Friction Stir Welding of Discontinuously Reinforced Aluminum Matrix Composites: A Review

doi:10.1007/s40195-014-0143-2

Abstract

Abstract:

Friction stir welding (FSW) is considered a promising welding technique for joining the aluminum matrix composites (AMCs) to avoid the drawbacks of the fusion welding. High joint efficiencies of 60%-100% could be obtained in the FSW joints of AMCs. However, due to the existence of hard reinforcing particles in the AMCs, the wearing of welding tool during FSW is an unavoidable problem. Moreover, the low ductility of the AMCs limits the welding process window. As the hard materials such as Ferro-Titanit alloy, cermet, and WC/Co were applied to produce the welding tools, the wearing of the tools was significantly reduced and the sound joints could be achieved at high welding speed for the AMCs with low reinforcement volume fraction. In this article, current state of understanding and development of welding tool wearing and FSW parameters of AMCs are viewed. Furthermore, the factors affecting the microstructure and mechanical properties of the joints are evaluated in detail.

Key words: Metal matrix composite, Friction stir welding, Particle, microstructure, Wear

Wang D., L. Xiao B., R. Ni D., Y. Ma Z.. Friction Stir Welding of Discontinuously Reinforced Aluminum Matrix Composites: A Review[J]. Acta Metallurgica Sinica (English Letters), 2014, 27(5): 816-824.

Figures/Tables 9

References 46

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Materials	Rotation rate (r/min)	Welding speed (mm/min)	Tool material	Wearing of tool	Welding distance (mm)
15 vol% B4Cp/6061Al [15]	670	114	H13 tool steel	Serious	254
20 vol% Al2O3p/6061Al [16]	500-2,000	60	Standard tool steel	Serious	310
15 vol% SiCp/2009Al [17]	600	50	H13 tool steel	Serious	-
20 vol% SiCp/A359 [18]	1,000	180-540	Standard tool steel	Serious	610
15 vol% SiCp/A356 [19]	1,200	30	D2 tool steel	-	60
25 vol% SiCp/2,009Al [20]	800	120	TiAlN-coated HSS-steel	-	-
10 vol% Al2O3p/7005Al [12]	600	300	Ferro-Titanit alloy	-	-
30 vol% SiCp/AC4A Al [21]	1,500-2,000	25-150	WC-Co hard alloy	Normal	240
30 vol% SiCp/A359 [14]	1,000	76	WC-Co hard alloy	Normal	1320

Materials	Rotation rate (r/min)	Welding speed (mm/min)	Tool material	Wearing of tool	Welding distance (mm)
15 vol% B4Cp/6061Al [15]	670	114	H13 tool steel	Serious	254
20 vol% Al2O3p/6061Al [16]	500-2,000	60	Standard tool steel	Serious	310
15 vol% SiCp/2009Al [17]	600	50	H13 tool steel	Serious	-
20 vol% SiCp/A359 [18]	1,000	180-540	Standard tool steel	Serious	610
15 vol% SiCp/A356 [19]	1,200	30	D2 tool steel	-	60
25 vol% SiCp/2,009Al [20]	800	120	TiAlN-coated HSS-steel	-	-
10 vol% Al2O3p/7005Al [12]	600	300	Ferro-Titanit alloy	-	-
30 vol% SiCp/AC4A Al [21]	1,500-2,000	25-150	WC-Co hard alloy	Normal	240
30 vol% SiCp/A359 [14]	1,000	76	WC-Co hard alloy	Normal	1320

Materials	Plate thickness (mm)	Rotation rate (r/min)	Welding speed (mm/min)	BM condition	YS (MPa)	UTS (MPa)	El (%)	Joint eff. (%)
22 vol% Al₂O₃p/6061 [35]	4	880	260	Cast	-	217	-	99
10 vol% TiB₂/Al [25]	6	2,000	30	Cast	-	223-282	3.4-6.7	79-99
15 vol% Mg₂Si/Al [36]	6	1,120	125	Cast	-	115	-	100
10 wt% ZrB₂/6061 [37]	6	1,150	50	Cast	-	240	1	95
20 wt% AlNp/6061 [38]	6	1,200	55	Cast	-	225	-	93
10 vol% SiCp/6061 [39]	6	1,100	45	Cast	126	206	6.8	74
10 vol% Al₂O₃p/7005 [12]	7	600	300	Extruded + T6	263	299	1.2	82
10 vol% Al₂O₃p/7005 [40]	7	800	56	T6	245	260	0.58	84
20 vol% Al₂O₃p/6061 [40]	7	800	56	T6	280	329	1.3	87
20 vol% Al₂O_3p/6061 [28]	7	-		Extruded + T6	234	251	-	70
20 vol% Al₂O₃p/6061 [41]	7	-		Extruded + T6	193	262	2.8	72
6 vol% B₄C/6063 [42]	4.5	1,500	600	Extruded + T5	125	172	2.5	62
10.5 vol% B₄C/6063 [42]	4.5	1,500	600	Extruded +T5	125	176	2.5	62
25 vol% SiCp/2124 [43]	15	550	75	Forged + T6	407	552	2.6	74.4
17 vol% SiCp/2009 [44]	3	1,000	50	Rolled + T351	278	443	4.7	77
17 vol% SiCp/2009 [13]	3	1,000	800	Rolled + T4	341	501	3.5	97

Materials	Plate thickness (mm)	Rotation rate (r/min)	Welding speed (mm/min)	BM condition	YS (MPa)	UTS (MPa)	El (%)	Joint eff. (%)
22 vol% Al₂O₃p/6061 [35]	4	880	260	Cast	-	217	-	99
10 vol% TiB₂/Al [25]	6	2,000	30	Cast	-	223-282	3.4-6.7	79-99
15 vol% Mg₂Si/Al [36]	6	1,120	125	Cast	-	115	-	100
10 wt% ZrB₂/6061 [37]	6	1,150	50	Cast	-	240	1	95
20 wt% AlNp/6061 [38]	6	1,200	55	Cast	-	225	-	93
10 vol% SiCp/6061 [39]	6	1,100	45	Cast	126	206	6.8	74
10 vol% Al₂O₃p/7005 [12]	7	600	300	Extruded + T6	263	299	1.2	82
10 vol% Al₂O₃p/7005 [40]	7	800	56	T6	245	260	0.58	84
20 vol% Al₂O₃p/6061 [40]	7	800	56	T6	280	329	1.3	87
20 vol% Al₂O_3p/6061 [28]	7	-		Extruded + T6	234	251	-	70
20 vol% Al₂O₃p/6061 [41]	7	-		Extruded + T6	193	262	2.8	72
6 vol% B₄C/6063 [42]	4.5	1,500	600	Extruded + T5	125	172	2.5	62
10.5 vol% B₄C/6063 [42]	4.5	1,500	600	Extruded +T5	125	176	2.5	62
25 vol% SiCp/2124 [43]	15	550	75	Forged + T6	407	552	2.6	74.4
17 vol% SiCp/2009 [44]	3	1,000	50	Rolled + T351	278	443	4.7	77
17 vol% SiCp/2009 [13]	3	1,000	800	Rolled + T4	341	501	3.5	97