Friction Stir Welding of 2024 Aluminum Alloy to 2198 Aluminum-Lithium Alloy Mahdi MASOUMI KHALILABAD
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Friction Stir Welding of 2024 Aluminum Alloy to 2198 Aluminum-Lithium Alloy by Mahdi MASOUMI KHALILABAD THESIS PRESENTED TO ÉCOLE DE TECHNOLOGIE SUPÉRIEURE IN PARTIAL FULFILLMENT FOR A MASTER’S DEGREE WITH THESIS IN MECHANICAL ENGINEERING M.A.Sc. MONTREAL, August, 25 2017 ÉCOLE DE TECHNOLOGIE SUPÉRIEURE UNIVERSITÉ DU QUÉBEC Mahdi Masoumi Khalilabad, 2017 This Creative Commons license allows readers to download this work and share it with others as long as the author is credited. The content of this work can’t be modified in any way or used commercially. BOARD OF EXAMINERS THIS THESIS HAS BEEN EVALUATED BY THE FOLLOWING BOARD OF EXAMINERS Mr. Philippe Bocher, Thesis Supervisor Département de génie mécanique at École de technologie supérieure Mr. Mohammad Jahazi, Thesis Co-supervisor Département de génie mécanique at École de technologie supérieure Mr. Jean-François Chatelain, President of the Board of Examiners Département de génie mécanique at École de technologie supérieure Mr. Ricardo Zednik, Member of the jury Département de génie mécanique at École de technologie supérieure THIS THESIS WAS PRENSENTED AND DEFENDED IN THE PRESENCE OF A BOARD OF EXAMINERS AND PUBLIC AUGUST 18, 2017 AT ÉCOLE DE TECHNOLOGIE SUPÉRIEURE ACKNOWLEDGMENT The author would like to thank M.A.Sc research director, Professor Philippe Bocher and co- director, for their guidance, support and expertise during the degree, without which none of this would have been possible. Gratitude is also expressed for Yasser Zedan, Damien Texier, Ludovic Diez-Jahier, Remi Bertrand, Hossein Monajati, Eric Marcoux and Michel Orsini, for their cooperation the entire duration of the diploma. A part of the research presented in this paper was financed by the Fonds de recherche du Québec – Nature et technologies by the intermediary of the Aluminum Research Centre – REGAL that without their valuable assistance, this work would not have been completed. SOUDAGE PAR FRICTION DES MATÉRIAUX AA2024 ET AL-Li 2198 Mahdi MASOUMI KHALILABAD RÉSUMÉ L'amélioration des propriétés mécaniques des structures hybrides fabriquées par soudage par friction (FSW) des matériaux AA2198 et AA2024 est l'objectif de cette recherche. Différentes conceptions d'outils, paramètres de vitesse de soudage, traitements thermiques en métal de base (T8 et T3) et après soudure (PWHT) ont été étudiés afin d'améliorer les propriétés mécaniques de l'articulation. La tige cylindrique conique avec un épaulement de ventilateur surélevé était la configuration optimale de la conception d'outil en termes de limite d'élasticité et d'élongation. Une gamme de paramètres de vitesse de soudage a ensuite été étudiée pour la conception optimale de l'outil pour trouver des conditions de soudure appropriées. L'efficacité de l'assemblage peut atteindre jusqu'à 78% en choisissant des paramètres de vitesse de soudage optimum de 750 tr / min et 450 mm.min-1. On observe que l'utilisation des plaques en T3 ou en T8 créera des joints avec des propriétés mécaniques similaire en raison de la perte de propriétés mécaniques dans TMAZ / HAZ du côté AA2198. T8 PWHT avec et sans précontrainte a été appliqué sur des échantillons soudés dans des conditions T3 pour récupérer les propriétés mécaniques des zones articulaires. Les deux processus T8 PWHT ont amélioré la dureté du TMAZ / HAZ du côté AA2198 alors qu'ils n'avaient aucun effet positif sur TMAZ / HAZ du côté AA2024 et les propriétés mécaniques finales ne s'améliorent pas. On peut conclure que T8 PWHT n'est pas efficace pour l'articulation différente AA2024-AA2198. De plus, la répartition de la température dans la pièce a été étudiée avec la méthode des éléments finis. La simulation montre que le refroidissement pendant le soudage pourrait être efficace pour améliorer les propriétés mécaniques des articulations en diminuant la température maximale et le temps d'exposition à la chaleur. Mots-clés : AA2024, AA2198, DIC, soudage par friction, traitements thermiques, simulation FRICTION STIR WELDING OF 2024 ALUMINUM ALLOY TO 2198 ALUMINUM- LITHIUM ALLOY Mahdi MASOUMI KHALILABAD ABSTRACT Mechanical properties improvement of the hybrid structures made by friction stir welding (FSW) of AA2198 and AA2024 materials is the goal of this research. Different tool designs, welding speed parameters, base metal heat treatment (T8 and T3) and post weld heat treatment (PWHT) were investigated in order to improve the mechanical properties of the joint. The tapered cylindrical pin with a raised fan shoulder was the optimal tool design configuration in terms of yield strength and elongation. A range of welding speed parameters was subsequently studied for the optimum tool design to find appropriate welding conditions. The joint efficiency can reach up to 78% by choosing optimum welding speed parameters of 750 RPM and 450 mm.min-1. It is observed that employing the plates in T3 or T8 will create joints with similar mechanical properties due to loss of mechanical properties in TMAZ/HAZ of AA2198 side. T8 PWHT with and without pre-straining was applied on welded samples in T3 conditions to recover the mechanical properties of joint areas. Both T8 PWHT process improved the hardness of TMAZ/HAZ of AA2198 side while they have not positive effect on TMAZ/HAZ of AA2024 side and the final mechanical properties did not improve. It can be concluded that T8 PWHT is not effective for the AA2024-AA2198 dissimilar joint. Besides, the temperature distribution of workpiece was achieved through FEM simulation. The simulation shows that cooling during welding could be effective for improving the joint mechanical properties by decreasing peak temperature and heat exposure time. Keywords: AA2024, AA2198, DIC, friction stir welding, post weld heat treatment, simulation TABLE OF CONTENTS Page INTRODUCTION .....................................................................................................................1 CHAPTER 1 LITERATURE REVIEW ....................................................................................3 1.1 Historical Development of Al-Li alloys ........................................................................3 1.1.1 First generation of AL-Li alloys ................................................................. 3 1.1.2 Second generation of aluminum- lithium alloys ......................................... 4 1.1.3 Third generation of aluminum- lithium alloys ............................................ 5 1.2 Friction Stir welding process .........................................................................................9 1.2.1 Welding joint zones .................................................................................. 10 1.2.2 Friction stir welding process parameters .................................................. 11 1.2.3 Friction stir welding imperfections ........................................................... 25 1.2.4 Characterization of AA2198 to AA2024 joint .......................................... 29 1.3 Base metal heat treatment and post weld heat treatment .............................................31 1.4 Summaries....................................................................................................................32 CHAPTER 2 EXPERIMENTAL PROCEDURES, MATERIALS AND METHODS ...........35 2.1 Introduction ..................................................................................................................35 2.2 Tools and fixture designs .............................................................................................35 2.3 Base materials ..............................................................................................................39 2.4 Welding process ...........................................................................................................39 2.5 Base metal heat treatment and post weld heat treatment .............................................40 2.6 Sample preparation ......................................................................................................41 2.7 Temperature measurement ...........................................................................................42 CHAPTER 3 TOOL SELECTION FOR JOINING AA2198 TO AA2024 ............................43 3.1 Introduction ..................................................................................................................43 3.2 Surface finish quality ...................................................................................................43 3.3 Microstructure and microhardness maps .....................................................................44 3.4 Tensile test ...................................................................................................................47 3.5 Fractography ................................................................................................................49 3.6 Nugget size and material flow .....................................................................................50 3.7 Conclusions ..................................................................................................................50 CHAPTER 4 OPTIMIZATION OF WELDING SPEED PARAMETERS ............................51 4.1 Introduction ..................................................................................................................51 4.2 Joint macrograph ..........................................................................................................51 4.3 Microhardness map ......................................................................................................52