Effects of different friction stir welding conditions on the microstructure and mechanical properties of copper plates

Friction stir welding is a new and innovative welding method used to fuse materials. In this welding method, the heat generated by friction and plastic flow causes significant changes in the microstructure of the material, which leads to local changes in the mechanical properties of the weld. In this study, the effects of various welding parameters such as the rotational and traverse speeds of the tool on the microstructural and mechanical properties of copper plates were investigated; additionally, Charpy tests were performed on copper plates for the first time. Also, the effect of the number of welding passes on the aforementioned properties has not been investigated in previous studies. The results indicated that better welds with superior properties are produced when less heat is transferred to the workpiece during the welding process. It was also found that although the properties of the stir zone improved with an increasing number of weld passes, the properties of its weakest zone, the heat-affected zone, deteriorated.     

下扎深度对AZ91镁合金回填式搅拌摩擦点焊接头组织和断裂行为的影响

We used refill friction stir spot welding (RFSSW) to join 2-mm-thick AZ91D-H24 magnesium alloy sheets, and we investigated in detail the effect of tool plunge depth on the microstructure and fracture behavior of the joints. A sound joint surface can be obtained using plunge depths of 2.0 and 2.5 mm. Plunge depth was found to significantly affect the height of the hook, with greater plunge depths corresponding to more severe upward bending of the hook, which compromised the tensile-shear properties of the joints. The hardness reached a minimum at the thermo-mechanically affected zone due to the precipitation phases of this zone as it dissolved into the α-matrix during the welding process. The fracture modes of RFSSW joints can be divided into three types: shear fracture, plug fracture, and shear–plug fracture. Of these, the joint with a shear–plug fracture exhibited the best tensile-shear load of 6400 N.     

Microstructure and mechanical properties of friction welded carbon steel(EN24) and nickel-based superalloy(IN718)

Continuous-drive rotary friction welding was performed to join cylindrical specimens of carbon steel(EN24) and nickel-based superalloy(IN718), and the microstructures of three distinct weld zones—the weld interface(WI)/thermo-mechanically affected zone(TMAZ),the heat-affected zone(HAZ), and the base metal—were examined.The joint was observed to be free of defects but featured uneven flash formation.Electron backscatter diffraction(EBSD) analysis showed substantial changes in high-angle grain boundaries, low-angle grain boundaries, and twin boundaries in the TMAZ and HAZ.Moreover, significant refinement in grain size(2 –5 μm) was observed at the WI/TMAZ with reference to the base metal.The possible causes of these are discussed.The microhardness profile across the welded joint shows variation in hardness.The changes in hardness are ascribed to grain refinement, phase transformation, and the dissolution of strengthening precipitates.The tensile test results reveal that a joint efficiency of 100% can be achieved using this method.     

摩擦焊接碳钢（EN24）和镍基高温合金（IN718）的显微组织和力学性能

Continuous-drive rotary friction welding was performed to join cylindrical specimens of carbon steel (EN24) and nickel-based superalloy (IN718), and the microstructures of three distinct weld zones—the weld interface (WI)/thermo-mechanically affected zone (TMAZ), the heat-affected zone (HAZ), and the base metal—were examined. The joint was observed to be free of defects but featured uneven flash formation. Electron backscatter diffraction (EBSD) analysis showed substantial changes in high-angle grain boundaries, low-angle grain boundaries, and twin boundaries in the TMAZ and HAZ. Moreover, significant refinement in grain size (2–5 μm) was observed at the WI/TMAZ with reference to the base metal. The possible causes of these are discussed. The microhardness profile across the welded joint shows variation in hardness. The changes in hardness are ascribed to grain refinement, phase transformation, and the dissolution of strengthening precipitates. The tensile test results reveal that a joint efficiency of 100% can be achieved using this method.     

AA2198-T34合金搅拌摩擦焊的应力腐蚀行为及其特征

To better understand the stress-corrosion behavior of friction stir welding (FSW), the effects of the microstructure on the stress-corrosion behavior of the FSW in a 2198-T34 aluminum alloy were investigated. The experimental results show that the low-angle grain boundary (LABs) of the stir zone (SZ) of FSW is significantly less than that of heated affected zone (HAZ), thermo-mechanically affected zone (TMAZ), and parent materials (PM), but the grain boundary precipitates (GBPs) T1 (Al₂CuLi) were less, which has a slight effect on the stress corrosion. The dislocation density in SZ was greater than that in other regions. The residual stress in SZ was +67 MPa, which is greater than that in the TMAZ. The residual stress in the HAZ and PM is ?8 MPa and ?32 MPa, respectively, and both compressive stresses. The corrosion potential in SZ is obviously less than that in other regions. However, micro-cracks were formed in the SZ at low strain rate, which indicates that the grain boundary characters and GBPs have no significant effect on the crack initiation in the stress-corrosion process of the AA2198-T34. Nevertheless, the residual tensile stress has significant effect on the crack initiation during the stress-corrosion process.     

Surface treatment of 0Cr19Ni9 stainless steel SMAW joint by plasma melting

Micro-plasma are surface melting of 0Crl9Ni9 shielded metal are welding joint with a micro-plasma are welder produced a thin surface melted layer with a refined microtructure. The surface treatment changed the anodie polarization behavior in 0.5 mol/L H2SO4 solution. The polarization tests showed that for the as-welded joint both the heat-affected zone and the weld metal decreased in resis-tance to corrosion compared with the as-received parent material while for the micro-plasma are surface melted joint the corrosion resistance increased significantly. This increase in corrosion resistance is attributed to the rapid solidification of the melted layer. Rapid solidification of the melted layer refines its mierostrueture, decreases its mierosegregation, and inhibits the precipitation of chromium carbides at the grain boundaries.     

DINSAR measurement of glacier motion in Antarctic Grove Mountain

Grove Mountain is an important nunatak region on East Antarctic Glacier that blocks the ice flow to- ward Lambert Glacier. The existence of nunataks and subglacial mountains leads to complex ice flow patterns, which are difficult to be measured by conventional ground-based methods. In this study, several JERS-1 and ERS-1/2 SAR images covering this area are used for 3-pass and 4-pass differential interferometric processing. The ice flow field of Grove Mountain and the eastern zone are derived and validated with related knowledge. The research shows that DINSAR is an effective method for meas- uring complex ice flow in Antarctic inland glacier. L-band DINSAR is more suitable for mid or fast ice flow than C-band over this region.     

Ultrasound Imaging Signal Analysis of Underwater Topography in River Model Experiment

In this paper, we analyze the feature of ultrasonic image and investigate the effect of topography material, flow velocity and sediment concentration on the imaging of underwater topography by imaging experiments of model sands. These imaging experiments are conducted in river engineering physical model.The results show that the vertical distribution of pixel values is changed hugely at the position of imaging bright band of underwater topography. The imaging of underwater topography is not affected when flow velocity is below 40 cm/s and sediment concentration is below 5.0 ‰. The main influence factors of imaging signals are flow velocity and sediment concentration near the topographical bed. The resolution of ultrasound imaging signals is high, and the topography consisted of model sands with particle size smaller than 0.1 mm can be monitored well in the river model experiment.     

Affected zone generated around the erosion pit on carbon steel surface at the incipient stage of vibration cavitation

The characteristics of erosion pits on a carbon steel surface were investigated at the incipient stage of cavitation erosion. After a 5-minute experiment performed in an ultrasonic vibration system, needle-like erosion pits appeared on the polished steel surface, and a specially affected zone was formed around the pit. The shape of the pit and the plastic deformation of the affected zone indicate that the me-chanical impaction on the surface is the main reason for the cavitation damage. On the other hand, the iridescent color, the decreased surface hardness and the precipitated carbides on the affected zone prove that the affected zone has experienced a tempering process with the temperature higher than 300℃. The lack of oxygen in the affected zone also proves that it is not a chemical oxygen result. A special phenomenon that a carbon ring forms in the affected zone is explained as a result of the tor- oidal bubbles＇ heating effect at the final stage of the bubble collapse.     

Formation mechanism of the graphite-rich protective layer in blast furnace hearths

A long campaign life of blast furnaces is heavily linked to the existence of a protective layer in their hearths. In this work, we conducted dissection studies and investigated damage in blast furnace hearths to estimate the formation mechanism of the protective layer. The results illustrate that a significant amount of graphite phase was trapped within the hearth protective layer. Furthermore, on the basis of the thermodynamic and kinetic calculations of the graphite precipitation process, a precipitation potential index related to the formation of the graphite-rich protective layer was proposed to characterize the formation ability of this layer. We determined that, under normal operating conditions, the precipitation of graphite phase from hot metal was thermodynamically possible. Among elements that exist in hot metal, C, Si, and P favor graphite precipitation, whereas Mn and Cr inhibit this process. Moreover, at the same hot-face temperature, an increase of carbon concentration in hot metal can shorten the precipitation time. Finally, the results suggest that measures such as reducing the hot-face temperature and increasing the degree of carbon saturation in hot metal are critically important to improve the precipitation potential index.     

Material flow behavior and microstructural evolution during refill friction stir spot welding of alclad 2A12-T4 aluminum alloy

In this study, we used the stop-action technique to experimentally investigate the material flow and microstructural evolution of alclad 2A12-T4 aluminum alloy during refill friction stir spot welding.There are two material flow components, i.e., the inward-or outward-directed spiral flow on the horizontal plane and the upward-or downward-directed flow on the vertical plane.In the plunge stage, the flow of plasticized metal into the cavity is similar to that of a stack, whereby the upper layer is pushed upward by the lower layer.In the refill stage, this is process reversed.As such, there is no obvious vertical plasticized metal flow between adjacent layers.Welding leads to the coarsening of S(Al_2CuMg) in the thermo-mechanically affected zone and the diminishing of S in the stir zone.Continuous dynamic recrystallization results in the formation of fine equiaxed grains in the stir zone, but this process becomes difficult in the thermo-mechanically affected zone due to the lower deformation rate and the pinning action of S precipitates on the dislocations and sub-grain boundaries, which leads to a high fraction of low-angle grain boundaries in this zone.     

铝合金搅拌摩擦裂纹修复区的显微组织及力学性能

对表面预制了0.8mm深、0.5mm宽裂纹的2A12铝合金进行搅拌摩擦修复,修复后对其修复区显微组织变化规律和力学性能进行了详细研究.结果表明:在合理修复工艺下,实现了裂纹的修复,修复区的平均抗拉强度R_○m、屈服强度R_eL可达到母材的90.1%和92.2%.修复区存在3个组织变化区,其中修复核心区的晶粒被反复碎化、长大及动态再结晶;热机影响区晶粒具有明显的塑性变形,与晶粒显著长大的热影响区共同构成组织软化区;表面硬度与截面上部硬度曲线相似,截面硬度上部依次高于下部;修复核心区存在大量的小角晶粒,并且内部存在一定密度的位错,在晶粒四周均匀分布细小强化相.     

7075-T6铝合金搅拌摩擦焊接头腐蚀疲劳断口

利用电子显微镜和扫描电镜对7075-T6铝合金搅拌摩擦焊接头腐蚀疲劳断口进行研究,分析了 7075-T6铝合金搅拌摩擦焊接头腐蚀疲劳裂纹的发展过程。结果表明,搅拌摩擦焊接头腐蚀疲劳裂纹萌生 于焊核区和热力影响区的交界处并逐渐向热力影响区内部扩展,最终延伸并断裂于热影响区。腐蚀疲劳断 口存在多个裂纹源,裂纹源萌生于腐蚀坑处。腐蚀疲劳裂纹扩展分为低速扩展、稳态扩展和快速亚稳态扩展 3个阶段。在低速扩展阶段,产生了很多点蚀坑。在稳态扩展阶段,腐蚀疲劳具有脆性断裂特征。在快速亚 稳态扩展阶段,循环荷载成为裂纹扩展的主要驱动力而腐蚀作用的影响减弱。腐蚀疲劳裂纹扩展的瞬断区 呈现以脆性断裂为主的断裂特征。     

Stress-corrosion behavior and characteristics of the friction stir welding of an AA2198-T34 alloy

To better understand the stress-corrosion behavior of friction stir welding(FSW), the effects of the microstructure on the stress-corrosion behavior of the FSW in a 2198-T34 aluminum alloy were investigated. The experimental results show that the low-angle grain boundary(LABs) of the stir zone(SZ) of FSW is significantly less than that of heated affected zone(HAZ), thermo-mechanically affected zone(TMAZ), and parent materials(PM), but the grain boundary precipitates(GBPs) T1(Al_2CuLi) were less, which has a slight effect on the stress corrosion. The dislocation density in SZ was greater than that in other regions. The residual stress in SZ was +67 MPa, which is greater than that in the TMAZ. The residual stress in the HAZ and PM is -8 MPa and-32 MPa, respectively, and both compressive stresses. The corrosion potential in SZ is obviously less than that in other regions. However, micro-cracks were formed in the SZ at low strain rate, which indicates that the grain boundary characters and GBPs have no significant effect on the crack initiation in the stress-corrosion process of the AA2198-T34.Nevertheless, the residual tensile stress has significant effect on the crack initiation during the stress-corrosion process.     

搅拌摩擦加工IF钢的组织性能

对3 mm厚的DC04冷轧IF钢板进行搅拌摩擦加工,研究加工区域的微观组织与力学性能. 在旋转速度为950 r· min-1 ,加工速度为60 mm·min-1时,采用加工后强制冷却技术可获得光滑平整且没有缺陷的加工表面. 搅拌摩擦加工后组织显著细化,加工中心的平均显微硬度约为HV 135. 6,是母材硬度的1. 4倍,表面细晶层硬度最高可达到HV 312. 8,细晶层和过渡层的抗拉强度分别比母材的抗拉强度提高50. 9%和47. 6%,加工前后试样的拉伸断口均呈微孔聚合韧性断裂特征. 细晶强化对材料抗拉强度的提高起主要作用.     

7075-T6合金超声辅助搅拌摩擦焊接头搅拌区组织与力学性能

搅拌区的金属流动不充分容易导致轴肩影响区与搅拌针影响区之间的过渡区出现疏松缺陷并恶化接头的力学性能.在不同焊接参数条件下,对7075-T6铝合金分别进行常规搅拌摩擦焊接(FSW)和超声辅助搅拌摩擦焊接(UAFSW),研究了超声振动对接头搅拌区的金属流动行为、微观组织特征和力学性能的影响.结果表明:相同焊接参数下,UAFSW接头搅拌区的力学性能均优于FSW接头.焊接参数为1000r/min-110mm/min 的UAFSW接头搅拌区的抗拉强度和延伸率最高,分别达到515MPa和17.3%.在搅拌摩擦焊接过程中施加轴向超声振动可以显著降低搅拌区金属的屈服应力和流变应力,促进塑化金属沿板厚方向的流动.消除搅拌区中过渡区的疏松缺陷,并细化微观组织,是接头力学性能提高的主要原因.     

垂直-倾斜半环组合对撞流干燥的实验研究

为了提高对撞流干燥的干燥幅度,改善物料在半环中的粘壁和流动特性,设计、制造、安装、调试了新型垂直半环组合对撞流干燥实验台·该实验台结构新颖、紧凑,以小米为物料进行的干燥和流动特性实验表明:该干燥器不仅能够充分利用干燥介质的干燥能力和最大限度地提高物料的干燥幅度,而且还避免了半环中的粘壁和堆积问题;物料降水率主要受进气温度和载带率的影响;对撞面随着上、下进气流量的变化而上、下浮动,对撞区内物料的向下运动速度大于向上运动的速度