International Journal of Research in Engineering and Innovation Vol-7, Issue-1 (2023), 15-22 International Journal of Research in Engineering and Innovation (IJREI) journal home page: http://www.ijrei.com ISSN (Online): 2456-6934 REVIEW ARTICLE Recent advances in friction stir welding and processing of light metal alloys Mohd Sajid, Gaurav Kumar, Mukesh Kumar Department of Mechanical Engineering, Vidya College of Engineering, Meerut, India ____________________________________________________________________________________________________________________ Abstract Due to its excellent energy efficiency and environmental friendliness, friction stir welding (FSW), a very effective solid-state joining process, has been referred to as green Article Information technology. It is a method that makes it possible to combine metallic materials, especially lightweight, high-strength aluminum and magnesium alloys that conventional fusion Received: 15 Jan 2023 welding had deemed unweldable. As a result, it is regarded as the most critical advance Revised: 09 Feb 2023 in material joining over the last 20 years. Later, friction stir processing (FSP) was created Accepted: 15 March 2023 based on the fundamental ideas of FSW. FSP has been shown to be a reliable and Available online: 18 March 2023 adaptable metalworking process for altering and manufacturing metallic materials. Since _____________________________ FSW/FSP of aluminum alloys has the potential to change the production process in the aerospace, defense, marine, automotive, and railway industries, it has attracted significant Keywords: scientific and technological interest. It is crucial to optimize the process parameters and comprehensively assess the microstructural changes and mechanical characteristics of Friction stir welding the welded/processed samples to promote the use of FSW/FSP technology and assure the Tensile strength structural integrity, safety, and durability of the FSW/FSP components. Thus, this review Green Technology paper aims to summarize current developments in the mechanical characteristics and Microhardness microstructural evolution of FSW/FSP aluminum alloys. The mechanism of Microstructure. recrystallization, grain boundary properties, phase transformation, texture evolution, characteristic microstructures, and the impact of these elements on the hardness, tensile and fatigue properties, and superplastic behaviour of FSW/FSP aluminium alloys are all given special consideration. ©2023 ijrei.com. All rights reserved _________________________________________________________________________________________________________ 1. Introduction Automotive, aerospace, electronics, transportation, and other industries extensively employ light metal alloys like aluminium and magnesium alloys [1–5]. This is caused by low density, excellent electromagnetic shielding, high specific strength, high damping, and good hot formability [2-4,6,7]. On the other hand, these alloys may be recycled and are inexpensive to cast [1,2,7,8]. Due to their strong resistance to carbon dioxide, appropriate thermal conductivity, and low inclination to absorb neutrons, magnesium alloys are also utilized in the nuclear industry [2]. Additionally, due to their excellent corrosive properties, aluminum alloys are used in marine, aerospace and automobile industries [9–14]. The ductility and formability of magnesium alloys are unsatisfactory at room temperature, leading to early failure under challenging stress conditions. The hexagonal closepacked (HCP) crystal lattice's poor symmetry, high basal roughness, and restriction on the number of active slip systems all contribute to this [2,15–17]. Due to these factors, there is insufficient strength, severe fatigue, and little creep resistance [2]. FSW's fundamental idea is incredibly straightforward. According to the schematic in Fig. 1a unique rotating tool made of a shoulder and pin is first placed into the margins of Corresponding author: Gaurav Kumar Email Address: gaurav.me86@gmail.com https://doi.org/10.36037/IJREI.2022.7103 15 Mohd Sajid et al., / International journal of research in engineering and innovation (IJREI), vol 7, issue 1 (2023), 15-22 two sheets that need to be welded before moving along the joint line. The material flows intricately around the tool during FSW, from the advancing side (AS) to the retreating side (RS). The AS signifies the side when the rotating and welding directions are the same, and the RS marks the side where they are opposite. A revolving tool produces heat, transforming the material nearby from a hard solid state into a soft "plastic-like" state. Due to its lightweight nature, appealing look, fabricability, and corrosion resistance, aluminum became the choice for many applications [18]. In its purest form, aluminum is weak. Its mechanical qualities are enhanced by alloying it with iron, silicon, manganese, and magnesium to create non-heat-treatable alloys. Pure alloying of aluminum with copper, magnesium silicate, and zinc results in the development of heat-treatable high-strength aluminum alloys [19]. Depending on their mechanical and physical qualities, these alloys are employed in various disciplines, such as airframes, engines, missile bodies, fuel cells, and satellite components. Arc welding is one of the most frequently used modern industrial methods by heating metal components to their melting point and joining them together. Aluminum alloys that cannot be fused using the traditional arc welding process are created by factors such as the formation of aluminum oxide in the molten stage, hydrogen solubility, thermal expansion, and shrinkage during solidification [20]. Figure 2: (a) EBSD diagram of base metal AA6061, (b) Nugget Zone [21] Figure 3: TEM image of friction stir welded joint of AA7075, (a) Subgrain boundaries, (b) Uniform and tiny disseminated precipitates, (c) Grain structure, (d) 2nd phase particles at NZ [24]. Figure 1: Schematic diagram of friction stir welding 1. Modification/enhancement of microstructure and mechanical properties of light metal alloys A fine and equiaxed recrystallized grain structure distinguishes the center-located NZ. For instance, the 6061Al-T651 alloy's massive, elongated, pancake-shaped grains have been refined into tiny recrystallized grains (Fig. 2) [21]. The NZ material is thought to have undergone SPD at a high strain rate. Depending on the material, tool design, and operating conditions, cumulative strain and peak temperatures in this location might vary from 0.8 to 0.95 T m [22, 23]. In the NZ, DRX developed refined and equiaxed grains after severe plastic deformation and high-temperature exposure. Figure 42. Separation bands on transverse cross sections of (a) FSW 2024Al-T351 alloy joint produced at a TRS of 800 rpm and a welding speed of 200 mm/min, magnified (b) OM and (c) SEM images of position B in (a), and (d) magnified image of arrow zone in (c) [28]. Characteristic microstructures in the NZ of the FSW joints, including onion-ring structures, segregation bands, zigzag lines, and kissing bonds, are generated and are related to the particular and intricate deformation mode in FSW/FSP. The mechanical characteristics and fracture behavior of the FSW joints of aluminum alloys are often significantly influenced by 16 Mohd Sajid et al., / International journal of research in engineering and innovation (IJREI), vol 7, issue 1 (2023), 15-22 these distinctive microstructures, which draw a lot of attention from researchers. The NZ was distinguished by a fine and equiaxed recrystallized grain structure after FSW [24, 25]. Examinations using transmission electron microscopy (TEM) revealed no fine precipitates (Fig. 2) [24]. This suggests that FSW caused the fine ή phase to dissolve. Mahoney et al. reported similar outcomes as well [26]. Despite total dissolving occurring in the NZ, according to Dumont et al. [27], it did recover some hardness after cooling and subsequent natural age. GP zones formed and expanded in areas where supersaturation was sufficient during this time [27]. In the shoulder-driven zone (SDZ) of the NZ in FSW joints of precipitation-strengthened aluminum alloys, linear segregation S.No 1 Materials ZE41A & AA6061 2 AZ31 & AA1100 3 AZ31 & AA6013 4 AZ31B-O & 6061-T6 5 AZ31 & AA6061 6 AZ31-O & AA6061-T6 7 AA2024 & AA6061 8 AZ31&AA6061-T6 9 Mg & AA6061 10 Pure Mg & AA6063 11 AZ31B & 6063 12 AZ31C-O & 5083 13 AZ31 & AA5754 14 AZ31B & AA6061 15 AZ31 & AA6061-T6 16 17 AZ31B-H24 & 6061-T6 AZ31B-H24 & 6061-T6 18 AZ31 & A5052 19 AZ31B & A5083 20 AZ31 & AA6061 21 AZ31B-H24 & 2024-T3 22 AZ31 & AA6040 23 AZ31B-O & A5052P-O 24 AZ31B-O & A5052P-O 25 AZ31B &A5052-H bands made up of second-phase particles were occasionally seen in addition to the onion-ring structure. As indicated by the black lines in Fig. 4a [28], such linear segregation bands displayed distinct distribution characteristics from the onionring structure. Continuous linear segregation bands were readily discernible at higher magnifications in both optical microscopy (OM) and SEM images (Fig. 4 and 4c) [28]. Additionally, an SEM picture showed that practically all of the second-phase particles in the matrix had been dissolved (Fig. 4c). Secondary phase particles separated at the grain borders, as seen by the magnified picture of the arrow zone in Fig. 4c. The linear microstructure in Figure 42d was made up of a vast number of secondary phase particles at grain boundaries [29]. Table 1: Research summary of FSW/FSP of light metal alloys Authors Conclusions Champagne III et (2016)al. Hybrid joint obtained using FSW and cold spray. Maximum tensile strength of 122 MPa was achieved of Azizieh et al. (2016) base metal. Maximum tensile strength obtained 152.3 MPa through Zhao et al. (2015) UFSW. Maximum tensile strength achieved 70% of base metal Fu et al. (2015) (Mg). Consideration of peak temperature plasticity over creep Regev et al. (2014) analysis. Maximum tensile strength of 76% and 60% of Mg and Masoudian et al. (2014) respectively was achieved.Al The tensile strength of 194 Mpa and 209 Mpa were Sadeesh (2014) attained. Lee et al. (2014) Observation of plane orientation and fine grains in SZ. Influence of tool rotatory speed and tool offset on weld Liang et al. (2013) properties. Material flow analysis and IMCs development by steel Pourahmad et al. (2013) shots. Showing relationship between weld interface and Venkateswaran (2012)and tensile strength. Water cooling effect on maximum temperature and Mofid et al. (2012) IMCs formation. Simoncini et al. (2012) Influence of FSW constraints and tool shape. Influence of tool shoulder diameter (heat generation) Malarvizhi (2012) and Mg–Al weldment quality.on Improved the tensile strength to 66% of base Mg by Chang et al. (2011) Hybrid laser-FSW. Firouzdor and (2010b)Kou Base metals Positioning affects the IMCs formation. Firouzdor and (2010a)Kou Formation constitutional liquation was perceived. Maximum hardness was obtained twice the base Yan et al. (2010) metals. Tensile strength of 115 MPa and IMCs Al12 Mg17 & Yamamoto et al. (2009) Al3 Mg2 was achieved. Material positioning directly affects the heat input Firouzdor and (2009)Kou during FSW. Showing galvanic corrosion due to the Al-Mg galvanic Liu et al. (2009) couples growth Kostka et al. (2009) Observed 1 m thick IMC of fine-grained Al12 Mg17. Maximum tensile strength of 143 MPa was achieved at Shigematsu et al. (2009) 1400 rpm. The tensile strength of 132 MPa was achieved at 1000 Kwon et al. (2008) rpm. The SZ hardness was lower than the laser Morishige et al. (2008) welding fusion zone. References [30] [31] [32] [33] [34] [35] [36] [37] [38] [39] [40] [41] [42] [43] [44] [45] [46] [47] [48] [49] [50] [51] [52] [53] [54] 17 Mohd Sajid et al., / International journal of research in engineering and innovation (IJREI), vol 7, issue 1 (2023), 15-22 26 2024-T3 & AZ31 Khodir et al. (2007) 27 AZ31 & Al6040 Zettler et al. (2006) 28 AZ31 & 1060 Yan et al. (2005) 29 6061-T6- AZ91D & AZ31B-H24 Somasekharan et al. (2004) 30 AZ31 & A1050 Sato et al. (2004) 31 AA6082 & AA8011 Husain Mehdi et al. (2022) 32 AZ31 & A1050 McLean et al. (2003) 33 AZ31 & A1050 Hirano et al. (2003) 34 Al–Zn–Mg–Cu alloy Park et al. (2002) 35 AA6061-T6 Aluminum alloy C. Hamilton et al [2009] 36 A 3D FE model, with general validity for different joint was used to simulate C. Hamilton et al [2008] 37 Magnesium Alloy Mg-YRe G. Buffa et al [2011] 38 Al Alloy 1100 G.R. Argade at al [2012] 39 AA7075 and AA6061 Mehdi et al. [2022] 40 Pure Titanium L. Fratini et al [2010] 41 AZ31 Magnesium Alloy S.Mironov et al [2009] 42 AA7449 aluminium alloy. L.Commin et al [2009] 43 6061Al–T651 N.Kamp et al [2006] Variation in hardness value over SZ due to IMCs formation. Attained 80% weld efficiency of base material (AZ31). IMCs like Al12 Mg17 and Al3 Mg2 cause the cracking during FSW. Lamellar shear bands were seen in either side of Al or Mg. The IMC Al12 Mg17 was formed by constitutional liquation FSW. Formation of a very thin IMC layer, results in virtually no ductility. FSP was applied on single and double V groove TIG welded joint and observed excellent mechanical properties compared to TIG and FSW joints. Intermixing two phases at the intermediate layer. The formation of IMCs in SZ is restricted. Preliminary study and defect-free joining by FSW of Al–Mg alloy. In this study, the model accurately forecasts the maximum welding temperature distributions over the studied energy range. A novel slip factor based on the weld's energy per unit length was used to develop a thermal model for friction stir welding. Over a broad range of energy levels, the thermal model correctly predicts the maximum welding temperature. In friction stir welding operations, a new numerical method is studied to predict residual stress distributions. A friction stir processed Mg-Y-RE alloy's corrosion behavior was investigated with grain refinement and heat treatment. With electrochemical testing and continual immersion testing, many patterns between microstructural conditions and corrosion behavior were found. AA1100 which had been accumulatively roll-bonded (ARBed) underwent friction stir welding (FSW). FSW caused the fine granules of the SZ to reproduce and the ultrafine grains of the ARBed material nearby to somewhat increase. Optimization technique was used to predict the mechanical properties of TIG+FSP welded joint. It investigated how the microstructure of commercialquality titanium changed during FSW. The material flow was discovered to be caused mainly by prism slip and to be close to simple-shear deformation. The development of grain structure has been proven to be a multi-stage, complicated process. On the side that is receding, there are more signs of stress. Grain expansion is shown with an increase in the processing variables that encourage heat generation. For this hot-rolled BM, FSW reduced the tensile mechanical characteristics. To predict the precipitate dissemination in 7xxx alloys during FSP, a numerical, analytical model built on the Kampmann and Wagner numerical (KWN) model. The TS is crucial in affecting the welds' tensile characteristics and fracture mechanism under the welding conditions. FSW 6061Al-T651 joints welded at 400 mm/min had greater strength with a 45-shear fracture, whereas samples welded at 100 mm/min showed lower UTS with almost vertical fractures. [55] [56] [57] [58] [59] [60] [61] [62] [63] [64] [65] [66] [67] [68] [69] [70] [71] [72] 18 Mohd Sajid et al., / International journal of research in engineering and innovation (IJREI), vol 7, issue 1 (2023), 15-22 44 Aluminium matrix composites (AMCs) Omar.S.Salih [2015] 45 Al-4Mg-1Zr alloy with grain size of 0.7 µm Z.Y. Ma [2010] 46 Al-Si alloy A356 Z.Y.Ma et al [2003] 47 AA6082 and AA8011 AA5083 and AA8011 Mabuwa et al. [2022] Hashmi et al. [2022] Salah et al. [2022] 48 Al-Mg-Sc alloy Nilseh Kumar et al [2012] 49 A356 Alloy S.R Sharma [2004] 50 AA6082 AA5083 and AA6061 H. Mehdi [2022] P. Rani et al [2022] 51 Cast Al-Alloy of F357 S. Jana et al [2007] 52 53 Al-SiC Composite R.S Mishra et al [2003] AA2024 and AA7050 A.N. Salah et al. [2021] 54 cast A356 aluminum Z.Y.Ma et al [2006] 55 Al–7Si–0.6 Mg alloy S.Jana, et al [2007] 56 Aluminum alloy 7050-T65 J-Q-Su et al [2002] 57 Commercial superplastic 7475 Al alloy sheets Indrajit Charit et al [2002] The quantity of heat generated and the strength of FSW joints are significantly influenced by welding parameters such as tool rotation, speed, transverse speed, and axial force. A microstructural analysis revealed that the improper flow of plasticized metal caused the creation of the tunnel defect. Low temperature and high strain rate super plasticity of greater than 1200% work was observed at 10-2 to -1x101 s-1. With higher tool rotation rates, FSP A356's strength improved. The tool's maximum strength for the conventional pin was seen at 900 rpm. Si particle size, aspect ratio, and dispersion were unaffected by overlapping FSP. The FSP-broken Si particles were evenly distributed across the multi-pass FSP-processed zones. Depending on the alloy's processing and initial thermos-mechanical state, the grain size ranged from 0.89 to 0.39 m. With an increase in the Zener-Holloman parameter, the grain size was reported to be reduced. Significant refining, microstructure homogeneity, and porosity reduction were linked to an improvement in fatigue life. The aluminum matrix underwent a considerable breakage and homogeneous dispersion of Si particles as a result of FSP, and porosity was also eliminated. Nanoparticles ZrB2 was used the reinforcement particles to enhance the mechanical and microstructure of AA6082. The processed region revealed the maximum tensile strength compared to the base metal. Si particles were not polished further than a particular point by the numerous passes. The multi-pass run of the second setup shows that FSPed material can limit the amount of AGG. When the desired depth (2.28mm) is too great, the tool's shoulder pushes all of the pre-placed SiC particles away, and little to no composite surface forms. SiC particles could not be mixed with Al-alloy because the target depth (1.78mm) was too tiny. Particles of SiC were successfully incorporated into the aluminum matrix at the target depth of 2.03 mm. The maximum tensile strength was achieved at high TRS of dissimilar aluminum alloys AA2024 and AA7050. The brittle intermetallic compound was generated at low TRS and low TS, disseminated at high TRS and observed excellent mechanical properties of the welded joints. Higher tool rotation rates produce a more homogenous microstructure. Si particles are distributed differently throughout the FSP zone, with varying sizes and volume fractions, indicating uneven material flow. When specimens were tested at the same stress level and with a stress ratio of R=0, FSP increased the fatigue life of a cast Al-7Si-0.6 Mg alloy by 15. During friction stir welding, the base metal's original grain structure is removed and replaced with a fragile equiaxed grain structure in the dynamic re-crystallized zone. The strengthening precipitates have coarsened substantially compared to the parent material microstructure (DXZ). Weld HAZ has a stable microstructure that nonetheless exhibits superplastic characteristics. Due to the increased flow stress at 783 K compared to source metal (16-18 MPa versus 2-9 MPa), the high-strength weld nugget is unlikely to deform during superplastic forming. [73] [74] [75] [76-78] [79] [80] [81-83] [84] [85] [86] [87] [88] [89] [90] 19 Mohd Sajid et al., / International journal of research in engineering and innovation (IJREI), vol 7, issue 1 (2023), 15-22 References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] Husain Mehdi, R.S. 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