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Microstructure of Friction Stir Welded AlSi9Mg Cast with 5083 and 2017A Wrought Aluminum Alloys

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Abstract

Wrought aluminum alloys 5083 and 2017A were each joined with cast aluminum alloy AlSi9Mg through friction stir welding in butt weld configurations. For each material system, the wrought and cast alloy positions, i.e., the advancing side or the retreating side, were exchanged between welding trials. The produced weldments were free from cracks and discontinuities. For each alloy configuration, a well-defined nugget comprised of alternating bands of the welded alloys characterized the microstructure. The degree of mixing, however, strongly depended on which wrought alloy was present and on its position during processing. In all cases, the cast AlSi9Mg alloy dominated the weld center regardless of its position during welding. Electron backscattered diffraction analysis showed that the grain size in both alloys (bands) constituting the nugget was similar and that the majority of grain boundaries exhibited a high angle character (20°-60°). Regardless of the alloy, however, all grains were elongated along the direction of the material plastic flow during welding. A numerical simulation of the joining process visualized the material flow patterns and temperature distribution and helped to rationalize the microstructural observations. The hardness profiles across the weld reflected the microstructure formed during welding and correlated well with the temperature changes predicted by the numerical model. Tensile specimens consistently fractured in the cast alloy near the weld nugget.

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Acknowledgment

This work was supported by the Polish National Science Center, Grant No. 2013/11/B/ST8/04409.

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Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, College of Engineering and Computing, Miami University, Oxford, OH, USA

    C. Hamilton

  2. Faculty of Metal Engineering and Industrial Computer Science, AGH University of Science and Technology, Kraków, Poland

    M. Kopyściański & S. Dymek

  3. Polish Welding Centre of Excellence, 16 – 18 Bł. Czesława Street, Gliwice, Poland

    A. Węglowska & A. Pietras

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  1. C. Hamilton
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  2. M. Kopyściański
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  4. A. Węglowska
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  5. A. Pietras
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Correspondence to C. Hamilton.

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Hamilton, C., Kopyściański, M., Dymek, S. et al. Microstructure of Friction Stir Welded AlSi9Mg Cast with 5083 and 2017A Wrought Aluminum Alloys. J. of Materi Eng and Perform 27, 1185–1193 (2018). https://doi.org/10.1007/s11665-018-3177-1

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  • DOI: https://doi.org/10.1007/s11665-018-3177-1

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