Engineering Transactions, 64, 3, pp. 301-309, 2016

The Effect of Process Parameters on Residual Stress in a Friction Stir Processed Cast Aluminium Alloy AlSi9Mg

Marek Stanislaw WĘGLOWSKI
Institute of Welding
Poland

Piotr SĘDEK
Institute of Welding
Poland

Carter HAMILTON
Miami University, College of Engineering and Computing
United States

The effect of friction stir processing (FSP) on residual stress in a modified cast aluminium alloy AlSi9Mg is presented. The influence of rotational speed and tool type were analysed. The trepanation method was utilized to experimentally measure the residual stress. The results indicate that an increase in rotational speed causes an increase in residual stress. The region around the FSP bead was characterised by tensile residual stress fields which were balanced by compressive stresses in the parent material. A higher residual stress was observed on the advancing side than on the retreating side. Moreover, this asymmetry in residual stress distribution is due to the asymmetry in the volume of material plasticized along the advancing and retreating sides of the stir zone, generating the observed heat distribution. A higher level of residual stress was achieved with the Triflute tool than with a conventional tool.
Keywords: cast aluminium alloy AlSi9Mg; friction stir processing; residual stress
Full Text: PDF

References

Ciućka T., Influence of vibration during crystallization on mechanical properties and porosity of EN AC –AlSI17 Alloy, Archives of Foundry Engineering, 13(1): 5–18, 2013.

Zyska A., Konopka Z., Łągiewka M., Nadolski M., Optimization of squeeze parameters and modification of AlSi7Mg alloy, Archives of Foundry Engineering, 13(2): 113–116, 2013.

Wrobel T., Szajnar J., Modification of pure al and AlSi2 alloy primary structure with use of electromagnetic stirring method, Archives of Metallurgy and Materials, 58(3): 941–944, 2013.

Węglowski M.St., Microstructure of cast aluminium alloy AlSi9Mg after FSP process, Archives of Foundry Engineering, 14(3): 75–78, 2014.

Węglowski M. St., Dymek S., Friction stir processing of an AlSi6Cu4 cast aluminium alloy, Archives of Foundry Engineering, 11(2): 213–217, 2011.

Węglowski M.St., Dymek S., Microstructural modification of cast aluminium alloy AlSi9Mg via friction modified processing, Archives of Metallurgy and Materials, 57(1): 71–78, 2012.

Darras B.M., Khraisheh M.K., et al., Friction stir processing of commercial AZ31 magnesium alloy, Journal of Materials Processing Technology, 191: 77–81, 2007.

Węglowski M.St., Pietras A., Friction stir processing – analysis of the process, Archives of Metallurgy and Materials, 56: 779–788, 2011.

Węglowski M.St., Dymek S., Hamilton C., Experimental investigation and modelling of friction stir processing of cast aluminium alloy AlSi9Mg, Bulletin of the Polish Academy of Sciences-Technical Sciences, 61: 893–904, 2013.

Węglowski M.St., Kwieciński K., Krasnowski K., Jachym R., Characteristics of Nd: YAG laser welded joints of dual phase steel, Archives of Civil and Mechanical Engineering, 9(4): 85–97, 2009.

Hamilton C., Węglowski M.St., Dymek S., Sedek P., Using a coupled thermal/material flow model to predict residual stress in friction stir processed AlMg9Si, Journal of Materials Engineering and Performance, 24: 1305–1312, 2015.

Sadeghi S., Najafabadi M.A., et al., Using ultrasonic waves and finite element method to evaluate through-thickness residual stresses distribution in the friction stir welding of aluminium plates, Materials & Design, 52,: 870–880, 2013.

Liu Ch., Yi X., Residual stress measurement on AA6061-T6 aluminium alloy friction stir butt welds using contour method, Materials and Design, 46: 366–371, 2013.

Ghidini T., Vugrin T., Dalle Donne C., Residual stresses, defects and non-destructive evaluation of FSW joints, Welding International, 19(10): 783–790, 2005.

Woo W., Choo H., Brown D.W., Feng Z., Liaw P.K., Angular distortion and through-thickness residual stress distribution in the friction-stir processed 6061-T6 aluminium alloy, Materials Science and Engineering A, 437(1): 64–69, 2006.

Peel M., Steuwer A., Preuss M., Withers P.J., Microstructure, mechanical properties and residual stresses as a function of welding speed in aluminium AA5083 friction stir welds, Acta Materialia, 51(16): 4791–4801, 2003.

Węglowski M.St., Sedek P., Hamilton C., Experimental and numerical analysis of residual stress in cast aluminium alloy after FSP process, Key Engineering Materials, 682: 18–23, 2016.

Hamilton C., Kopyściański M., Senkov O., Dymek S., A coupled thermal/material flow model of friction stir welding applied to Sc-modified aluminium alloys, Metallurgical and Materials Transactions A, 44: 1730–1740, 2013.

Kishta E.E.M., Abed F.H., Darras B.M., Nonlinear finite element simulation of friction stir processing of marine grade 5083 aluminium alloy, Engineering Transactions, 62(4): 313–328, 2014.

Hamilton C., Sommers A., Dymek S., A thermal model of friction stir welding applied to Sc-modified Al–Zn–Mg–Cu alloy extrusions, International Journal of Machine Tools & Manufacture, 49: 230–238, 2009.




Copyright © 2014 by Institute of Fundamental Technological Research
Polish Academy of Sciences, Warsaw, Poland