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Cladding and Butt-Joining Dissimilar Aluminum Alloys Simultaneously via Shear Assisted Processing and Extrusion

  • Solid-state Processing of Light Alloys
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Abstract

Shear assisted processing and extrusion has been used to fabricate multi-metallic tubing that incorporates regions with clad and butt-joined structures. In this work, aluminum alloys 6061, 7075, and 1100 are combined to create a monolithic extruded tubing with weldable ends (6061), a high strength center (7075), and a corrosion-resistant cladding (1100). Optical microscopy shows a gradual, defect-free, transition between alloys at the butt-joint interfaces and a sharp transition between alloys at the clad interface. Tensile testing proved the mechanical coherency of the joint, with failure occurring outside the tri-metallic structure. Smoothed particle hydrodynamic simulations identified a spiral pattern of the cladding alloy that leads to inconsistent cladding thickness, and identified a simplified 2-alloy combination of aluminum alloys 6082 and 2014 that accomplished the design objectives of the tri-metallic structure.

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Acknowledgements

This research was supported by the Solid Phase Processing Science Initiative, under the Laboratory Directed Research and Development (LDRD) Program at Pacific Northwest National Laboratory (PNNL). PNNL is a multi-program national laboratory operated for the U.S. Department of Energy (DOE) by Battelle Memorial Institute under Contract No. DE-AC05-76RL01830. The authors thank B. Scott Taysom and Jorge F. dos Santos for reviewing this manuscript.

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Authors and Affiliations

  1. Pacific Northwest National Laboratory, Richland, WA, USA

    Brian K. Milligan, Lei Li, Mageshwari Komarasamy, Timothy Roosendaal, Ayoub Soulami & Scott Whalen

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  1. Brian K. Milligan
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  2. Lei Li
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Milligan, B.K., Li, L., Komarasamy, M. et al. Cladding and Butt-Joining Dissimilar Aluminum Alloys Simultaneously via Shear Assisted Processing and Extrusion. JOM 75, 3033–3040 (2023). https://doi.org/10.1007/s11837-023-05855-x

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