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FRICTION STIR RESEARCH LABORATORY BRIGHAM YOUNG UNIVERSITY Progress in Friction Stir Welding High Temperature Materials Carl D. Sorensen Brigham Young University
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Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

Mar 25, 2018

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Page 1: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

BRIGHAM YOUNG UNIVERSITY

Progress in Friction Stir Welding High Temperature MaterialsCarl D. SorensenBrigham Young University

Page 2: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

AgendaHistoryTool MaterialsWeld Metal PropertiesMaterials Welded With PCBN ToolsRecent Advances

Page 3: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

HistoryFSW invented in 1991Commercial applications in Al alloys

Delta rocket casingsHigh-speed ferry deckingAutomotive componentsHeat sinks

∼80% of welded product is steel or stainless steelTool material has been major challenge

Page 4: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Tool Materials-RequirementsHigh-temperature strengthWear ResistanceLow ReactivityManufacturabilityToughness

Page 5: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Tool MaterialsRefractory Metal Alloys

TungstenMolybdenumTungsten-Rhenium

SuperabrasivesPolycrystalline Diamond (PCD)Polycrystalline Cubic Boron Nitride (PCBN)

Page 6: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Tungsten ToolsGood high-temperature strengthPoor room-temperature toughnessConcerns with rapid tool wear

Image from The Welding Institute

Page 7: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Tungsten-Rhenium ToolsHigher room-temperature toughness (no preheat)Improved densification (less wear)Some indications of chemical reaction with baseplate

Page 8: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

PCBN ToolsExcellent high-temperature strengthAbrasion resistantChemically inert

Limited in sizeRelatively low toughness

Page 9: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Polycrystalline Cubic Boron Nitride (PCBN)

Second in hardness only to diamondDiamond crystal structure, with C and B occupying alternate lattice sitesCBN powder Created in HT-UHP presses (1700 K, 6,000 MPa)CBN powder sintered in HT/UHP press to form polycrystalline blank

GasketingGasketing MaterialMaterial

Boron Nitride Sealed Container

GraphiteGraphite HeaterHeater

SaltSalt

Page 10: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

PCBN Tool Material GradesPCBN Properties Vary

CBN Particle SizeCBN Particle Size RangeCBN FractionSecond-phase Material

Can be Optimized for Welding Specific Materials

Page 11: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

PCBN Tool ConstructionComposite tool

WC ShankPCBN InsertNickel-based alloy locking collar to hold tool together

Page 12: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

PCBN Tool Performance80 m in A36 steelImproved Grades Under Development

Specific characteristics for difficult-to-weld alloysDramatic improvement in AL-6XN

Page 13: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

PropertiesFerritic Steels

DH-361018S355 C-Mn SteelHSLA-65Quenched and Tempered Steel

TitaniumStainless

304AL-6XN

Page 14: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

DH-36Full-penetration weldsSome evidence of tool debrisGood mechanical properties – weld overmatched compared to base

Page 15: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

1018Acceptable mechanical propertiesEvidence of tool material in weldFine microstructure near shoulder, coarser away from shoulderTemperatures extrapolated to maximum weld-zone temperature of 1200C

Page 16: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

S355 C-Mn SteelWeld zone higher strength than base metalSecond weld tempers firstEqual low-temperature Charpy values, lower high-temperature Charpy

Page 17: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

HSLA-65Excellent Mechanical PropertiesBallistic Testing (Shock-hole Test)

Page 18: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Quenched and Tempered SteelTempering of first pass by second passSoftening in HAZ observedCompared with GMA welding using carbon steel filler, FSW is stronger but less tough

Data from Paul Konkol, CTC

Page 19: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

TitaniumTi-17 to Ti-17, Ti-17 to Ti-6-4, Ti-6-2-4-2 to Ti-6-4Proprietary tool materials assumed to be W-basedStrength higher than base materialMost welds have evidence of tool debris; one tool material, AE-4, shows no visible debris

Page 20: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

304 StainlessWeld strength higher than base metalRefined grain structure in weldsDark bands appear to have extra fine grain structureSome welds show sigma in fine grain bandsHigh strength, excellent ductility

Page 21: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

AL-6XNDifficult to obtain full consolidationGood mechanical properties, even with small hole in weldTool wear a problem

Page 22: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Materials Welded with PCBNFerritic SteelsStainless SteelsDuplex SteelsSuperalloysSpecialty Alloys

Page 23: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Ferritic SteelsA-36 / 1018: 80 m tool lifeHSLA-65: 10 m tool life, excellent propertiesX80/X120: Minimal tool wear, good propertiesQuenched and Tempered C-Mn steel: excellent tool life, good propertiesDH-36: Minimal tool wear, excellent propertiesDual-Ten dual phase – excellent formability

Page 24: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Stainless and Nickel Alloys3042507 Super DuplexAlloy 201Alloy 600Alloy 718

Page 25: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

304 StainlessLarge process windowOutstanding mechanical propertiesAcceptable tool life – 30 m (100 feet)Weld Parameters

Rotation: 400 rev/minTravel: 3 in/minLoad control: 9,000 lbf

Page 26: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

304 StainlessLarge process windowOutstanding mechanical propertiesAcceptable tool life – 30 m (100 feet)Weld Parameters

Rotation: 400 rev/minTravel: 3 in/minLoad control: 9,000 lbf

Page 27: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

304 Process Window

800

900

1000

1100

1200

1300

Rot

atio

n sp

eed

(RPM

)

2 3 4 5 6 7Travel speed (IPM)

Preferentially etched region consists of only grain boundary attack.

Preferentially etched region consists of both heavily etched regions and G.B. attack.

There are holes at the advancing side of friction stir weld in the as-polished condition.

Page 28: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

304 Tensile Specimens

Page 29: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

2507 Super Duplex StainlessInitial parameters only

Rotation: 450 rev/minTravel: 3.5 in/min (88 mm/min)Load control: 7400 lbf

Page 30: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

2507 Microstructure

Base material (200x) Center of DXZ (200x)

Adv.Ret.

Page 31: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

2507 Phase Composition

00 A1.5A1.5 A3A3R1.5R1.5R3R3

Up1.5Up1.5

Ferrite : RedAustenite : Green

R3 R1.5 0 A1.5 A3

Up1.5

Page 32: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Alloy 201 WeldInitial Parameters

Rotation: 1000 rev/minTravel: 4 in/min (100 mm/min)

After 12 in. of weldAfter 12 in. of weld

0.6 in.

•Tool previously used in alloy 718

Page 33: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Base material (500x) TMAZ (50x)

Adv. Ret.

Alloy 201 Microstructure

DXZ (500x)

Page 34: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Alloy 201 Mechanical Properties

5059 (406)15 (103)Base Metal (from literature)

3465 (448)28 (193)1000 RPM, 4 IPM

Elongation %Ultimate Tensile

Strength KSI (MPa)

Yield Strength

0.2 % offset KSI (MPa)

Sample

Ni 201 FSW Transverse Tensile Properties

Page 35: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Alloy 600 WeldInitial Parameters

Rotation: 450 rev/minTravel: 2.25 in/min (56 mm/min)

After 6 feet of weld

Page 36: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Alloy 600 Microstructure

Base material (100x) Center of Stir zone (100x)

Ret. Adv.

Page 37: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Alloy 600 Mechanical Properties

5092 (631)38 (263)Base Metal(annealed condition)

27104 (719)54 (374)450RPM 2 ¼IPM

Elongation %Ultimate Tensile Strength KSI

(MPa)

Yield Strength0.2 % offset KSI

(MPa)

Sample

Alloy 600 FSW Transverse Tensile Properties

Page 38: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

0.6 in.

Alloy 718 WeldInitial Parameters

Rotation: 500 rev/minTravel: 2 IPM

After 4 feet of weldAfter 4 feet of weld

0.6 in.

Page 39: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Alloy 718 Microstructure

Base material (500x) Center of DXZ (500x)

Adv.

Page 40: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Alloy 718 properties

41130 (896)67 (462)Base Metal

(Annealed, from literature)

22202 (1392)170 (1172)Base Metal

(precipitation hardened, from

literature)

16143 (986)97 (668)500RPM , 2 IPM

Elongation %Ultimate Tensile Strength KSI

(MPa)

Yield Strength0.2 % offset KSI

(MPa)

Sample

Alloy 718 FSW Transverse Tensile Properties

Page 41: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

Recent DevelopmentsSpecialty alloys

InvarNarloy Z

Underwater welding – demonstrated ability to weld 304 stainless under water without shielding gas; properties being evaluated13 mm pin length – single side weld on 13mm platePipe Welding – automatic machine for welding of 12” pipe

Page 42: Progress in Friction Stir Welding High Temperature Materialsfsrl.byu.edu/presentations/Progress in Friction Stir Welding.pdf · Progress in Friction Stir Welding High Temperature

FRICTION STIR RESEARCH LABORATORY

SummaryFSW successfully applied to wide variety of iron and nickel alloysProperties look good in most cases

Low distortionGood strength Reasonable elongation

Tool life is high enough for high-value applications, and increasing