Skip to main content
SpringerLink
Log in

Effect of Various Welding Parameters on Corrosion Behavior of Friction-Stir-Welded AA 7075-T651 Alloys

  • Technical Article
  • Published:
Metallography, Microstructure, and Analysis Aims and scope Submit manuscript

Abstract

The 7000 series aluminum alloys provide the highest strength of all aluminum alloys and are widely used in the aerospace industries. They are practically unweldable by conventional fusion welding techniques. Friction stir welding is a widely accepted process to join this material. The paper intends to evaluate the electrochemical behavior of friction-stir-welded AA 7075-T651 alloy under varying welding conditions. An attempt has been made to evaluate the effect of tool rotation speed, welding speed, and shoulder diameter on its corrosion characteristics. The temperature histories during welding were continuously recorded with the help of thermocouples. The corrosion characteristics have been examined as per ASTM G-34 standards. The analysis is done by immersing the plates in EXCO solution and analyzing through optical imaging, SEM and TEM. The analysis revealed that the heat-affected zone was found to be most susceptible to corrosion. The corrosion resistance is found in the order—weld nugget > unwelded base metal > HAZ. The experiments revealed that the corrosion resistance of the welded plates is directly proportional to the heat input during the welding process. The plates welded with lower tool rotation speed, higher welding speed, and lower shoulder diameter exhibited higher corrosion resistance.

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
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22

Similar content being viewed by others

References

  1. S. Rajakumar, C. Muralidharan, V. Balasubramanian, Influence of friction stir welding process and tool parameters on strength properties of AA7075-T6 aluminium alloy joints. Mater. Des. 32(2), 535–549 (2011)

    Article  Google Scholar 

  2. D.M. Rodrigues, A. Loureiro, C. Leitao, R.M. Leal, B.M. Chaparro, P. Vilaça, Influence of friction stir welding parameters on the microstructural and mechanical properties of AA 6016-T4 thin welds. Mater. Des. 30(6), 1913–1921 (2009)

    Article  Google Scholar 

  3. A.H. Feng, D.L. Chen, Z.Y. Ma, Microstructure and cyclic deformation behavior of a friction-stir-welded 7075 Al alloy. Metall. Mater. Trans. A 41(4), 957–971 (2010)

    Article  Google Scholar 

  4. B.T. Gibson, D.H. Lammlein, T.J. Prater, W.R. Longhurst, C.D. Cox, M.C. Ballun, K.J. Dharmaraj, G.E. Cook, A.M. Strauss, Friction stir welding: Process, automation, and control. J. Manuf. Process. 16(1), 56–73 (2014)

    Article  Google Scholar 

  5. R.K. Gupta, P. Ramkumar, B.R. Ghosh, Investigation of internal cracks in aluminium alloy AA7075 forging. Eng. Fail. Anal. 13(1), 1–8 (2006)

    Article  Google Scholar 

  6. H.K. Rafi, G.D.J. Ram, G. Phanikumar, K.P. Rao, Microstructure and tensile properties of friction welded aluminum alloy AA7075-T6. Mater. Des. 31(5), 2375–2380 (2010)

    Article  Google Scholar 

  7. M.W. Mahoney, C.G. Rhodes, J.G. Flintoff, W.H. Bingel, R.A. Spurling, Properties of friction-stir-welded 7075 T651 aluminum. Metall. Mater. Trans. A 29(7), 1955–1964 (1998)

    Article  Google Scholar 

  8. M. Selvaraj, M. Vela, S.R. Koteswara Rao, Mechanism of weld formation during friction stir welding of aluminum alloy. Mater. Manuf. Process. 28(5), 595–600 (2013)

    Article  Google Scholar 

  9. K. Deepandurai, R. Parameshwaran, Multiresponse optimization of FSW parameters for cast AA7075/SiCp composite. Mater. Manuf. Processes 31(10), 1333–1341 (2016)

    Article  Google Scholar 

  10. K.V. Jata, S.L. Semiatin, Continuous dynamic recrystallization during friction stir welding of high strength aluminum alloys. Scr. Mater. 43(8), 743–749 (2000)

    Article  Google Scholar 

  11. C.G. Rhodes, M.W. Mahoney, W.H. Bingel, R.A. Spurling, C.C. Bampton, Effects of friction stir welding on microstructure of 7075 aluminum. Scr. Mater. 36(1), 69–75 (1997)

    Article  Google Scholar 

  12. P.L. Threadgill, A.J. Leonard, H.R. Shercliff, P.J. Withers, Friction stir welding of aluminium alloys. Int. Mater. Rev. 54(2), 49–93 (2009)

    Article  Google Scholar 

  13. A.O. Mosleh, F.H. Mahmoud, T.S. Mahmoud, T.A. Khalifa, Microstructure and static immersion corrosion behavior of AA7020-O Al plates joined by friction stir welding. Proc. Inst. Mech. Eng. L J. Mater. Des. Appl. 230(6), 1030–1040 (2015)

    Google Scholar 

  14. A. Behnagh, G. Besharati, M. Akbari, Mechanical properties, corrosion resistance, and microstructural changes during friction stir processing of 5083 aluminum rolled plates. Mater. Manuf. Process. 27(6), 636–640 (2012)

    Article  Google Scholar 

  15. D.A. Dragatogiannis, E.P. Koumoulos, I. Kartsonakis, D.I. Pantelis, P.N. Karakizis, C.A. Charitidis, Dissimilar friction stir welding between 5083 and 6082 Al alloys reinforced with TiC nanoparticles. Mater. Manuf. Process. 31(16), 2101–2114 (2016)

    Article  Google Scholar 

  16. J.B. Lumsden, M.W. Mahoney, G. Pollock, C.G. Rhodes, Intergranular corrosion following friction stir welding of aluminum alloy 7075-T651. Corrosion 55(12), 1127–1135 (1999)

    Article  Google Scholar 

  17. F.M. Khoshnaw, R.H. Gardi, Effect of aging time and temperature on exfoliation corrosion of aluminum alloys 2024-T3 and 7075-T6. Mater. Corros. 58(5), 345–347 (2007)

    Article  Google Scholar 

  18. T. Venugopal, K. Srinivasa Rao, K. Prasad Rao, Studies on friction stir welded AA 7075 aluminium alloy. Trans. Indian Inst. Met. 57(6), 659–663 (2004)

    Google Scholar 

  19. F. Andreatta, H. Terryn, J.H.W. de Wit, Corrosion behaviour of different tempers of AA7075 aluminium alloy. Electrochim. Acta 49(17–18), 2851–2862 (2004)

    Article  Google Scholar 

  20. C.S. Paglia, M.C. Carroll, B.C. Pitts, T. Reynolds, R.G. Buchheit, Strength, corrosion, and environmentally assisted cracking of a 7075-T6 friction stir weld. Mater. Sci. Forum 396–402, 1677–1684 (2002)

    Article  Google Scholar 

  21. J. Kang, R.-D. Fu, G.-H. Luan, C.-L. Dong, M. He, In-situ investigation on the pitting corrosion behavior of friction stir welded joint of AA2024-T3 aluminium alloy. Corros. Sci. 52(2), 620–626 (2010)

    Article  Google Scholar 

  22. Rajesh, S., Badheka, V.J.: Effect of friction stir lap weld and post weld heat treatment on corrosion behavior of dissimilar aluminum alloys, in Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 1464420717692150 (2017)

  23. G. Elatharasan, V.S. Senthil Kumar, Corrosion analysis of friction stir-welded AA 7075 Aluminium Alloy. J. Mech. Eng. 60(1), 29–34 (2014)

    Article  Google Scholar 

  24. I.J. Polmear, Light Alloys—Metallurgy of the light metals, 3rd edn. (Arnold Publishers, London, 1995)

    Google Scholar 

  25. C.S. Paglia, R.G. Buchheit, A look in the corrosion of aluminum alloy friction stir welds. Scr. Mater. 58(5), 383–387 (2008)

    Article  Google Scholar 

  26. W. Tian, S. Li, B. Wang, J. Liu, M. Yu, Pitting corrosion of naturally aged AA 7075 aluminum alloys with bimodal grain size. Corros. Sci. 113, 1–16 (2016)

    Article  Google Scholar 

  27. A. Chemin, D. Marques, L. Bisanha, A.D.J. Motheo, W.W. Bose Filho, C.O.F. Ruchert, Influence of Al7Cu2Fe intermetallic particles on the localized corrosion of high strength aluminum alloys. Mater. Des. 53, 118–123 (2014)

    Article  Google Scholar 

  28. S. Rajesh, V. Badheka, Influence of heat input/multiple passes and post weld heat treatment on strength/electrochemical characteristics of friction stir weld joint. Mater. Manuf. Process. 33(2), 156–164 (2018)

    Article  Google Scholar 

  29. K.D. Ralston, N. Birbilis, C.H.J. Davies, Revealing the relationship between grain size and corrosion rate of metals. Scr. Mater. 63(12), 1201–1204 (2010)

    Article  Google Scholar 

  30. K. Srinivasa Rao, K. Prasad Rao, Pitting corrosion of heat-treatable aluminium alloys and welds: a review. Trans. Indian Inst. Met. 57(6), 593–610 (2004)

    Google Scholar 

Download references

Acknowledgements

The writers would sincerely like to thank Indian Space Research Organisation (ISRO), India, for the monetary assistance given through a R&D Project No. E33011/60/2010-V. Authors would like to thank Pandit Deendayal Petroleum University (PDPU), Gandhinagar, India, for their help in providing a platform for conducting the experimental work required for the investigation.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Technology, Charusat University, Changa, Gujarat, 388421, India

    Pratik H. Shah

  2. Sardar Vallabhbhai Patel Institute of Technology (SVIT), Vasad, Gujarat, 388306, India

    Pratik H. Shah

  3. Department of Mechanical Engineering, School of Technology, Pandit Deendayal Petroleum University, Gandhinagar, Gujarat, 382007, India

    Vishvesh Badheka

Authors
  1. Pratik H. Shah
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Vishvesh Badheka
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Pratik H. Shah.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shah, P.H., Badheka, V. Effect of Various Welding Parameters on Corrosion Behavior of Friction-Stir-Welded AA 7075-T651 Alloys. Metallogr. Microstruct. Anal. 7, 308–320 (2018). https://doi.org/10.1007/s13632-018-0440-7

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13632-018-0440-7

Keywords

Search

Navigation