google Scholar 

  8. Yang, B., J. Yan, M.A. Sutton, and A.P. Reynolds, Materials Science and Engineering: A, 2004. 364(1–2): p. 55-65.

    Article  Google Scholar 

  9. Chen, Y., H. Liu, and J. Feng, Materials Science and Engineering: A, 2006. 420(1–2): p. 21-25.

    Article  Google Scholar 

  10. McNelley, T.R., S. Swaminathan, and J.Q. Su, Scripta Materialia, 2008. 58(5): p. 349-354.

    Article  Google Scholar 

  11. Su, J.-Q., T.W. Nelson, and C.J. Sterling, Materials Science and Engineering: A, 2005. 405(1–2): p. 277-286.

    Article  Google Scholar 

  12. Fonda, R.W., J.F. Bingert, and K.J. Colligan, Scripta Materialia, 2004. 51(3): p. 243-248.

    Article  Google Scholar 

  13. Liu, H.J., H. Fujii, M. Maeda, and K. Nogi, Journal of Materials Processing Technology, 2003. 142(3): p. 692-696.

    Article  Google Scholar 

  14. Charit, I. and R.S. Mishra, Materials Science and Engineering a-Structural Materials Properties Microstructure and Processing, 2003. 359(1-2): p. 290-296.

    Article  Google Scholar 

  15. Mishra, R.S. and Z.Y. Ma, Materials Science & Engineering R-Reports, 2005. 50(1-2): p. 1-78.

    Article  Google Scholar 

  16. Ma, Z.Y., Metallurgical and Materials Transactions a-Physical Metallurgy and Materials Science, 2008. 39A(3): p. 642-658.

    Article  Google Scholar 

  17. Wu, H., Y.-C. Chen, D. Strong, and P. Prangnell, Journal of Materials Processing Technology, 2015. 221: p. 187-196.

    Article  Google Scholar 

  18. Y. Hovanski, P. Upadhyay, J. Carsley, T. Luzanski, B. Carlson, M. Eisenmenger, A. Soulami, D. Marshall, B. Landino, and S. Hartfield-Wunsch: JOM, 2015. 67(5): p. 1045-1053.

    Article  Google Scholar 

  19. Jata, K.V., K.K. Sankaran, and J.J. Ruschau, Metallurgical and Materials Transactions A, 2000. 31(9): p. 2181-2192.

    Article  Google Scholar 

  20. Su, J.Q., T.W. Nelson, R. Mishra, and M. Mahoney, Acta Materialia, 2003. 51(3): p. 713-729.

    Article  Google Scholar 

  21. Upadhyay, P. and A.P. Reynolds, JOM, 2015. 67(5): p. 1022-1031.

    Article  Google Scholar 

  22. Zhang, Z., B.L. Xiao, and Z.Y. Ma, Materials Characterization, 2015. 106: p. 255-265.

    Article  Google Scholar 

  23. Nourani, M., A.S. Milani, and S. Yannacopoulos, The International Journal of Advanced Manufacturing Technology, 2015. 79(9): p. 1425-1441.

    Article  Google Scholar 

  24. Kadaganchi, R., M.R. Gankidi, and H. Gokhale, Defence Technology, 2015. 11(3): p. 209-219.

    Article  Google Scholar 

  25. Ji, P., Z. Yang, J. Zhang, L. Zheng, V. Ji, and V. Klosek, Journal of Materials Science, 2015. 50(22): p. 7262-7270.

    Article  Google Scholar 

  26. G. Rambabu, D. Balajinaik, C.H. Venkatarao, K. Srinivasarao, and G. Madhusudanreddy: Def. Technol., 2015. 11(4): p. 330-337.

    Article  Google Scholar 

  27. Rodrigues, D.M., C. Leitão, R. Louro, H. Gouveia, and A. Loureiro, Science and Technology of Welding and Joining, 2010. 15(8): p. 676-681.

    Article  Google Scholar 

  28. H.S. Lee, Y.R. Lee, and K.J. Min: MATEC Web of Conferences, 2016. 45: p. 01003.

  29. C. Deng, H. Wang, B. Gong, X. Li, and Z. Lei: Int. J. Fatigue, 2016. 83, p. 100-108.

    Article  Google Scholar 

  30. Malopheyev, S., I. Vysotskiy, V. Kulitskiy, S. Mironov, and R. Kaibyshev, Materials Science and Engineering: A, 2016. 662: p. 136-143.

    Article  Google Scholar 

  31. Morita, T. and M. Yamanaka, Materials Science and Engineering: A, 2014. 595: p. 196-204.

    Article  Google Scholar 

  32. Fonda, R.W., K.E. Knipling, and J.F. Bingert, Scripta Materialia, 2008. 58(5): p. 343-348.

    Article  Google Scholar 

  33. Liu, L., H. Nakayama, S. Fukumoto, A. Yamamoto, and H. Tsubakino, MATERIALS TRANSACTIONS, 2004. 45(8): p. 2665-2668.

    Article  Google Scholar 

  34. Zhou, L., T. Wang, W.L. Zhou, Z.Y. Li, Y.X. Huang, and J.C. Feng, Journal of Materials Engineering and Performance, 2016. 25(6): p. 2542-2550.

    Article  Google Scholar 

  35. P. Cavaliere, A. Squillace, and F. Panella: J. Mater. Process. Technol., 2008. 200(1–3): p. 364–72.

  36. Silva, A.C.F., D.F.O. Braga, M.A.V. de Figueiredo, and P.M.G.P. Moreira, The International Journal of Advanced Manufacturing Technology, 2015. 79(5): p. 805-814.

    Article  Google Scholar 

  37. Wang, Q.Z., Z.X. Zhao, Y. Zhao, K. Yan, and H. Zhang, Materials & Design, 2015. 88: p. 1366-1376.

    Article  Google Scholar 

  38. Çevik, B., Y. Özçatalbaş, and B. Gülenç, Practical Metallography, 2016. 53(1): p. 6-23.

    Article  Google Scholar 

  39. Barenji, R.V., Proceedings of the Institution of Mechanical Engineers Part L-Journal of Materials-Design and Applications, 2016. 230(2): p. 663-673.

    Google Scholar 

  40. Donne, C.D., R. Braun, G. Staniek, A. Jung, and W.A. Kaysser, Materialwissenschaft Und Werkstofftechnik, 1998. 29(10): p. 609-617.

    Article  Google Scholar 

  41. P. Staron, M. Koçak, S. Williams, and A. Wescott: Physica B: Condensed Matter, 2004. 350(1–3): p. 491-493.

    Article  Google Scholar 

  42. Cavaliere, P., Cerri, E., Squillace, A., Journal of Materials Science, 2005. 40(14): p. 3669-3676.

    Article  Google Scholar 

  43. Liu, H.J., H. Fujii, and K. Nogi, Journal of Materials Science, 2005. 40(12): p. 3297-3299.

    Article  Google Scholar 

  44. Chen, Y.C., H.J. Liu, and J.C. Feng, Journal of Materials Science, 2006. 41(1): p. 297-299.

    Article  Google Scholar 

  45. Paglia, C., K. Jata, and R. Buchheit, Materials and Corrosion, 2007. 58(10): p. 737-750.

    Article  Google Scholar 

  46. Motohashi, Y., T. Sakuma, A. Goloborodko, T. Ito, and G. Itoh, Materialwissenschaft Und Werkstofftechnik, 2008. 39(4-5): p. 275-278.

    Article  Google Scholar 

  47. Fratini, L., G. Buffa, and R. Shivpuri, International Journal of Advanced Manufacturing Technology, 2009. 43(7-8): p. 664-670.

    Article  Google Scholar 

  48. Li, W.Y., R.R. Jiang, Z.H. Zhang, and Y.E. Ma, Advanced Engineering Materials, 2013. 15(11): p. 1051-1058.

    Article  Google Scholar 

  49. Ramulu, P.J., R.G. Narayanan, S.V. Kailas, and J. Reddy, International Journal of Advanced Manufacturing Technology, 2013. 65(9-12): p. 1515-1528.

    Article  Google Scholar 

  50. Fehrenbacher, A., N.A. Duffie, N.J. Ferrier, F.E. Pfefferkorn, and M.R. Zinn, International Journal of Advanced Manufacturing Technology, 2014. 71(1-4): p. 165-179.

    Article  Google Scholar 

  51. Costa, M.I., D.M. Rodrigues, and C. Leitao, International Journal of Advanced Manufacturing Technology, 2015. 79(5-8): p. 719-727.

    Article  Google Scholar 

  52. Chen, S.J., H. Li, S. Lu, R.Y. Ni, and J.H. Dong, International Journal of Advanced Manufacturing Technology, 2016. 86(1-4): p. 337-346.

    Article  Google Scholar 

  53. He, J., Z.M. Ling, and H.M. Li, International Journal of Advanced Manufacturing Technology, 2016. 84(9-12): p. 1953-1961.

    Article  Google Scholar 

  54. Ji, S.D., X.C. Meng, Z.W. Li, L. Ma, and S.S. Gao, International Journal of Advanced Manufacturing Technology, 2016. 84(9-12): p. 2391-2399.

    Article  Google Scholar 

  55. Ji, S.D., X.C. Meng, L. Ma, and S.S. Gao, International Journal of Advanced Manufacturing Technology, 2016. 87(9-12): p. 3051-3058.

    Article  Google Scholar 

  56. Papahn, H., P. Bahemmat, and M. Haghpanahi, International Journal of Advanced Manufacturing Technology, 2016. 83(5-8): p. 1003-1012.

    Article  Google Scholar 

  57. Chen, S.J., Y. Zhou, J.R. Xue, R.Y. Ni, Y. Guo, and J.H. Dong, Journal of Materials Engineering and Performance, 2017. 26(3): p. 1337-1345.

    Article  Google Scholar 

  58. Liu, H., X. Liu, X. Wang, T. Wang, and S. Yang, The International Journal of Advanced Manufacturing Technology, 2017. 88(9): p. 3139-3149.

    Article  Google Scholar 

  59. Song, M. and R. Kovacevic, International Journal of Machine Tools & Manufacture, 2003. 43(6): p. 605-615.

    Article  Google Scholar 

  60. Chen, C.M. and R. Kovacevic, International Journal of Machine Tools & Manufacture, 2003. 43(13): p. 1319-1326.

    Article  Google Scholar 

  61. Yadav, D. and R. Bauri, Materials Science and Engineering: A, 2012. 539: p. 85-92.

    Article  Google Scholar 

  62. Rhodes, C.G., M.W. Mahoney, W.H. Bingel, and M. Calabrese, Scripta Materialia, 2003. 48(10): p. 1451-1455.

    Article  Google Scholar 

  63. Su, J.Q., T.W. Nelson, and C.J. Sterling, Materials Science and Engineering a-Structural Materials Properties Microstructure and Processing, 2005. 405(1-2): p. 277-286.

    Article  Google Scholar 

  64. Jata, K.V. and S.L. Semiatin, Scripta Materialia, 2000. 43(8): p. 743-749.

    Article  Google Scholar 

  65. Ericsson, M. and R. Sandstrom, International Journal of Fatigue, 2003. 25(12): p. 1379-1387.

    Article  Google Scholar 

  66. J. Zhang, P. Upadhyay, Y. Hovanski, and D.P. Field: in Friction Stir Welding and Processing IX, Y. Hovanski, et al., Editors. 2017, Springer International Publishing: Cham. p. 125–35.

  67. Ahmed, M.M.Z., B.P. Wynne, W.M. Rainforth, and P.L. Threadgill, Materials Characterization, 2012. 64: p. 107-117.

    Article  Google Scholar 

  68. Li, Y., L.E. Murr, and J.C. McClure, Materials Science and Engineering a-Structural Materials Properties Microstructure and Processing, 1999. 271(1-2): p. 213-223.

    Article  Google Scholar 

  69. Sato, Y.S., H. Kokawa, M. Enomoto, and S. Jogan, Metallurgical and Materials Transactions a-Physical Metallurgy and Materials Science, 1999. 30(9): p. 2429-2437.

    Article  Google Scholar 

  70. Reynolds, A.P., W. Tang, Z. Khandkar, J.A. Khan, and K. Lindner, Science & Technology of Welding & Joining, 2005. 10(2): p. 190-199.

    Article  Google Scholar 

  71. A. Deschamps, Y. Bréchet, P. Guyot, and F. Livet: Metallkd, 1997. 88: p. 601-606.

    Google Scholar 

  72. Du, Z.W., Z.M. Sun, B.L. Shao, T.T. Zhou, and C.Q. Chen, Materials Characterization, 2006. 56(2): p. 121-128.

    Article  Google Scholar 

  73. Stiller, K., P.J. Warren, V. Hansen, J. Angenete, and J. Gjønnes, Materials Science and Engineering: A, 1999. 270(1): p. 55-63.

    Article  Google Scholar 

  74. Z.C. Sun, L.S. Zheng, and H. Yang: Mater. Charact., 2014. 90: p. 71-80.

    Article  Google Scholar 

  75. Mirzadeh, H., Journal of Materials Engineering and Performance, 2015. 24(3): p. 1095-1099.

    Article  Google Scholar 

  76. A. Tabei, D.S. Shih, H. Garmestani, and S.Y. Liang: J. Manuf. Sci. Eng., 2016. 138(7): p. 071010-071010-7.

  77. Upadhyay, P. and A.P. Reynolds, Materials Science and Engineering: A, 2012. 558: p. 394-402.

    Article  Google Scholar 

  78. Wade, M. and A.P. Reynolds, Science and Technology of Welding and Joining, 2010. 15(1): p. 64-69.

    Article  Google Scholar 

  79. R.W Armstrong: Department of Mechanical Engineering University of Maryland College Park. 2016.

  80. Starink, M., A. Deschamps, and S. Wang, Scripta materialia, 2008. 58(5): p. 377-382.

    Article  Google Scholar 

  81. Feng, X., H. Liu, and S.S. Babu, Scripta Materialia, 2011. 65(12): p. 1057-1060.

    Article  Google Scholar 

  82. Chang, C.I., C.J. Lee, and J.C. Huang, Scripta Materialia, 2004. 51(6): p. 509-514.

    Article  Google Scholar 

  83. Li, Y.S., Y. Zhang, N.R. Tao, and K. Lu, Acta Materialia, 2009. 57(3): p. 761-772.

    Article  Google Scholar 

  84. Zener, C. and J.H. Hollomon, Journal of Applied Physics, 1944. 15(1): p. 22-32.

    Article  Google Scholar 

  85. Y. Morisada, T. Imaizumi, and H. Fujii, Scr. Mater., 2015. 106: p. 57-60.

    Article  Google Scholar 

  86. Deng, Y., Z. Yin, and J. Huang, Materials Science and Engineering: A, 2011. 528(3): p. 1780-1786.

    Article  Google Scholar 

  87. Cerri, E., E. Evangelista, A. Forcellese, and H.J. McQueen, Materials Science and Engineering: A, 1995. 197(2): p. 181-198.

    Article  Google Scholar 

  88. Schneider, J., R. Stromberg, P. Schilling, B. Cao, W. Zhou, J. Morfa, and O. Myers. Vol. 92. 2013. 11S-19S.

    Google Scholar 

  89. Ahmed, M., B. Wynne, W. Rainforth, and P. Threadgill, Scripta Materialia, 2008. 59(5): p. 507-510.

    Article  Google Scholar 

  90. Fonda, R.W., K.E. Knipling, and D.J. Rowenhorst, JOM, 2013. 66(1): p. 149-155.

    Article  Google Scholar 

  91. Woo, W., H. Choo, D.W. Brown, P.K. Liaw, and Z. Feng, Scr. Mater., 2006. 54(11): p. 1859-1864.

    Article  Google Scholar 

  92. Sato, Y.S., H. Kokawa, K. Ikeda, M. Enomoto, S. Jogan, and T. Hashimoto, Metallurgical and Materials Transactions a-Physical Metallurgy and Materials Science, 2001. 32(4): p. 941-948.

    Article  Google Scholar 

  93. Xu, S., X. deng, A.P. Reynolds, and T.U. Seidel, Science and Technology of Welding and Joining, 2001. 6(3): p. 191-193.

    Article  Google Scholar 

  94. Schmidt, H.N.B., T.L. Dickerson, and J.H. Hattel, Acta Materialia, 2006. 54(4): p. 1199-1209.

    Article  Google Scholar 

  95. Fratini, L., G. Buffa, D. Palmeri, J. Hua, and R. Shivpuri, Science & Technology of Welding & Joining, 2006. 11(4): p. 412-421.

    Article  Google Scholar 

  96. Schneider, J., S. Brooke, and A.C. Nunes, Metallurgical and Materials Transactions B, 2016. 47(1): p. 720-30.

    Article  Google Scholar 

  97. N. Dialami, M. Chiumenti, M. Cervera, C. Agelet de Saracibar, and J.P. Ponthot: Int. J. Mater. Form., 2015. 8(2): p. 167–81.

  98. D.P. Field, T.W. Nelson, Y. Hovanski, and K.V. Jata: Metall. Mater. Trans. A, 2001. 32(11): p. 2869-2877.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical and Materials Engineering, Washington State University, Pullman, WA, 99164, USA

    Jingyi Zhang & David P. Field

  2. Pacific Northwest National Laboratory, Richland, WA, 99354, USA

    Piyush Upadhyay

  3. Brigham Young University, Provo, UT, 84602, USA

    Yuri Hovanski

Authors
  1. Jingyi Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Piyush Upadhyay
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yuri Hovanski
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. David P. Field
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jingyi Zhang.

Additional information

Manuscript submitted May 18, 2017.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, J., Upadhyay, P., Hovanski, Y. et al. High-Speed Friction Stir Welding of AA7075-T6 Sheet: Microstructure, Mechanical Properties, Micro-texture, and Thermal History. Metall Mater Trans A 49, 210–222 (2018). https://doi.org/10.1007/s11661-017-4411-4

Download citation

  • Received:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11661-017-4411-4

Search

Navigation