Fatigue crack propagation of 7050 aluminum alloy FSW joints after surface peening

The surface composite modification of the 7050 aluminum alloy friction stir-welded joints was performed by shot peening(SP)/multiple rotation rolling(MRR)and MRR/SP,and the fatigue performance of the nugget zone(NZ)was investigated.The results demonstrated that the fatigue life of SP/MRR samples is longer than that of MRR/SP.On the plane 150μm below the surface.The grains with high angle grain boundary account for 71.5%and 34.3%for MRR/SP and SP/MRR samples,respectively.The crack propagation path of the MRR/SP is transgranular and intergranular,and it is intergranular for the MRR/SP.Multitudinous fatigue striations and some voids appeared at the fracture during the stable crack propagation stage.However,fatigue striations for SP/MRR are with smaller spacing,fewer holes,and smaller size under SP/MRR compared with fatigue fracture of MRR/SP.The differences in fatigue properties and fracture characteristics of the NZ are related to the microstructure after the two combined surface modifications.

Residual Stress Relaxation of Thin‑walled Long Stringer Made of Aluminum Alloy 7050‑T7451 under Transportation Vibration

Thin-walled long stringer made of aluminum alloy 7050-T7451 is prone to deformation during transportation,so a research of residual stress relaxation was launched in this paper.The transport resonance stress of long stringer was analyzed based on the power spectral density of road transport acceleration.The residual stress relaxation experiment of aluminum alloy 7050-T7451 under different equivalent stress levels was designed and carried out.According to the amount of residual stress relaxation in the experiment,an analytical model was established with the equivalent stress level coefficient.The deflection range of long stringer was evaluated under different damping ratios.The results show that when the equivalent stress exceeds 0.8σ0.2,the residual stress relaxation of the thin-walled samples occurs.The residual stress relaxation increases linearly with the equivalent stress,which is logarithmically related to the loading cycle.The deformation caused by residual stress relaxation of the long stringer is proportional to the square of the length and the bending moment caused by stress rebalance,and inversely proportional to the moment of inertia of the structure.As the damping ratio decreases from 0.03 to 0.01,the total deflection of the long stringer increases from 0 to above 1.55 mm.

Influence of two-step aging on structure and stress corrosion sensitivity of friction stir welded 7050-T7451 aluminum alloys

3 mm thick 7050-T7451 aluminum alloy joint was obtained by friction stir welding, and the two-step aging treatment was performed at 121 ℃ × 5 h + 163 ℃× 27 h after welding. Microstructure, hardness profiles and stress corrosion sensitivity of the joint were measured and studied. The results indicate that through the two-step aging, the grain size is coarsened, the age-hardening precipitates and PFZ become wider at the same time, which results in the discontinuous grain boundary;the microhardness of the FSW joints decreased, but the heat-affected zone significantly narrowed, which increased the uniformity of the microhardness of the FSW joints;and the two-stage aging effectively reduced the stress corrosion sensitivity of the FSW joints. The joints with aging treatment were not broken after 60 days,however all the joints without aging treatment were broken within 1 day.

Milling surface roughness for 7050 aluminum alloy cavity influenced by nozzle position of nanofluid minimum quantity lubrication

In nanofluid minimum quantity lubrication(NMQL)milling of aviation aluminum alloy,it is the bottleneck problem to adjust the position parameters(target distance,incidence angle,and elevation angle)of the nozzle to improve the surface roughness of milling,which has large and uncontrollable errors.In this paper,the influence law of milling cutter speed,helical angle,and cavity shape on the flow field around the milling cutter was studied,and the optimal nozzle profile parameters were obtained.Using 7050 aluminum alloy as the workpiece material,the milling experiment of the NMQL cavity was conducted by utilizing cottonseed oil-based Al2 O3 nanofluid.Results show that the high velocity of the surrounding air flow field and the strong gas barrier could be attributed to high rotating velocities of the milling cutter.The incidence angle of the nozzle was consistent with the helical angle of the milling cutter,the target distance was appropriate at 25–30 mm,and the elevation angle was suitable at 60°–65°.The range and variance analyses of the signal-to-noise ratio of milling force and roughness were performed,and the chip morphology was observed and analyzed.The results show that the optimal combination of nozzle position parameters was the target distance of 30 mm,the incidence angle of 35°,and the elevation angle of 60°.Among these parameters,target distance had the largest impact on cutting performance with a contribution rate of more than 55%,followed by incidence angle and elevation contribution rate.Analysis by orthogonal experiment revealed that the nozzle position parameters were appropriate,and Ra(0.087 lm)was reduced by 30.4%from the maximum value(0.125 lm).Moreover,Rsm(0.05 mm)was minimum,which was 36%lower than that of the seventh group(Rsm=0.078 mm).

Study on the reaming process of aluminum alloy 7050-T7451 under different cooling conditions

Aluminum alloy 7050 is widely used in the aeronautical industries.However,owing to their highly ductile property,chips created during high-speed machining cannot be naturally broken,and long continuous chips are unavoidably formed,impacting the machining stability and quality of the parts.Because a smaller cutting allowance is required compared with conventional machining operations,the behavior of the chips during reaming operation may be more complex and different from those determined in previous investigations.Therefore,studying the characteristics of chip formation and hole quality during the reaming process is essential to improve the machinability of aluminum alloy 7050.In this study,three different cooling conditions were applied to reaming aluminum alloy 7050-T7451 with polycrystalline diamond(PCD)reamers.The finite element models(FEMs)were established to simulate the chip formation.The macro-and micro-morphologies of chips under the three cooling conditions were compared to analyze the chip behaviors.The diameter,surface roughness,and micro-morphologies of the reamed holes were also analyzed to evaluate the hole quality.The results showed that the chip morphology was strongly influenced by the cutting parameters and cooling strategies.It was found that the desired chip morphologies satisfactory geometrical accuracy and surface quality during the reaming of aluminum alloy 7050-T7451 could be achieved using internal cooling at a spindle speed of 8000 r/min and a feed rate of 0.0l mm/z.This study also demonstrates the feasibility of an internal cooling strategy for breaking chips when reaming aluminum alloy 7050-T7451,which opens new possibilities for improving the chip-snarling that occurs during hole machining.