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Acta Metall Sin  2019, Vol. 55 Issue (1): 149-159    DOI: 10.11900/0412.1961.2018.00220
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Fatigue Behavior of Friction Stir Welded SiCp/6092Al Composite
Chen WANG1,2, Beibei WANG2,3, Peng XUE2(), Dong WANG2, Dingrui NI2, Liqing CHEN1, Bolü XIAO2, Zongyi MA2
1 State Key Laboratory of Rolling and Automation, Northeastern University, Shenyang 110819, China
2 Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, Chinal
3 School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
Cite this article: 

Chen WANG, Beibei WANG, Peng XUE, Dong WANG, Dingrui NI, Liqing CHEN, Bolü XIAO, Zongyi MA. Fatigue Behavior of Friction Stir Welded SiCp/6092Al Composite. Acta Metall Sin, 2019, 55(1): 149-159.

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Abstract  

Al matrix composites (AMCs) have been used in the aerospace and automotive industries due to the desirable properties including high specific strength, superior wear resistance and low thermal expansion. However, the traditional fusion welding process of AMCs usually brings defects such as pores, particles segregation and detrimental phases, which limits the application of AMCs. So more and more attentions are paied on friction stir welding (FSW), a solid state welding method possessing great potential in the welding of AMCs. In this work, to acquire high quality and excellent fatigue property of friction stir welded SiCp/6092Al composite joint, 3 mm-thick rolled SiCp/6092Al composite plates with T6 state were conducted by FSW at a constant rotational rate of 1000 r/min, and at a low welding speed of 50 mm/min and a high welding speed of 800 mm/min, respectively. Microstructure evolution, mechanical properties and high cycle fatigue behavior of the FSW joints were evaluated. The results showed that high welding speed resulted in a much rougher surface of scale-like ripple and the morphology of the nugget zone was different from that of the joint at low welding speed. Significant enhancement of the hardness and tensile strength were achieved in the joints at the high welding speed, but the fatigue properties were not improved for the joints with unpolished surfaces. The fatigue limit of the joint at low welding speed was 150 MPa, however the fatigue limit reduced to 140 MPa at the high welding speed. For the joints with polished surfaces, obviously enhanced fatigue limit was achieved at the high welding speed of 800 mm/min compared to that of the joint at the low welding speed of 50 mm/min. Different fracture characteristics were observed in the specimens with unpolished surfaces at various cyclic stress loading. Under a low cyclic stress loading, crack initiated at the scale-like ripple on the surface of the specimen; under a high cyclic stress loading, crack also initiated at the scale-like ripple at the low welding speed, while the crack initiated at the swirl zone in the bottom of the nugget zone at the high welding speed. The results of three-dimension surface topography showed that a large surface roughness was achieved on the surface of the joint at the high welding speed, resulting in lower fatigue limit compared to that of the joint at the low welding speed. For the specimens with polished surfaces, the fatigue limit was improved by 40~65 MPa compared to that of the specimens with unpolished surfaces. In this case, a high fatigue limit of 205 MPa was obtained in the joint at the high welding speed of 800 mm/min, and all the specimens failed at the lowest hardness zone and nearby.

Key words:  aluminum matrix composite      friction stir welding      high welding speed      high cycle fatigue     
Received:  22 May 2018     
ZTFLH:  TB333  
Fund: Supported by National Key Research and Development Program of China (No.2017YFB0703104) and National Natural Science Foundation of China (Nos.U1508216, 51331008 and 51671191)

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2018.00220     OR     https://www.ams.org.cn/EN/Y2019/V55/I1/149

Fig.1  Surface topographies (a, b) and cross sectional macrostructures (c, d) of friction stir welding (FSW) joints at the welding speeds of 50 mm/min (a, c) and 800 mm/min (b, d) (NZ—nugget zone, SDZ—shoulder deformation zone, PDZ—pin deformation zone, RS—retreating side, AS—advancing side)
Fig.2  Microstructures of base material (BM) (a) and FSW joints in the NZ at the welding speeds of 50 mm/min (b) and 800 mm/min (c)
Fig.3  Microhardness distributions of FSW joint in the cross section at the welding speeds of 50 mm/min (a) and 800 mm/min (b)
Sample Yield strength MPa Ultimate tensile strength / MPa Elongation
%
Joint efficiency
%
Fracture location
1000-50 236±3 310±3 5.5±0.3 63 LHZ
1000-800 262±3 355±5 3.8±0.5 72 LHZ
BM 413±3 490±2 8.0±0.5 - -
Table 1  Tensile properties and fracture locations of FSW joints
Fig.4  S-N curves of BM (a) and FSW joints (b) for unpolished specimens (σmax—maximum stress, 2Nf—cycles to failure)
Fig.5  Fracture locations of unpolished specimens at different maximum stresses and the welding speeds of 50 mm/min (a) and 800 mm/min (b)
Fig.6  Macro morphology of fracture (a) and magnified images of regions A (b), B (c) and C (d) in Fig.6a of unpolished specimen at the welding speed of 50 mm/min and maximum stress of 150 MPa
Fig.7  Macro morphologies of fractured samples (a, c) and corresponding magnified images of crack sources (region A) (b, d) of unpolished specimen at the welding speed of 800 mm/min and maximum stresses of 150 MPa (a, b) and 220 MPa (c, d)
Fig.8  S-N curves for polished specimens
Fig.9  Morphologies of polished specimens after fatigue tests at the welding speeds of 50 mm/min (a) and 800 mm/min (b)
Fig.10  SEM fractographs of polished specimens showing different crack initiation sites
(a) lateral (b) corner (c) top or bottom (d) magnified image of region A in Fig.10a
Fig.11  SEM fractographs along the fatigue loading direction of polished specimens at the welding speeds and stresses of 50 mm/min, 220 MPa (a) and 800 mm/min, 220 MPa (b)
Fig.12  Surface profiles of FSW welds at the welding speed of 50 mm/min (a) and 800 mm/min (b) (2b— peak-to-peak distance, a—depth of defect)
Sample 2b / μm a (Ra) / μm H / HV Predicted fatigue limit MPa Experimental fatigue limit / MPa
1000-50 42.74 12.37 105 146 150
1000-800 821.28 26.12 120 138 140
Table 2  Comparision of predicted and experimental fatigue limits
Fig.13  Schematics for position of stir tool (a) and metal flow pattrens (b) during FSW
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