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ACHIEVING ULTRAFINE GRAINS in Mg AZ31B-O ALLOY by CRYOGENIC FRICTION STIR PROCESSING and MACHINING

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ACHIEVING ULTRAFINE GRAINS in Mg AZ31B-O ALLOY by CRYOGENIC FRICTION STIR PROCESSING and MACHINING University of Kentucky UKnowledge Theses and Dissertations--Manufacturing Systems Engineering Manufacturing Systems Engineering 2011 ACHIEVING ULTRAFINE GRAINS IN Mg AZ31B-O ALLOY BY CRYOGENIC FRICTION STIR PROCESSING AND MACHINING Anwaruddin Mohammed University of Kentucky, [email protected] Right click to open a feedback form in a new tab to let us know how this document benefits ou.y Recommended Citation Mohammed, Anwaruddin, "ACHIEVING ULTRAFINE GRAINS IN Mg AZ31B-O ALLOY BY CRYOGENIC FRICTION STIR PROCESSING AND MACHINING" (2011). Theses and Dissertations--Manufacturing Systems Engineering. 1. https://uknowledge.uky.edu/ms_etds/1 This Master's Thesis is brought to you for free and open access by the Manufacturing Systems Engineering at UKnowledge. It has been accepted for inclusion in Theses and Dissertations--Manufacturing Systems Engineering by an authorized administrator of UKnowledge. For more information, please contact [email protected]. STUDENT AGREEMENT: I represent that my thesis or dissertation and abstract are my original work. Proper attribution has been given to all outside sources. I understand that I am solely responsible for obtaining any needed copyright permissions. I have obtained and attached hereto needed written permission statements(s) from the owner(s) of each third-party copyrighted matter to be included in my work, allowing electronic distribution (if such use is not permitted by the fair use doctrine). I hereby grant to The University of Kentucky and its agents the non-exclusive license to archive and make accessible my work in whole or in part in all forms of media, now or hereafter known. I agree that the document mentioned above may be made available immediately for worldwide access unless a preapproved embargo applies. I retain all other ownership rights to the copyright of my work. I also retain the right to use in future works (such as articles or books) all or part of my work. I understand that I am free to register the copyright to my work. REVIEW, APPROVAL AND ACCEPTANCE The document mentioned above has been reviewed and accepted by the student’s advisor, on behalf of the advisory committee, and by the Director of Graduate Studies (DGS), on behalf of the program; we verify that this is the final, approved version of the student’s dissertation including all changes required by the advisory committee. The undersigned agree to abide by the statements above. Anwaruddin Mohammed, Student Dr. I.S. Jawahir, Major Professor Dr. D.P. Sekulic, Director of Graduate Studies ACHIEVING ULTRAFINE GRAINS IN Mg AZ31B-O ALLOY BY CRYOGENIC FRICTION STIR PROCESSING AND MACHINING ___________________ THESIS ___________________________ A thesis submitted in partial fulfillment of the requirements for the degree of Master of Science in Manufacturing Systems Engineering in the College of Engineering at the University of Kentucky By Anwaruddin Mohammed Lexington, Kentucky Director: Dr. I.S. Jawahir, Professor of University of Kentucky Lexington, Kentucky 2011 Copyright © Anwaruddin Mohammed 2011 ABSTRACT OF THESIS ACHIEVING ULTRAFINE GRAINS IN Mg AZ31B-O ALLOY BY CRYOGENIC FRICTION STIR PROCESSING AND MACHINING This thesis presents results from the application of cryogenic cooling on multiple-pass friction stir processing and the subsequent orthogonal machining on friction stir processed and as-received Mg AZ31B-O disks, and shows their combined effects on microstructure and microhardness values. A simple friction stir tool, a specially designed fixture and liquid nitrogen are used to perform multiple-pass friction stir processing experiments on Mg AZ31B-O alloy. The friction stir processed and as-received sheets are then made into disks for the orthogonal machining experiments. This study analyzes the microhardness, microstructure changes by cryogenic friction stir processing and the effect of machining conditions such as dry, MQL and cryogenic and cutting parameters on the Mg AZ31B-O alloy. Four different speeds and three different feed rates are used for the orthogonal machining experiments. The effects of stirring parameters such as the translational feed, rotational speed, cooling conditions and the machining parameters are studied. The resulting microstructure and microhardness from these processes hold a key to the mechanical properties of the alloy. This analysis would help to understand and evaluate the specific aspects of grain size and microhardness that influence the fatigue life of a component. Keywords: Friction Stir Processing, Cryogenic Cooling, Orthogonal Machining, Microstructure, Microhardness Anwaruddin Mohammed 7th December 2011 ACHIEVING ULTRAFINE GRAINS IN Mg AZ31B-O ALLOY BY CRYOGENIC FRICTION STIR PROCESSING AND MACHINING By Anwaruddin Mohammed Dr. I.S. Jawahir ----------------------------------------- (Director of Thesis) Dr. D.P. Sekulic ---------------------------------------- (Director of Graduate Studies) Date: 12/07/2011 -------------------------------------- To: My Parents, Family and Friends ACKNOWLEDGEMENT First, I express my sincere thanks to my advisor, Dr. I.S Jawahir for having given me the chance to work under him and for his continuous support, mentoring, advising, and guidance extended throughout the period I spent at the University of Kentucky. I would like to express my sincere gratitude to Dr. Oscar W. Dillon Jr., for all the guidance, support and the valuable time he has spent in helping me successfully complete my thesis work. He has dedicated lot of time towards reviewing my thesis. Without his help it would have been very difficult for me to have it in the complete form. I would like to thank Dr. Haluk E. Karaca for all his help, support and guidance he has given me in successfully completing the project. I would like to thank Mr. Kent VonKuster, Mr. Richard Anderson, and Mr. Charles Arvin for their technical support and guidance throughout the experimental work. I would like to thank my research team members and my friends, Mr. Tao Lu, Ms. Shu Yang, Mr. Sharif Aljoaba, Mr. Yusuf Kaynak, Mr. Bo Huang, Mr. Pu Zhengwen and all the other members of the Machining Research Group with whom I have discussed this project and have sought their valuable help. I would like to thank my parents, brother and sisters for their continuous support and motivation. Above all, I am very thankful to Almighty God for His endless bounties, grace and guidance throughout my academic studies. iii TABLE OF CONTENTS ACKNOWLEDGEMENTS………………………………………………………..... iii LIST OF TABLES…………………………………………………………………... ix LIST OF FIGURES…………………………………………………………………. xii CHAPTER 1: INTRODUCTION AND OVERVIEW OF THESIS 1.1 Introduction………………………………………………………………… 1 1.2 Objective…………………………………………………………………… 1 1.3 Statement of problem to be studied………………………………………… 3 1.4 Overview of thesis………………………………………………………….. 4 CHAPTER 2: LITERATURE REVIEW 2.1 Background………………………………………………………………… 5 2.2 Friction Stir Welding (FSW)………………………………………………. 5 2.3 Friction Stir Processing (FSP)……………………………………………… 7 2.4 Previous work……………………………………………………………… 9 2.4.1 Microstructure and dynamic recrystallization……………………….. 11 2.5 Cooling methods for FSP………………………………………………….. 19 2.6 Selection of work material…………………………………………………. 20 2.7 Cutting tool for machining………………………………………………… 21 2.8 Machinability of magnesium alloys………………………………………. 21 2.9 Cooling methods for machining………………………………………….. 22 2.10 Cutting speed and cutting temperature……………………………………. 23 iv CHAPTER 3: FRICTION STIR PROCESSING (FSP) EXPERIMENTS 3.1 Introduction………………………………………………………………… 25 3.2 Research plan …………………………………………………………….. 25 3.3 Experimental setup………………………………………………………….. 27 3.4 Description of the metallographic examination …………………………… 30 3.4.1 Equipment used……………………………………………………… 30 3.4.2 Description of procedure…………………………………………….. 31 3.5 Experimental work………………………………………………….............. 34 3.5.1 MP (1-sided) with Swiss Lube coolant underneath the fixture……… 35 3.5.2 MP (2-sided) with Swiss Lube coolant underneath the fixture……….. 37 3.5.3 MP (1-sided) with flood coolant on top and underneath the fixture… 38 3.5.4 MP (1-sided) with flood coolant and 45 seconds waiting time between successive passes……………………………………………………… 40 3.5.5 MP (2-sided) with Swiss Lube flood coolant and 45 seconds waiting between passes………………………………………………………… 41 3.5.6 MP with cryogenic cooling on top and Swiss Lube coolant underneath the fixture………………………………………………………………….. 43 3.5.7 MP with cryogenic cooling underneath the fixture (bottom)………….. 44 3.5.8 MP with flood cooling (Swiss Lube) on top and cryogenic cooling underneath the fixture (bottom) …………………………………….. 46 3.5.9 MP with cryogenic cooling on top as well as underneath the fixture (bottom)……………………………………………………………….. 48 3.6 Microhardness ………………………………………………........................ 51 v 3.6.1 Measurement of microhardness…………………………………… 51 3.6.2 Measurement of microhardness on the FSP sheet…………………… 51 3.6.3 Microhardness for samples obtained from MP (1-sided) and MP (2-sided) with Swiss Lube coolant underneath the fixture……… 52 3.6.4 Microhardness data for processed samples obtained from MP (1-sided) with cryogenic cooling underneath the fixture section 3.5.7………………………………………………………… 54 CHAPTER 4: MACHINING EXPERIMENTAL TECHNIQUES 4.1 Introduction………………………………………………………………… 62 4.2 FSP and AR disk material …………………………………………………. 62 4.3 Cutting tools and experimental equipment…………………………………. 63 4.4 Cutting tool insert …………………………………………………………. 64 4.4.1 Cutting tool edge radius measurements using Zygo………………… 64 4.4.2 Technique and the procedure to measure
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