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

Pitting corrosion of aluminum

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

Stainless steels are used in countless diverse applications for their corrosion resistance. Although they have extremely good general resistance, they are nevertheless susceptible to pitting corrosion. This localized dissolution of an oxide-covered metal in specific aggressive environments is one of the most common and catastrophic causes of failure of metallic structures. The pitting process has been described as random, sporadic and stochastic and the prediction of the time and location of events remains extremely difficult. Many contested models of pitting corrosion exist, but one undisputed aspect is that manganese sulphide inclusions play a critical role. Indeed, the vast majority of pitting events are found to occur at, or adjacent to, such second-phase particles. Chemical changes in and around sulphide inclusions have been postulated as a mechanism for pit initiation but such variations have never been measured. Here we use nanometre-scale secondary ion mass spectroscopy to demonstrate a significant reduction in the Cr:Fe ratio of the steel matrix around MnS particles. These chromium-depleted zones are susceptible to high-rate dissolution that 'triggers' pitting. The implications of these results are that materials processing conditions control the likelihood of corrosion failures, and these data provide a basis for optimizing such conditions.

Why stainless steel corrodes

A theoretical model for porous structure formation during electrochemical anodization of aluminium is developed taking into account anodic oxide growth at the oxide/electrolyte and oxide/aluminium interfaces, electrochemical and field-enhanced oxide dissolution, and a three-dimensional configuration of electric field and current in the scalloped barrier oxide layer at pore bottoms. A system of equations ensuring a general description of the porous structure formation is evolved and is further applied to the analysis of stationary pore growth on aluminium. In this particular case analytical expressions are obtained establishing the relations of pore geometry and electric field in oxide with the parameters of anodic process (voltage, temperature, pH). They are found to be in agreement with existing experimental data.

https://iopscience.iop.org/article/10.1088/0022-3727/25/8/017/pdf

Theoretical modelling of porous oxide growth on aluminium

A pit model was developed on the assumption that the metal ions hydrolyze inside the pits and that the corrosion products are transported by diffusion. Concentrations of Me2+, , and H+ ions, as a function of pit depth and current density, for Zn, Fe, Ni, Co, Al, and Cr were calculated. The main reason for passivity breakdown at the initial stages of pit growth, was found to be the localized acidification due to metal ions hydrolysis. Assuming a criticalpH value for pit initiation, the following experimental facts could be explained: (i) the effect of the external pH on the pitting potential of Fe and stainless steel; (ii) the effect of sodium borate concentration on the pitting potential of Zn; (iii) the effect of weak acid salts on the pitting potential of Al; (iv) the oscillations of the electrode potential of stainless steel and nickel in solutions of ions; (v) the existence of a pitting inhibition potential ; and (vi) the existence of a pitting protection potential. Through analysis of the transport processes inside a pit it was also concluded that the pitting potential of a metal should change with the Cl− ion concentration according to the equation being the slope of the curve at room temperature.

Jose R. Galvele

Papers

Transport Processes and the Mechanism of Pitting of Metals

Mechanism of intergranular corrosion of Al-Cu alloys

Pitting potential of high purity binary aluminium alloys—II. AlMg and AlZn alloys

Transport processes and the mechanism of pitting of metals

Surface mobility mechanism of stress-corrosion cracking