Mode I Fracture Behavior of 6061 Aluminum Alloy Processed by Friction Stir Processing

Document Type : Manufacturing and Production

Authors

1 M.Sc., Department of Mechanical Engineering, Faculty of Engineering, University of Maragheh, Maragheh, Iran

2 Corresponding author: Associate Professor, Department of Mechanical Engineering, Faculty of Engineering, University of Maragheh, Maragheh, Iran

3 Postdoctoral researcher,, Department of Mechanics and Aerospace Engineering, College of Engineeringو Southern University of Science and Technology, Shenzhen, China

4 Associate Professor, Department of Manufacturing and Production Engineering, Faculty of Mechanical Engineering, University of Tabriz, Tabriz, Iran

Abstract

Crack nucleation mechanisms, its growth, and the determination of critical failure parameters are of industrial importance. Therefore, it is inevitable to study the mechanical behavior of cracked materials under applied load during severe plastic deformation. The present study studied the mode I fracture behavior, mechanical properties, and microstructure characterization of the 6061 aluminum alloy fabricated by friction stir processing (FSP). For this purpose, a milling machine made a perfect stirring zone to perform the FSP method with the specific non-consumable tool. According to the tensile test results, the yield and ultimate tensile strength of the FSP-processed sample have increased by 39% and 37%, respectively. Based on the three-point bending test, the fracture toughness of the processed aluminum was calculated as 10.86 MPa√m, which shows a 14.3% improvement compared to the as-received annealed state. Eventually, the average grain size of the annealed and processed samples was measured as 35 and 15, respectively, which indicated a 57% reduction in the aluminum grain size after FSP. Note that this grain refinement is associated with improved strength and toughness.

Highlights

  • The yield and ultimate tensile strength of the FSP-processed sample increased by 39% and 37%, respectively, compared to the as-received annealed sample.
  • The fracture toughness of the FSP-processed sample was equal to 10.86 MPa√m, which showed a 14.3% increase compared to the annealed condition.
  • About 57% reduction was obtained on the average grain size of the FSP-processed sample compared to the annealed state.

Keywords

Smiley face

References

[1] Zykova AP, Tarasov SY, Chumaevskiy AV, Kolubaev EA. A review of friction stir processing of structural metallic materials: Process, properties, and methods. Metals. 2020;10(6):772.##
[2] Iwaszko J, Kudła K, Fila K, Strzelecka M. The effect of friction stir processing (FSP) on the microstructure and properties of AM60 magnesium alloy. Archives of Metallurgy and Materials. 2016;61(3):1555.##
[3] Thapliyal S, Mishra A. Machine Learning for Friction Stir Welding. InAdvanced Computational Methods in Mechanical and Materials Engineering. 2021;21:43-56.##
[4] Ebrahimi M, Par MA. Twenty-year uninterrupted endeavor of friction stir processing by focusing on copper and its alloys. Journal of Alloys and Compounds. 2019;781:1074-1090.##
[5] Gairola S, Jayaganthan R. XFEM Simulation of Tensile and Fracture Behavior of Ultrafine-Grained Al 6061 Alloy. Metals. 2021;11(11):1761.##
[6] Ebrahimi M, Shaeri MH, Naseri R, Gode C. Equal channel angular extrusion for tube configuration of Al-Zn-Mg-Cu alloy. Materials Science and Engineering: A. 2018;731:569-576.##
[7] Kuna M. Finite elements in fracture mechanics. Solid Mechanics and Its Applications. 2013; 201:153-92.##
[8] Ebrahimi M, Wang Q, Attarilar Sh. A comprehensive review of magnesium-based alloys and composites processed by cyclic extrusion compression and the related techniques. Progress in Materials Science. 2023;131:101016.##
[9] Balakrishnan V, Roshan P, Goel S, Jayaganthan R, Singh IV. Experimental and XFEM simulation of tensile and fracture behavior of al 6061 alloy processed by severe plastic deformation. Metallography, Microstructure, and Analysis. 2017;6(1):55-72.##
[10] Hohenwarter A, Pippan R. Fracture and fracture toughness of nanopolycrystalline metals produced by severe plastic deformation. Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences. 2015;373(2038):20140366.##
[11] Sinha S, Nene SS, Frank M, Liu K, Lebensohn RA, Mishra RS. Deformation mechanisms and ductile fracture characteristics of a friction stir processed transformative high entropy alloy. Acta Materialia. 2020;184:164-78.##
[12] Xue P, Xiao BA, Ma ZY. Effect of interfacial microstructure evolution on mechanical properties and fracture behavior of friction stir-welded Al-Cu joints. Metallurgical and Materials Transactions A. 2015;46(7):3091-103.##
[13] Ebrahimi M, Djavanroodi F, Tiji SAN, Gholipour H, Gode C. Experimental Investigation of the equal channel forward extrusion process. Metals. 2015;5(1):471-483.##
[14] Gairola S, Jayaganthan R. XFEM Simulation of Tensile and Fracture Behavior of Ultrafine-Grained Al 6061 Alloy. Metals. 2021;11(11):1761.##
[15] Lim YB, Lee KJ. Microtexture and Microstructural Evolution of Friction Stir Welded AA5052-H32 Joints. Journal of Welding and Joining. 2019;37(2):35-40.##
[16] Roudini G, Shiri SG, Rahvard MM. Tool design and speed parameters effects on microstructure and tensile strength of friction stir welding (FSW) 5052 Al alloys. InApplied Mechanics and Materials 2012;110:3165-3170.##
[17] Ebrahimi M, Attarilar Sh, Gode C, Djavanroodi F. Damage prediction of 7025 aluminum alloy during equal-channel angular pressing. International Journal of Minerals, Metallurgy, and Materials. 2014;21:pages 990-998.##
[18] Malopheyev S, Vysotskiy I, Zhemchuzhnikova D, Mironov S, Kaibyshev R. On the fatigue performance of friction-stir welded aluminum alloys. Materials. 2020; 13(19):4246.##
[19] Yazdi SR, Beidokhti B, Haddad-Sabzevar M. Pinless tool for FSSW of AA 6061-T6 aluminum alloy. Journal of materials processing technology. 2019;267:44-51.##
[20] Wu J, Djavanroodi F, Shamsborhan M, Attarilar Sh, Ebrahimi M. Improving mechanical and corrosion behavior of 5052 aluminum alloy processed by cyclic extrusion compression. Metals. 2022;12(8):1288.##
[21] Elyasi M, Aghajani Derazkola H, Hosseinzadeh M. Investigations of tool tilt angle on properties friction stir welding of A441 AISI to AA1100 aluminium. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2016;230(7):1234-41.##
[22] Derazkola HA, Aval HJ, Elyasi M. Analysis of process parameters effects on dissimilar friction stir welding of AA1100 and A441 AISI steel. Science and Technology of Welding and Joining. 2015;20(7):553-62.##
[23] Derazkola HA, Elyasi M. The influence of process parameters in friction stir welding of Al-Mg alloy and polycarbonate. Journal of Manufacturing Processes. 2018;35:88-98.##
[24] Elyasi M, Derazkola HA. Experimental and thermomechanical study on FSW of PMMA polymer T-joint. The International Journal of Advanced Manufacturing Technology. 2018;97(1):1445-56.##
[25] Eyvazian A, Hamouda AM, Aghajani Derazkola H, Elyasi M. Study on the effects of tool tile angle, offset and plunge depth on friction stir welding of poly (methyl methacrylate) T-joint. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2020;234(4):773-87.##
[26] Derazkola HA, Garcia E, Elyasi M. Underwater friction stir welding of PC: Experimental study and thermo-mechanical modelling. Journal of Manufacturing Processes. 2021 65:161-73.##
[27] Elyasi M, Derazkola HA, Hoseinzadeh M. Study on joint zone Microstructure Evolution and Hardness in Friction Stir welding of AA1100 Aluminum alloy to A441 AISI steel. Modares Mechanical Engineering. 2015;14(14):97-107.##
[28] Elyasi M, Aghajani H, Hosseinzadeh M. Effects of friction stir welding parameters on mechanical quality of AA1100 aluminum alloy to A441 AISI steel joint. Modares Mechanical Engineering. 2015;15(4):379-90.##
[29] Rahmatabadi D, Hashemi R, Mohammadi B, Shojaee T. Experimental investigation of plane stress fracture toughness for aluminum sheets produced by cold roll bonding process. Modares Mechanical Engineering. 2017;17(2),101-108.##
[30] Rahmatabadi D, Ahmadi M, Pahlavani M, Hashemi R. DIC-based experimental study of fracture toughness through R-curve tests in a multi-layered Al-Mg (LZ91) composite fabricated by ARB. Journal of Alloys and Compounds. 2021;883, 160843.##
[31] Medhi T, Das A, Pankaj P, Kapil S, Biswas P. Multi-pass friction stir lap welding of AA 6061-T6: Implication of tool pin overlapping on microstructure and mechanical properties of joints. Metals. 2018;11(15):1669.##
Aerospace Mechanics
Volume 19, Issue 2 - Serial Number 72
Serial No. 72, Summer Quarterly
September 2023
Pages 83-94

Files

History

  • Receive Date: 06 December 2022
  • Revise Date: 26 January 2023
  • Accept Date: 07 February 2023
  • Publish Date: 21 April 2023

Share

How to cite

Statistics