Enhancing the mechanical performance of Al-Zn-Mg alloy builds fabricated via underwater friction stir additive manufacturing and post-processing aging

Our previous studies have demonstrated that underwater friction stir additive manufacturing(FSAM)could effectively suppress the macroscale softening of the fabricated Al-Zn-Mg-Cu alloy build from top to bottom.However,the accompanying local softening problem,i.e.,a low-hardness region at the bottom of each stir zone,becomes prominent.In this study,an Al-Zn-Mg alloy with low quench sensitivity was used to fabricate a multilayered build via underwater FSAM.In-process water cooling could effectively solve the macroscale and local softening problems in the FSAM of the Al-Zn-Mg alloy and improve the mechanical performance of the build.The microhardness and ultimate tensile strength(UTS)of the water-cooled build in as-fabricated and aged states were more uniform along the building direction and higher than those of their counterparts.After 90 days of natural aging,the UTS of the water-cooled build in building and traveling directions reached 398 and 400 MPa,respectively,slightly higher than that of the base metal(392 MPa).The enhancement in the mechanical performance of the water-cooled build was attributed to a high degree of supersaturation and age-strengthening ability because of a high cooling rate of the underwater FSAM process and low quench sensitivity of the base metal.

Chemical Composition Effect on Microstructures and Mechanical Properties in Friction Stir Additive Manufacturing

The variation of chemical compositions can affect the mechanical property of friction stir additive manufacturing(FSAM).Quantitative characterization of the relationship between the chemical composition and the mechanical property of FSAM components is key to control the quality of FSAM components.The effect of chemical composition on the mechanical property of 6 xxx series aluminum alloy FSAM joint was studied by both experimental and numerical methods.A moving heat source model was established to simulate the heat transfer in FSAM process.The average grain size was calculated by Monte Carlo model,and the precipitate evolution model was used to calculate the hardness and constitutive stress-strain relationship.The validity of the numerical model was verified by experiments.Results indicate that the hardness and yield stress of 6 xxx series aluminum alloy FSAW joint can be enhanced by increasing silicon or magnesium contents.By increasing the content of magnesium(silicon),the volume fraction and the mean radius of MgSi can be increased when the content of silicon(magnesium) is excessive.With the decrease in volume fraction,the average grain size can be increased.By changing the weight percentage of magnesium and silicon in different layers,the hardness and yield stress along the build direction can be controlled.

Friction stir based welding and processing technologies-processes,parameters,microstructures and applications:A review

Friction stir welding [FSW） has achieved remarkable success in the joining and processing of aluminium alloys and other softer structural alloys. Conventional FSW, however, has not been entirely successful in the joining, processing and manufacturing of different desired materials essential to meet the sophis- ticated green globe requirements. Through the efforts of improving the process and transferring the existing friction stir knowledge base to other advanced applications, several friction stir based daughter technologies have emerged over the timeline, A few among these technologies are well developed while others are under the process of emergence. Beginning with a broad classification of the scattered fric- tions stir based technologies into two categories, welding and processing, it appears now time to know, compile and review these to enable their rapid access for reference and academia. In this review article, the friction stir based technologies classified under the categol^J of welding are those applied for join- ing of materials while the remnant are labeled as friction stir processing （FSP） technologies. This review article presents an overview of four general aspects of both the developed and the developing friction stir based technologies, their associated process parameters, metallurgical features of their products and their feasibility and application to various materials. The lesser known and emerging technologies have been emphasized.