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Friction Stir Processing of Cast Magnesium Alloys Scholars' Mine Masters Theses Student Theses and Dissertations Spring 2007 Friction stir processing of cast magnesium alloys Timothy A. Freeney Follow this and additional works at: https://scholarsmine.mst.edu/masters_theses Part of the Materials Science and Engineering Commons Department: Recommended Citation Freeney, Timothy A., "Friction stir processing of cast magnesium alloys" (2007). Masters Theses. 4613. https://scholarsmine.mst.edu/masters_theses/4613 This thesis is brought to you by Scholars' Mine, a service of the Missouri S&T Library and Learning Resources. This work is protected by U. S. Copyright Law. Unauthorized use including reproduction for redistribution requires the permission of the copyright holder. For more information, please contact [email protected]. FRICTION STIR PROCESSING OF CAST MAGNESIUM ALLOYS by TIMOTHY ALAN FREENEY A THESIS Presented to the Faculty of the Graduate School of the UNIVERSITY OF MISSOURI-ROLLA In Partial Fulfillment of the Requirements for the Degree MASTER OF SCIENCE IN MATERIALS SCIENCE AND ENGINEERING 2007 Approved by _______________________________ _______________________________ Dr. Rajiv S. Mishra, Advisor Dr. F. Scott Miller _______________________________ Dr. Von L. Richards iii PUBLICATION THESIS OPTION This thesis consists of the following two papers that have been submitted for publication as follows: Pages 1–23 are expanded publication in TMS 2007 Friction Stir Welding and Processing IV Symposium. Pages 24–53 are intended for submission in Materials Science and Engineering A. iv ABSTRACT This thesis investigates the feasibility and benefits of using friction stir processing as a thermo-mechanical microstructural modification tool for local property enhancement or casting repair of magnesium alloys, specifically high strength EV31A and WE43. Castings often have usage limitations due to the inherent microstructural inhomogeneity from solidification; in addition magnesium cast alloys generally suffer from poor ductility and relatively low strength, yet the low density of magnesium is very attractive for weight critical applications. Friction stir processing (FSP) is a proven tool for enhancement of aluminum alloys, imparting a fine-grained, homogeneous microstructure. The alloys in this study are designed for elevated temperature service in the aerospace and high performance automotive industries and are suitable in applications were lightweight and exceptional strength are desired. WE43 has excellent temperature resistance up to 300°C, and EV31A is a more industry cost-effective alternative to WE43 and has excellent strength retention up to 200°C. Results from the present work showed that both alloys are easily adapted to the use of FSP, and significant strength and ductility gains were achieved in both alloys over their respective as-cast peak strengthened states. v ACKNOWLEDGMENTS I thank first and foremost my advisor; Dr. Rajiv Mishra, for his patience, guidance and support throughout my undergraduate and graduate studies. Dr. Mishra’s dedication to the group and his students has demonstrated that kindness fosters diligence. His generosity and mentorship have made my stay at UMR not only possible in many ways, but also enjoyable. In addition, I am grateful to my committee members, Dr. F. Scott Miller and Dr. Von L. Richards, for their guidance. I also take this opportunity to thank Dr. David G. Robertson for providing kind support and an open door through many difficult times. Also, I thank Dr. Kent D. Peaslee for being a pivotal figure of my introduction to this field and university. I am truly indebted to the Metallurgical Engineering faculty at the University of Missouri-Rolla, as they have been tremendous as educators and mentors; and I truly believe that without their caring and patience I would not have completed my studies. I also express my gratitude to Joyce Erkiletian, Pricilla Winner and Paula Cochran for their kind assistance and wonderful personalities. I further extend my warm thanks to all of my dear colleagues who have come and gone throughout the years; especially, Siddharth Sharma whose patience, mentorship and friendship were crucial to my development as a researcher and person. I also thank Indrajit Charit, Lucie Johannes, Vikas and Manisha Dixit, Dr. Yanwen Wang, Manasij Yadava; and all of the past and present group members who have assisted my learning and provided friendship through my tenure at UMR. I also thank my dear friends Steve, Bret, Jeff, Brad, Greg, Mark; and all of my friends from Sigma Nu and otherwise. This thesis is dedicated to my parents who brought me into this world; to my grandparents who have fostered my desire for education; and to all my family for shaping the person I am today. I will never forget my humble beginnings, and to those to whom I am indebted, “ Pigmaei gigantum humeris impositi plusquam ipsi gigantes vident”. vi TABLE OF CONTENTS Page PUBLICATION THESIS OPTION...................................................................................iii ABSTRACT....................................................................................................................... iv ACKNOWLEDGMENTS .................................................................................................. v LIST OF ILLUSTRATIONS...........................................................................................viii LIST OF TABLES.............................................................................................................. x PAPER I Effect of friction stir processing parameters on the microstructural and mechanical properties of high strength magnesium cast alloy Abstract ........................................................................................................................ 1 1. Introduction ............................................................................................................. 1 2. Alloying Elements................................................................................................... 3 2.1. Mg-Zr............................................................................................................ 3 2.2. Mg-Y-Nd ...................................................................................................... 3 3. Experimental Approach........................................................................................... 4 4. Results and Discussion............................................................................................ 6 4.1. Microstructure............................................................................................... 6 4.1.1. As-Cast............................................................................................6 4.1.2. Cast + T6.........................................................................................7 4.1.3. FSP Microstructure .........................................................................8 4.2. Material Flow.............................................................................................. 13 4.3. Mechanical Properties................................................................................. 15 5. Conclusions ........................................................................................................... 20 Acknowledgments...................................................................................................... 20 References .................................................................................................................. 20 vii Page PAPER II Effect of friction stir processing on the microstructure and mechanical properties of a cast magnesium-rare earth alloy Abstract ...................................................................................................................... 24 1. Introduction ........................................................................................................... 24 2. Effect of Alloying Elements.................................................................................. 26 2.1 Mg-Zr........................................................................................................... 27 2.2 Mg-Zn .......................................................................................................... 28 2.3 Zr-Zn............................................................................................................ 28 2.4 Zn-RE........................................................................................................... 29 2.5 Mg-Nd-Gd ................................................................................................... 29 3. Experimental ......................................................................................................... 29 4. Results and Discussion.......................................................................................... 31 4.1 Microstructure.............................................................................................. 31 4.1.1 Microstructure – As-Cast...............................................................31 4.1.2. Microstructure – As-Cast + T6 .....................................................34 4.1.3. Microstructure – FSP ....................................................................37 4.1.4. Microstructure – FSP + HT ..........................................................40 4.2. Mechanical Properties................................................................................. 42 4.3. Fractography..............................................................................................
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