Assessing the Bonding Interface Characteristics and Mechanical Properties of Bobbin Tool Friction Stir Welded Dissimilar Aluminum Alloy Joints

doi:10.1007/s40195-020-01101-4

Abstract

Abstract:

This study focuses on the bonding interface characteristics and mechanical properties of the bobbin tool friction stir welded dissimilar AA6056 and AA2219 aluminum alloy joints using different welding speeds. Voids arise solely in the stir zone at the AA2219 side. A distinct boundary with limited material mixing develops at the middle section of the bonding interface, while excellent material mixing with an irregularly jagged pattern forms at the top and bottom sections of the bonding interface. Increasing the welding speed, the material mixing is rarely changed at the middle section in comparison with the bottom section. Furthermore, a small difference between Guinier-Preston dissolution and Q phase precipitation leads to rare change of hardness in the heat affected zone (HAZ) at the AA6056 side. The increased hardness of the HAZ at the AA2219 side is attributed to avoidance of the dissolution of θ″ phase precipitates. A maximum tensile strength of 181 MPa is obtained at 300 mm min ^-1. Fractures occur at the AA6056 side near the top and bottom surfaces and at the bonding interface in the middle section of the joints. The regions close to the top and bottom surfaces of the joints show a better ductility.

Key words: Bobbin tool friction stir welding, Dissimilar aluminum alloy, Bonding interface, Precipitation, Mechanical property

Quan Wen, Wenya Li, Vivek Patel, Luciano Bergmann, Benjamin Klusemann, Jorge F. dos Santos. Assessing the Bonding Interface Characteristics and Mechanical Properties of Bobbin Tool Friction Stir Welded Dissimilar Aluminum Alloy Joints[J]. Acta Metallurgica Sinica (English Letters), 2021, 34(1): 125-134.

Figures/Tables 13

Table 1 Chemical compositions of the AA6056 and AA2219 plates (wt%)

AA6056-T4	Al	Mg	Si	Cu	Mn	Fe
AA6056-T4	Bal.	0.73	0.87	0.67	0.62	0.12
AA2219-T87	Al	Cu	Mn	Ti	Zr	Si
AA2219-T87	Bal.	6.38	0.32	0.06	0.18	0.08

Fig. 1 BT-FSW process of dissimilar aluminum alloys

Fig. 2 Variations of a the force in the welding direction and torque, b line energy for different welding parameters

Fig. 3 Macrographs of the BT-FSWed joints with different welding speeds: a 300 mm min-1, b 350 mm min-1, c 400 mm min-1

Fig. 4 Microstructures of the different zones marked in Fig. 3a: a zone A, b zone B, c zone C, d zone D

Fig. 5 Bottom and middle sections of bonding interface of the joints welded at different welding speeds of a, b 300 mm min-1, c, d 350 mm min-1, e, f 400 mm min-1

Fig. 6 a Bonding interface of the joint obtained at 300 mm min-1; b EDS analysis of the bonding interface

Fig. 7 DSC curves of the BM and HAZ a at the AA2219 side, b AA6056 side for different welding speeds

Fig. 8 Hardness maps across the cross section of the joints at different welding speeds

Fig. 9 Hardness curves of bonding interface at the weld center for different welding speeds

Fig. 10 Tensile strength and elongation at different welding speeds

Fig. 11 Cross sections of the fracture joints welded at different welding speeds: a 300 mm min-1, b 350 mm min-1 and c 400 mm min-1

Fig. 12 SEM morphologies of typical positions in Fig. 11: a zone A, b zone B, c zone C and d zone D

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