Unified Principal S-N Equation for Friction Stir Welding of 5083 and 6061 Aluminum Alloys

With the popularization of friction stir welding(FSW),5083-H321 and 6061-T6 aluminum alloy materials are widely used during the FSW process.In this study,the fatigue life of friction stir welding with two materials,i.e.,5083-H321 and 6061-T6 aluminum alloy,are studied.Fatigue tests were carried out on the base metal of these two materials as well as on the butt joints and overlapping FSW samples.The principle of the equivalent structural stress method is used to analyze the FSW test data of these two materials.The fatigue resistances of these two materials were com-pared and a unified principal S-N curve equation was fitted.Two key parameters of the unified principal S-N curve obtained by fitting,Cd is 4222.5,and h is 0.2693.A new method for an FSW fatigue life assessment was developed in this study and can be used to calculate the fatigue life of different welding forms with a single S-N curve.Two main fatigue tests of bending and tension were used to verify the unified principal S-N curve equation.The results show that the fatigue life calculated by the unified mean 50%master S-N curve parameters are the closest to the fatigue test results.The reliability,practicability,and generality of the master S-N curve fitting parameters were verified using the test data.The unified principal S-N curve acquired in this study can not only be used in aluminum alloy materials but can also be applied to other materials.

Modeling effects of constituents and dispersoids on tensile ductility of aluminum alloy

The modeling effects of constituents and dispersoids on the tensile ductility of aluminum alloy were studied.The results show that the tensile ductility decreases with the increase of the volume fraction and size of constituents.Thus,purification can improve the tensile ductility by decreasing the volume fraction of constituents(normally compositions of Fe and Si)and the first-class microcracks.The model also indicates that the tensile ductility decreases with the increase in the volume fraction of dispersoids.Decreasing the volume fraction of dispersoids along the grain boundaries by proper heat-treatment and improving the cohesion strength between dispersoids and matrix can also improve the tensile ductility by decreasing the volume fraction of the second-class microcracks.

Tensile ductility improvement of AlSi9Cu1 alloy by chemical composition optimization

Diesel engines, characterized by higher breakout pressure and compression ratio in comparison with gasoline engines, require particularly elevated tensile properties for their engine parts. In order to maintain both high strength and high ductility in the cylinder head, i.e., to obtain higher percent elongation without further reducing the tensile strength, Al Si9Cu1 alloy was used to prepare the cylinder head in an aluminum diesel engine. At the same time, the effect of different modification elements, Na or Sr, and Fe content on the reduction of secondary dendrite arm spacing(SDAS) was discussed, and the design of T7 heat treatment parameters were analyzed in order to improve the tensile ductility. The result shows:(1) The SDAS is as small as 18±3 μm for the Sr modified alloy.(2) The percent elongation of the alloy with Sr modification increases by 66.7% and 42.9%, respectively, compared with the unmodified alloy and the alloy with Na modification.(3) Lower Fe content alloy(0.10%) gives good results in percent elongation compared to the alloy with higher Fe content(0.27%); in particular, after Sr modification and T7 heat treatment, the elongation of over 5% is obtained.

Effect of quenching cooling rate on residual stress and microstructure evolution of 6061 aluminum alloy

In this study,the cooling rate was manipulated by quenching with water of different temperatures(30,60 and 100℃).Surface and internal residual stresses in the quenched 6061 aluminum alloy samples were measured using hole-drilling and crack compliance methods,respectively.Then,the processability of the quenched samples was evaluated at cryogenic temperatures.The mechanical properties of the as-aged samples were assessed,and microstructure evolution was analyzed.The surface residual stresses of samples W30℃,W60℃and W100℃is−178.7,−161.7 and−117.2 MPa,respectively along x-direction,respectively;and−191.2,−172.1 and−126.2 MPa,respectively along y-direction.The sample quenched in boiling water displaying the lowest residual stress(~34%and~60%reduction in the surface and core).The generation and distribution of quenching residual stress could be attributed to the lattice distortion gradient.Desirable plasticity was also exhibited in the samples with relatively low quenching cooling rates at cryogenic temperatures.The strengthes of the as-aged samples are 291.2 to 270.1 MPa as the quenching water temperature increase from 30℃to 100℃.Fine and homogeneous β"phases were observed in the as-aged sample quenched with boiling water due to the clusters and Guinier-Preston zones(GP zones)premature precipitated during quenching process.

Simulation of temperature and stress in 6061 aluminum alloy during online quenching process

The cooling curves of 6061 aluminum alloy were acquired through water quenching experiment. The heat transfer coefficient was accurately calculated based on the cooling curves and the law of cooling. The online quenching process of complex cross-section profile was dynamically simulated by the ABAQUS software. The results suggest that the heat transfer coefficient changes during online quenching process. Different parts of the profile have different cooling velocity, and it was verified by water quenching experiment. The maximum residual stress of the profile was predicted using FEM simulation based on ABAQUS software The relations between the temperature and stress were presented by analyzing the data of key points.

Influences of electric-hydraulic chattering on backward extrusion process of 6061 aluminum alloy

The possibility of the electric-hydraulic chattering technology and its application in the cold extrusion were presented.The conventional and electric-hydraulic chattering assisted backward extrusion processes were performed on 6061 aluminum alloy billets at room temperature.The experimental results showed that 5.65% reduction in the extrusion load was attained if the die and ejector were vibrated at a frequency of 100 Hz and amplitude of 0.013 mm in the longitudinal direction.The friction coefficient at the billet and tool system interface determined from the finite element analysis（FEA） decreased from 0.2 without chattering to 0.1 with application of electric-hydraulic chattering.The higher values of instantaneous velocity and direction change of material flow were achieved during the chattering assisted backward extrusion process.The strain distribution of the chattering assisted backward extrusion billet revealed lower maximum strain and smoother strain distribution in comparison with that produced by the conventional extrusion method.

6061铝合金FSW接头组织与耐蚀性能的研究

对4 mm厚的6061-T6铝合金板进行了搅拌摩擦焊接,通过浸泡腐蚀试验和电化学腐蚀试验研究焊缝腐蚀性能,采用金相显微镜、透射电镜等观察接头的微观组织。结果表明:6061铝合金FSW焊核区晶粒显著细化,晶界第二相较少;焊核区的耐剥落腐蚀和晶间腐蚀性能优于热影响区的;焊核区比热影响区的腐蚀电位较高,腐蚀电流密度较小,焊核区表现出更好的耐腐蚀性能。

旋转摩擦挤压加工对不同时效态6061铝合金显微组织和力学性能的影响

采用旋转摩擦挤压(rotational friction extrusion,RFE)工艺对不同时效态6061铝合金进行加工,研究RFE对不同时效态6061铝合金显微组织和力学性能的影响。结果表明:RFE能够破碎6061铝合金中的难熔AlFeMnSi相,导致合金中的AlFeMnSi相细小且分布均匀。预析出粗大Mg2Si相在RFE加工过程中摩擦热和变形作用下,回溶后重新析出,致使预析出粗大Mg2Si相对材料动态再结晶中的粒子激发形核(particle stimulated nucleation,PSN)机制无影响,RFE加工后的晶粒尺寸变化较小。RFE使淬火态6061铝合金强度下降,但长时间时效态6061铝合金经RFE加工后强度得到提升。然而,RFE加工的材料内部存在孔洞,合金断后伸长率降低。

固溶处理对6061铝合金显微组织与力学性能的影响

采用光学显微镜(OM)、电子背散射衍射(EBSD)和维氏显微硬度计研究了固溶处理对压缩态6061铝合金显微组织与力学性能的影响。结果表明:压缩态6061铝合金经过固溶处理后有细小等轴再结晶晶粒形成,再结晶晶粒的形成弱化了其织构强度。随着固溶处理时间增加,合金中的再结晶晶粒增多,织构强度降低。6061铝合金经过固溶处理后由于固溶强化的作用导致其硬度显著增大,但随着固溶处理时间的增加,合金的晶粒尺寸增大,细晶强化作用降低,致使合金的硬度值有所减小。

膜层厚度对6061铝合金黑色微弧氧化陶瓷膜层结构与性能的影响

为了明确膜层厚度对铝合金黑色微弧氧化陶瓷膜层的黑度、耐蚀性和硬度的影响规律,促进其实际应用,在硅酸盐-钒酸盐复合溶液体系中对6061铝合金进行微弧氧化处理,通过控制微弧氧化时间获得具有不同膜层厚度的铝合金黑色陶瓷膜层。利用测厚仪、粗糙度测量仪、SEM和EDS对黑色陶瓷膜层的表面结构、膜层成分和粗糙度等进行表征,并借助色差仪、维氏硬度计和电化学工作站等研究了膜层厚度对陶瓷膜层的黑度、显微硬度和耐蚀性的影响。结果表明:膜层厚度对黑色陶瓷膜层的表面形貌、粗糙度、显色特性、硬度和耐蚀性有较大影响。随着微弧氧化时间延长,膜层厚度增加,膜层表面更为粗糙,表层放电微孔数量减少,放电微孔孔径增大;当膜厚达到30.786μm时,陶瓷膜层的放电微孔显著增大,孔径达到10μm。随着膜层厚度增加,陶瓷膜层的黑度增加,显微硬度提高,但耐蚀性先增强后降低。当膜层厚度为20.781μm时,陶瓷膜层的黑度和硬度较高,耐蚀性最好,其在3.5%NaCl溶液中的自腐蚀电流密度为1.093×10^(-6) A/cm^(2)。

Effects of processing parameters on microstructure and mechanical properties of powder-thixoforged 6061 aluminum alloy

A new processing technology,powder thixoforming,for preparation of particle reinforced metal matrix composites was proposed and 6061 aluminum alloy was prepared by powder thixoforging.6061 ingots were first prepared by cold-pressing the atomized 6061 alloy powders,and then the ingots were partially remelted followed by thixoforging.The effects of reheating time,mould temperature and reheating temperature on microstructure and mechanical properties of the thixoforged alloys were investigated.The results indicate that all of the three parameters have large effects on the microstructure and mechanical properties.Owing to the microstructure changes,the fracture regime varies with the processing parameters.Furthermore,cracks always initiate from shrinkage porosities and inclusions,and then propagate either along the secondarily solidified structures or primary particles.The ultimate tensile strength,elongation and hardness of the resulting alloy are up to 196 MPa,11.0%and HV 55.7 respectively.

ZL101/6061铝合金搅拌摩擦焊接头组织及性能研究

采用搅拌摩擦焊接ZL101铸造铝合金和6061铝合金,转速为1000 r/min,研究不同焊接速度和压入量对铝合金接头组织和性能的影响。结果表明:当焊接速度为150 mm/min,压入量为6 mm时,铝合金接头的成型较美观;接头主要以α(Al)相为基体,在基体上分布着Al4Si第二相;铝合金接头的抗拉强度达到最大值,为92.53 MPa;焊接接头的硬度总体上呈“W”趋势,焊核区硬度高,热机械影响区的硬度略微下降,热影响区的硬度又有所回升。此工艺参数条件下铝合金接头的耐腐蚀性能最好,自腐蚀电位和自腐蚀电流密度分别为-0.6933 V和3.17×10^(-7) A/cm^(2)。

温轧及T6热处理对Al_(2)O_(3)/RGO颗粒增强6061铝基复合材料力学性能及摩擦性能的影响

以6061铝合金为基体,三氧化二铝负载还原氧化石墨烯(Al_(2)O_(3)/RGO)为增强体颗粒,采用粉末冶金的方法,制备了添加Al_(2)O_(3)/RGO颗粒质量分数为0.1%的6061铝基复合材料,然后对其进行温轧和T6热处理。利用扫描电镜、透射电镜、X射线衍射仪、万能拉伸实验机和摩擦磨损实验机等研究了温轧及T6热处理对Al_(2)O_(3)/RGO增强6061铝基复合材料力学性能及摩擦性能的影响。结果表明:Al_(2)O_(3)可以有效负载到RGO上,并抑制RGO与Al基体的结合,减少Al_(4)C_(3)相的产生,但是随着温轧温度的升高,在铝基复合材料中Al_(2)O_(3)/RGO颗粒与Al基体的结合面增大,当温轧温度超过330℃时,再经过T6热处理,复合材料中开始析出Al_(4)C_(3)相;当温轧温度为330℃时,复合材料的抗拉强度、屈服强度、硬度和伸长率分别为259.7 MPa、179.2 MPa、96.58 HV100和10.2%,综合力学性能最佳;随着温轧温度的升高,平均摩擦系数逐渐降低,当温轧温度为390℃时,平均摩擦系数最低为0.31。

Effect of ball milling on microstructural evolution during partial remelting of6061 aluminum alloy prepared by cold-pressing of alloy powders

The effect of ball milling on the microstructural evolution was investigated during partial remelting of 6061 aluminum alloy prepared by cold-pressing of atomized alloy powders.The results indicate that the microstructural evolution of 6061 aluminum alloy can be divided into three stages,the dissolution of eutectic phases and the coarsening and growth behavior of the resulting grains,structural separation and spheroidization of primary particles,and the final coarsening behavior of the particles.Compared with the alloy without ball milling,ball milling accelerates the first stage of microstructural evolution due to the energy stored in the powders,but the latter two stages are slowed down because of the formation of large-sized powders.Moreover,the finer the as-cold-pressed microstructure is,the smaller and more spherical the primary particles in the final semisolid microstructure are.Furthermore,properly elevating the heating temperature is beneficial for obtaining small and spheroidal particles.

6061铝合金非连续搅拌摩擦增材制造与性能研究

目的利用非连续搅拌摩擦沉积增材制造技术制备了6061铝合金并研究了z方向非连续搅拌对合金性能的影响。方法使用超景深电子显微镜分析了预热时间对沉积增材成形工艺的影响,并探究了该工艺条件下沉积层的宏/微观缺陷、材料流动及拉伸力学性能关联规律。结果采用z方向非连续搅拌摩擦沉积增材成形工艺,在预热时间为35 s的条件下,除无横向约束的前进侧和后退侧出现了孔洞、弧形飞边及弱结合等微观缺陷外,沉积层中原料棒与凸起搅拌作用区的组织表现为高致密无孔洞的良好形态,原料棒及刀具凸起的强搅拌作用造成z方向材料流动存在差异,进而获得力学性能沿z方向具有梯度分布的完整沉积层,提高了搅拌摩擦沉积增材制造6061铝合金的成形效率。结论在相应的主轴转速(420 r/min)、平移速度(72 mm/min)、进料速度(72 mm/min)、刀具凸起高度(1.5 mm)与预热时间(35 s)工艺参数下,获得了稳定的增材沉积层,有效抑制了沉积层原料棒及凸起搅拌作用区的宏观缺陷,并使材料性能沿z方向呈梯度分布;沉积层抗拉强度达到了原料棒的57.15%;同时伸长率提升了185.8%,为高效率沉积增材及制备梯度性能构件提供了工艺借鉴。

超声喷丸对6061铝合金表面性能及拉伸性能影响

为研究超声喷丸对6061铝合金表面性能及拉伸性能的影响。采用光学显微镜、三维形貌仪、显微硬度仪、电子拉伸试验机、扫描电子显微镜(SEM)分析不同喷丸时间下6061铝合金试样的微观组织、表面形貌、表面粗糙度、显微硬度、拉伸性能及拉伸断口形貌。喷丸处理后,试样表面发生塑性变形,晶粒得到细化,表面显微硬度由105Hv增加到144.1Hv,硬化层厚度约500μm,表面粗糙度随喷丸时间先增加后减小;相比于未喷丸试样,喷丸处理后试样的拉伸性能有不同程度改善。试验结果表明,超声喷丸处理能有效改善6061铝合金的表面性能和拉伸性能,不同时间的喷丸处理效果存在差异,喷丸时间为180s时,试样拉伸性能较好。

Influence of sequence of cold working and aging treatment on mechanical behaviour of 6061 aluminum alloy

The influence of combination of different designated precipitation hardening and cold working on the tensile properties of 6061 aluminum alloy was investigated. The results indicate that applying single aging at 180 ℃ for 4 h in different thermal-mechanical treatments improves both the strength and elongation. However, double aging does not improve the mechanical properties. In addition, pre-aging shows a negative effect on the subsequent precipitation hardening of material. The changes in mechanical properties were discussed by explanation of microstructural evolution due to the competition of precipitation hardening, strain hardening and work softening processes.

Effect of post-weld heat treatment on microstructure and mechanical properties of welded joints of 6061-T6 aluminum alloy

6061 aluminum alloy T-joints were welded by double-pulsed MIG welding process. Then, the post-weld heat treatment was performed on the welded T-joints. The weld microstructure under different aging temperature and time was investigated by transmission electron microscopy and scanning electron microscopy. The mechanical properties were examined by hardness test and tensile test. The results showed that the micro-hardness was sensitive to heat treatment temperature and time. Increasing temperature was beneficial to the shortening of peak aging time. There were a large number of dislocations and few precipitates in the welded joints. With the increase of post-weld heat treatment temperature and time, the density of dislocation decreased. Meanwhile, the strengthening phase precipitated and grew up gradually. When the post-weld heat treatment temperature increased up to 200℃, large Q' phases were observed. And they were responsible for the peak value of the micro-hardness in the welded joints.

Solidification behavior of 6061 wrought aluminum alloy during rheo-diecasting process with self-inoculation method

The semisolid slurry of the 6061 wrought aluminum alloy was prepared by the self-inoculation method（SIM）. The effects of the isothermal holding parameters on microstructures of rheo-diecastings were investigated, and the solidification behavior of 6061 wrought aluminum alloy during the rheo-diecasting process was analyzed using OM, SEM, EDS and EBSD. The results indicate that the isothermal holding process during slurry preparation has great effect on primary α（Al） particles（α1）, but has little effect on the microstructure of secondary solidification in the process of thin-walled rheo-diecasting. Nucleation is expected to take place in the entire remaining liquid when the remaining liquid fills the die cavity, and the secondary solidification particles（α2） are formed after the process of stable growth, unstable growth and merging. The solute concentration of remaining liquid is higher than that of the original alloy due to the existence of α1 particles, hence the contents of Mg and Si in α2 particles are higher than those in α1 particles.

Optimization of ECAP-RAP process for preparing semisolid billet of 6061 aluminum alloy

6061 aluminum alloy semisolid billet was prepared by the equal-channel angular processing(ECAP)-recrystallization and partial(RAP)process(a combination of equal-channel angular processing and recrystallization and partial remelting).The effects of different process parameters on the alloy microstructure were studied and the quantitative relationship between the process parameters and microstructure was established by response surface methodology(RSM)to optimize the process parameters.According to the orthogonal test,the holding temperature and holding time of the four ECAP-RAP process parameters were found to have the greatest impact on the microstructural characteristics,including average grain size and average shape factor.Through RSM,it was also found that when the average grain size or the average shape factor is optimized separately,another will be degraded.When the two indexes were simultaneously considered,the optimal process parameters were found to be a holding temperature of 623°C and holding time of 13 min,and the corresponding average grain size and average shape factor were 35.97μm and 0.8535,respectively.Moreover,comparing the experimental and predicted values,the reliability of the established response surface model was verified.