Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a decade. Recently, friction stir processing (FSP) was developed for microstructural modification of metallic materials. In this review article, the current state of understanding and development of the FSW and FSP are addressed. Particular emphasis has been given to: (a) mechanisms responsible for the formation of welds and microstructural refinement, and (b) effects of FSW/FSP parameters on resultant microstructure and final mechanical properties. While the bulk of the information is related to aluminum alloys, important results are now available for other metals and alloys. At this stage, the technology diffusion has significantly outpaced the fundamental understanding of microstructural evolution and microstructure–property relationships.

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Friction Stir Welding and Processing

Atomic-level structure and structure–property relationship in metallic glasses

X-ray computer tomography (CT) is fast becoming an accepted tool within the materials science community for the acquisition of 3D images. Here the authors review the current state of the art as CT transforms from a qualitative diagnostic tool to a quantitative one. Our review considers first the image acquisition process, including the use of iterative reconstruction strategies suited to specific segmentation tasks and emerging methods that provide more insight (e.g. fast and high resolution imaging, crystallite (grain) imaging) than conventional attenuation based tomography. Methods and shortcomings of CT are examined for the quantification of 3D volumetric data to extract key topological parameters such as phase fractions, phase contiguity, and damage levels as well as density variations. As a non-destructive technique, CT is an ideal means of following structural development over time via time lapse sequences of 3D images (sometimes called 3D movies or 4D imaging). This includes information nee...

https://www.tandfonline.com/doi/pdf/10.1179/1743280413Y.0000000023

Quantitative X-ray tomography

The comprehensive body of knowledge that has built up with respect to the friction stir welding (FSW) of aluminium alloys since the technique was invented in 1991 is reviewed The basic principles of FSW are described, including thermal history and metal flow, before discussing how process parameters affect the weld microstructure and the likelihood of entraining defects After introducing the characteristic macroscopic features, the microstructural development and related distribution of hardness are reviewed in some detail for the two classes of wrought aluminium alloy (non-heat-treatable and heat-treatable) Finally, the range of mechanical properties that can be achieved is discussed, including consideration of residual stress, fracture, fatigue and corrosion It is demonstrated that FSW of aluminium is becoming an increasingly mature technology with numerous commercial applications In spite of this, much remains to be learned about the process and opportunities for further research a

Friction stir welding of aluminium alloys

A considerable part of the available literature on scandium in aluminium alloys is reviewed. Experimental data and assessments of the binary Al–Sc phase diagram, a wide range of ternary Al–Sc–X phase diagrams and a few higher order phase diagrams are accounted for, with emphasis on the aluminium rich part of the diagrams. The phase which is in equilibrium with Al, Al3Sc, can form by several different mechanisms, all of which are described. The precipitation kinetics of Al3Sc in binary Al–Sc alloys are discussed, and an overview of the reported influences of ternary alloying elements on the precipitation of Al3Sc is given. The Al3Sc phase particles can serve as a grain refiner in the Al melt, a dispersoid for controlling the grain structure of the alloy and a strengthening precipitate. Several examples of these three effects are mentioned, both in binary Al–Sc alloys, and in more complex alloys. The reported effects of Sc on the precipitation behaviour in Al–Cu, Al–Mg–Si, Al–Zn–Mg and Al–Li alloys ...

http://www.arc.nucapt.northwestern.edu/refbase/files/Royset-2005.pdf

Scandium in aluminium alloys

A thermomechanical process for grain refinement in precipitation hardening aluminum alloys is reported. The process includes severe overaging, deformation, and recrystallization steps. Microstructural studies by optical and transmission electron microscopy of grain refinement in 7075 aluminum have revealed that precipitates formed during the overaging step create preferential nucleation sites for recrystallizing grains. The relationship between precipitate density following severe overaging and recrystallized grain density has been investigated; the results show that the localized deformation zones associated with particles larger than about 0.75 μ m can act at preferential nucleation sites for recrystallizing grains. The density of particles capable of producing nucleation sites for new grains is approximately ten times greater than the density of recrystallized grains. A close relationship between dislocation cell size after the deformation step and recrystallized grain density has also been established. Both quantities saturate for rolling reductions larger than approximately 85 pct. The grain size produced in 2.5 mm thick sheet by the optimum processing schedule is approximately 10 μm in longitudinal and long transverse directions and 6 μm in the short transverse direction.

Grain refinement in 7075 aluminum by thermomechanical processing

A number of properties of amorphous materials including fatigue, fracture and component performance are governed by the magnitude of strain fields around inhomogeneities such as inclusions, voids and cracks At present, localized strain information is only available from surface probes such as optical or electron microscopy1,2 This is unfortunate because surface and bulk characteristics in general differ Hence, to a large extent, the assessment of strain distributions relies on untested models Here we present a universal diffraction method for characterizing bulk stress and strain fields in amorphous materials and demonstrate its efficacy by work on a material of current interest in materials engineering: a bulk metallic glass3,4,5 The macroscopic response is shown to be less stiff than the atomic next-neighbour bonds because of structural rearrangements at the scale of 4–10 A The method is also applicable to composites comprising an amorphous matrix and crystalline inclusions

Measuring strain distributions in amorphous materials

Measurements of plastic displacement gradient components in three dimensions using marker particles and synchrotron X-ray absorption microtomography

Microstructures of friction stir weld joints between an aluminium-base metal matrix composite and a monolithic aluminium alloy

A model that combines the phenomenological theory of martensite with a generalized Schmid’s law has been used to predict the principal stress combinations required to induce the martensitic transformation in unconstrained NiTi shape memory alloy (SMA) single crystals. The transformation surfaces prescribed by the model are anisotropic and asymmetric, reflecting the unidirectional character of shear on individual martensite habit planes. Model predictions of the transformation strain as a function of stress axis orientation for a uniaxial applied stress further demonstrate the anisotropy of the stress-induced transformation in NiTi single crystals. Model results for the uniaxial stress case compare favorably with previously published experimental observations for aged NiTi single crystals.

John A. Wert

Papers

Grain refinement in 7075 aluminum by thermomechanical processing

Measuring strain distributions in amorphous materials

Measurements of plastic displacement gradient components in three dimensions using marker particles and synchrotron X-ray absorption microtomography

Microstructures of friction stir weld joints between an aluminium-base metal matrix composite and a monolithic aluminium alloy

Modeling the effects of stress state and crystal orientation on the stress-induced transformation of NiTi single crystals