Predicting Tensile Properties of Friction-Stir-Welded 6063 Aluminum with Experimentally Measured Welding Heat Input

doi:10.1007/s40195-020-01099-9

Abstract

Abstract:

This work aims to develop a reliable method to predict mechanical properties of friction-stir-welded 6xxx-series alloys with experimentally measured welding heat input. A calorimetrical method was utilized to experimentally measure the welding heat input in the friction stir welded of aluminum alloy 6063-T5. Good correlations between the input variables, i.e., welding parameters and physical properties of the materials, and the welding heat inputs obtained with experimental measurements were discovered. The welding heat input can be predicted using the empirical equation derived based on these correlations. Moreover, the results suggested that the thermal conductivities of the welded alloys affected the welding heat input significantly. Mechanical properties, including hardness and tensile properties, of friction-stir-welded aluminum alloy 6063 were in good correlation to the heat input obtained with experimental measurement. These correlations were explained by the evolution of the strengthening precipitates during welding. This work proposed a reliable new route to predict these mechanical responses through the estimation of heat input.

Key words: Heat input, Friction stir welding, Calorimetrical, Mechanical properties, Hardness

Tianbo Zhao, Yutaka S. Sato, Hiroyuki Kokawa, Kazuhiro Ito. Predicting Tensile Properties of Friction-Stir-Welded 6063 Aluminum with Experimentally Measured Welding Heat Input[J]. Acta Metallurgica Sinica (English Letters), 2020, 33(9): 1235-1242.

Figures/Tables 9

Fig. 1 Schematic illustration of the apparatus used for heat-input measurement

Table 1 Chemical compositions and physical properties of the materials

Name	Chemical compositions (wt%)								Material	C	λ	σ
AA	Si	Fe	Cu	Mn	Mg	Ti
6063	0.48	0.20	0.02	0.03	0.52	0.01			6063-T5	900	209	145
AA	Cr	Cu	Fe	Mg	Mn	Si	Ti	Zn	5083-O	900	117	145
5083	0.15	0.10	0.40	4.5	0.7	0.4	0.15	0.25	1100-O	904	222	25
AA	Cu	Mn	Ti	Zn	Si + Fe	Be			Water	4182	0.6
1100	0.15	0.05	0.95	0.05	0.1	0.001			Copper	385	401

Fig. 2 Illustration of tensile specimens and locations of hardness test (shown with spot dash)

Fig. 3 Effects of rotational speed and travel speed on the heat input in AA6063

Fig. 4 Effect of material type on the heat input of friction-stir-welded AA1100, AA5083 and AA6063 (travel speed: 300 mm min-1)

Fig. 5 Graphical illustration of the empirical relationship between the input variables and the measured heat input

Fig. 6 Hardness profiles of AA6063 friction stir welded at different heat inputs

Fig. 7 a Typical samples of fracture locations of friction stir welds produced at various welding heat inputs; b relationship between yield strength and hardness of the softest region

Fig. 8 Mechanical responses to the welding heat input in the friction-stir-welded AA6063

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