Effects of Process Parameters on Mechanical Properties and Microstructure of AA6063-T6 and AA5052-H32 Dissimilar Friction Stir Welded Joints

Abstract

Abstract  This work established a process window aimed at minimizing discontinuities and improving mechanical properties in dissimilar friction stir welded joints between AA6063-T6 and AA5052-H32 alloys. A different set of rotational and traverse speed value combinations were experimentally evaluated using graphical analysis, which was compared to information from the literature. Microstructure characterization of the welded joints was conducted using optical microscopy, X-ray diffraction, and SEM-EDS. Microhardness measurements were performed, and an experimental design statistical analysis was carried out to establish the correlation between the process parameters and tensile properties. The results showed that a speed ratio of 1800/163 (R=ω/v rev/mm) produced discontinuity-free welded joints with higher microhardness and tensile strength values, being 159 MPa for ultimate strength.

Key-words:
Friction stir welding; Dissimilar welded joints; Process parameters; Mechanical properties; Microstructure

1. Introduction

Friction stir welding (FSW) is a solid-state joining process that was developed and patented in 1991 by The Welding Institute [¹]. Due to the highlighted manufacturing advances that the FSW process has achieved in recent years, important applications have been developed for welding alloys with good strength-to-weight ratios [²]. Several alloys, including aluminum alloys, have difficult weldability using conventional fusion welding processes. However, the FSW process has demonstrated the feasibility of joining these kinds of materials [³]. The FSW process uses a tool consisting of a pin coupled to a shoulder. The tool rotates while it contacts the surface of the joint line of the components to be welded until the two parts of the tool come into simultaneous contact with the parts to be welded. Once the rotation and penetration of the tool are stabilized, it advances longitudinally along the welding line. The mixture and extrusion of plasticized material occurs due to the shoulder and pin friction [⁴]. Currently, optimization strategies are being implemented in material selection for applications in the aerospace, marine, and automotive industries. New design challenges have led to the use of dissimilar aluminum joints to have better performance by combining properties of two different alloys and saving energy costs due to their good strength-to-weight ratio [⁵]. However, despite the increasing use of these kinds of joints, several difficulties arise during and after the process, such as cracking, lack of fill, tunneling, or the formation of intermetallic compounds, which can be controlled by choosing suitable variables, such as rotational speed, traverse speed, positioning of the base materials, and tool geometry, among others [⁶].

Most of the outcomes of FSW research deal with both similar and dissimilar welded joints of aluminum alloys and their relationships with process parameters, tensile strength, and microstructure observations, in accordance with bibliometric studies [⁷]. It is well-known that discontinuity-free FSW welded joints exhibit better mechanical properties due to the improvement in joint quality. Therefore, the interaction between rotational and traverse speeds, and their relationships with geometrical and dimensional parameters, results in the control of heat generation, which is key to controlling the emergence of discontinuities [⁸]. The aforementioned is less complicated in similar welded joints; however, when dealing with dissimilar joints, variables such as the kinetics of precipitation, the difference in phase transformation temperature, and disparity in mechanical properties increase the problem.

The Aluminum-Magnesium (Al-Mg) alloy, commonly referred to as the AA5xxx series, and Aluminum-Magnesium-Silicon (Al-Mg-Si), generally referred to as the AA6xxx series, are groups of aluminum alloys widely used in the aerospace, naval, and automotive industries. Characteristics such as high extrudability, excellent corrosion resistance, good strength-to-weight ratio, and acceptable weldability make these alloys ideal replacements for ferrous materials. Recently, promising naval and automotive applications have been projected with the utilization of dissimilar welded joints between the AA5xxx and AA6xxx series [⁹,¹⁰]. Table 1 summarizes the mechanical properties of several dissimilar welded joints between the AA5xxx and AA6xxx series. The joint efficiency of these welded joints was calculated by taking the ratio of the tensile strength of the welding joint to the tensile strength of the weaker base material [¹⁷].

Table 1
Mechanical properties summary of AA5xxx and AA6xxx dissimilar welded joints.

Base materials		Tensile strength		Joint Efficiency	Type of tool	Defects	References
AS	RS	Su (MPa)	$\epsilon$ (%)
AA6061-T6	AA5052-H32	210.4	-	92.3	cylindrical	Free	[11]
AA6061-T6	AA5083-H12	218.17	-	80.7	cylindrical	Free	[12]
AA6082-T6	AA5083-H111	198.48	4.3	61.1	Triangular	Free	[13]
AA6082-T6	AA5083-H111	157.54	4	51.1	Taper Square	Free	[14]
AA6061-T651	AA5052-H32	209.8	7.3	92	Threaded conical and includes three flats	Free	[15]
AA5083	AA6061-T6	185.42	-	55.5	Tapered threaded cylindrical	Tunnel	[16]

Table 1 shows that discontinuities-free welded joints with the highest efficiency were produced with the AA5xxx series located on the retreating side and using a cylindrical or conical tool. The highest values of efficiency joint were obtained when was used AA5052-H32 (∼92%). The lowest hardness recorded in the cross-section of the joint was located in the heat-affected zone of the AA6061-T6 alloy side. Additionally, by increasing the rotation speed, the hardness in the agitation zone was lower [¹⁸]. An adequate process window for AA5xxx-AA6xxx has been identified among 800 to 1200 rpm of rotational speed, and 45 to 85 mm.min^-1 of traverse speed to obtain free-discontinuities friction stir welded joints [¹⁹].

Latent interest in AA6063-T6 aluminum alloy utilization is increasing due to possible use in electric-car battery structural and naval applications [¹⁰,²⁰]. Several studies developed on similar FSW AA6063-T6 joints show that maximum tensile strength efficiency is around 60% - 80% under diverse geometrical conditions [²¹-²³], even when it was welded at high rotational speeds [²⁰], and welded with acoustic assisted [²⁴], respectively. Due to its potential use and available limited information [²⁵] is interesting to study different process windows of dissimilar welded joints between AA6063-AA5052 aluminum alloys. Considering this, this research aims to establish experimental values of rotation and traverse speed, aiming to produce minimum discontinuities and maximum FSW welded joint efficiency between AA6063-T6 and AA5052-H32.

2. Materials and Methods

2.1. Base materials properties

Commercially obtained sheets of AA6063-T6 and AA5053-H-32 aluminum alloys with dimensions of 145 mm × 100 mm × 3 mm were used. Table 2 shows the chemical composition of both base materials, which were experimentally determined using optical emission spectrometry, and their mechanical properties are presented in Table 3.

Table 2
Chemical composition of used base materials.

Alloy	Si	Fe	Cu	Mn	Mg	Cr	Zn	Ti	Al
AA6063-T6	0.431	0.226	0.021	0.025	0.503	0.0044	0.0026	0.02	Balance
AA5052-H32	0.115	0.286	0.027	0.041	2.357	0.211	0.009	0.013	Balance

Table 3
Mechanical properties of used base materials.

Alloy	Yield strength (MPa)	Ultimate strength (MPa)	Elongation (%)	Microhardness (HV)
AA6063-T6	248	270	10.8	86 ± 2
AA5052-H32	195	235	14.2	76 ± 2

2.2. Friction stir welding process parameters

Figure 1c shows the geometrical and dimensional details of the tool and samples used to produce dissimilar welded joints. The AA6063-T6 alloy was placed on the advancing side (AS) to plasticize with higher heat generation because it is the hardest material, on the other hand, the AA5052-H32 alloy was placed on the retreating side (RS) because it is less hard and allows better fluidity in plasticized state [²⁶]. A search was carried out on studies of FSW joints similes of aluminum alloys of the 5xxx and 6xxx series, both in dissimilar joints between these two series. The tool geometry that best macroscopic appearance in the welds was the conical profile, therefore, a tool was designed by the methodology proposed by [²⁷]. A tool-tapered conical with a slotted shoulder was used with a tilt angle of 1.5 degrees, which was fabricated from quenched and tempered AISI H13 steel. After tool fabrication, this was the treated with plasma nitriding hardening.

Figure 1
Experimental setup. (a) Dimensions and disposition of samples in welded joints. (b) microhardness locations. (c) and (d) Details of shoulder and pin of the tool.

Welding of coupons were carried out in a conventional adapted milling machine Cervinia® model 250 with 4 HP of power. Process parameters were selected according to literature information, the speed setting of the milling machine, and experimental validations using a range of values of rotation speed between 900 to 1800 rpm and 30 to 252 mm.min^-1 of traverse speed.

2.3. Microstructure and x-ray diffraction analysis

Cross-section samples for microstructure analysis (Figure 1) were extracted from the welded joints aiming to explore using optical (OM) and scanning electron microscopy (SEM). Samples were prepared in accordance with ASTM E3-11 procedure [²⁸]. Observation surfaces were polished with 1 µm alumina, and after that were attacked with HF 5% v/v. Samples were explored using a stereoscope Motic® SMZ-171-TLED, and an optical microscope Olympus® model PME3B. Scanning electron microscopy was carried out in a Jeol® JSM-7100F SEM using an energy range of 15 to 20 keV, which was coupled to EDS Oxford X-Max® 51-XMX1178 detector for chemical microanalysis. X-ray diffraction (XRD) analyses were performed to characterize phases in studied welded joints. Samples had dimensions of 8 mm × 8 mm × 3 mm, which were duly grounded, and polished with 1200 abrasive paper. DRX test were carried out in a PANalytical® X’Pert Pro. A 2-theta scanning interval comprised between 30° and 90° was established using a step of 0.03 °/s, implemented a Cu-Kα target setting the energy within the range of 15 - 25 keV.

2.4. Microhardness and tensile tests

Microhardness tests were developed using a microindenter HVS-100A using a load of 0.1 kg was used for 10 seconds in each indentation, according to ASTM E384-22 procedure [²⁹]. Measurements were done along a row located at a half thickness of the cross-section of the weld, keeping 0.5 mm of each indentation covering all welding regions, such is shown in Figure 1b. Tensile samples were extracted from welded joints using water jet cutting (see Figure 1). Tensile tests were developed in a universal machine MTS Criterion® C45.305, using a stroke speed of 0.03 mm/s and 300 kN load cell, according to ASTM E8/E8M-24 procedure [³⁰]. Tensile test results were analyzed using an ANOVA statistical design, aiming to establish relationships with process parameters traverse and rotational speeds.

3. Results and Discussion

The process variables window is shown in Figure 2, which has been sketched using both experimental and reference data. With the aim to develop an accurate graphical analysis. In accordance with literature information [⁸], the regions with higher rotational and traverse speeds, produce hot and cold stir regions respectively, which consequently, generate welded joints with discontinuities. Experimental data obtained from previously welding joints developed in this work are represented with filled squares and literature data with filled circles. It can be noticed in Figure 2, that literature data, which are based on general information about AA5xxx-AA6xxx welded joints, displayed a discontinuities-free region between 750 to 1500 rpm, and 20 to 100 mm.min^-1, approximately. Experimental data contributed by this work extend these ranges between 25 to 250 mm.min^-1, and 900 to 1800 rpm, when was explored the AA5052-H32 and AA6063-T6 welded joints. Basically, the extension of parameters values in the process window is due to metallurgical characteristics of FSW welded AA6063-T6 alloy [²⁰,²¹,²⁵].

Figure 2
Process window obtained combining literature data and experimental data.

Figure 3 are shown the experimentally obtained welded joints, which were developed using the process window values aforementioned. There are observed the cross-section and top view aspects of welded joints carried out with rotation speeds of 900 and 1800 rpm, and traverse speed sets of 30, 36, and 56 mm.min^-1, and 112, 163, and 252 mm.min^-1, respectively. All welding beads have an acceptable appearance, with a moderate burr, and regular surface. The smoother surfaces on the top of the welding beads were obtained with higher traverse speeds. All welded joints exhibited a common mix pattern of the wine-glass profile, and it is predominantly visible a remnant line at the stir region [⁸]. At the bottom of welding, a little tunnel discontinuity was observed in the cross-section (yellow arrows) when the parameters 900 rpm – 56 mm.min^-1, and 1800 rpm - 112 mm.min^-1 were used, which are a lack of filling caused by the lack of heating due to inadequate thermal generation [⁸]. After an inspection of several cross-section cuts, was possible to verify that these discontinuities were not extended along the welding bead, as observed in other works [²²]. It can be noticed that the aforementioned values are on the boarding on the process window for defect-free FSW joints of aluminum alloys studied, as shown graphical analysis in Figure 2. Thereby, is reasonable the formation of discontinuities.

Figure 3
Top view and the cross-section of welded joints developed using studied process window.

Microstructure details of welded joints obtained with 900 rpm ad 30 mm.min^-1, and 1800 rpm and 112 mm.min^-1, are shown in Figures 4a and 4b, respectively. In the first case (Figure 4a) is observed a mixing pattern of overlapping layers produced by the plasticization of each base material. The abovementioned, is comparable to observed behavior in the SZ in dissimilar welded joints of AA6082-AA2024, as reported in other work [³¹]. In the second case is observed a remnant line in the SZ, which has an S-shape and delimits the plasticized proportions of both base materials, similar to the results observed by other researches [³²,³³]. Thermo-mechanically affected zone (TMAZ) and heat affected zone (HAZ) displayed an expected metallurgical behavior. The retreating side (RS) (see Figures 4b and 4f) exhibited AA5052-H32 aluminum alloy with elongated grain with changes in direction without apparently coarsening of grain [³⁴]. On the other hand, the advancing side (AS) displayed AA6063-T6 aluminum alloy (see Figures 4d and 4g) with apparently coarsening of grain produced by located overheating and deformation, as has been observed in other works [²²].

Figure 4
Microstructure of welded joints with 900 rpm and 30 mm.min^-1: (a) macrograph image, (b) TMAZ and HAZ details of RS, (c) SZ (d)TMAZ and HAZ of RS. Microstructure of welded joints with 1800 rpm and 112 mm.min^-1: (e) macrograph image, (f) TMAZ and HAZ details of RS, (g) SZ (h)TMAZ and HAZ of RS. (i) XRD analysis of BM and FSW welded joints. (j) Precipitates of welded joints with 900 rpm and 30 mm.min-1 (k) Precipitates of welded joints with 1800 rpm and 112 mm.min-1. Optical and SEM images of (l) BM AA5052-H32, (m) BM AA6063-T6.

Aiming to identify the phases in both base metals and stir zone (SZ) of selected welded joints, was developed the analysis of diffraction pattern results, which are shown in Figure 4i. From XRD analysis shows that both base metals AA5052-H32 and AA6063-T6 predominantly have a primary $\alpha$ Al-rich phase. Additionally, AA5052-H32 shows peaks of Al₃Fe phase [³⁵,³⁶]. On the other hand, AA6063-T6 exhibits Al₈Fe₂Si, Al₅FeSi, and Mg₂Si phases [²¹]. For comparison to base materials, there are shown the XRD analysis of FSW welded joints obtained with 900 rpm and 30 mm.min^-1 and 1800 rpm and 112 mm.min^-1, respectively. The intensity of DRX peaks changes in the welded joints due to the influence of texture change, level of residual stresses, and recrystallization in the SZ [²¹].

During the FSW process probably occur two well-known phenomena dissolution of particles of second phases and the formation of new phases due to the strong thermomechanical influence of pin in the mixing [²¹,³⁷]. Besides the abovementioned phases observed in each base metal, in the XRD analysis of the welded joints were probably detected, Al₈FeMg₃Si₆ [³⁸], and Al₈Fe₂Si [²¹,³⁹]. However, the intensity of DRX peaks of these phases is low, and it is necessary to do additional research to clear up this subject. Figures 4j and 4k show optical and SEM-EDS image analyses of FSW welded joints obtained with 900 rpm and 30 mm.min^-1 and 1800 rpm and 112 mm.min^-1, respectively. It can be observed the possible presence of intermetallic particles of the Al₃Mg₂, Al₅FeSi, and Al₃Fe phases, some of those were detected in XRD analysis. Finally, Figures 4l and 4m show details of each metal base.

Figure 5 shows the microhardness profiles for each one selected combination of rotational and traverse speed. The trend of all microhardness profiles follows a characteristic shape, showing asymmetry at the ends, decreasing in the heat-affected zones (HAZ), and increasing in the stir zone (SZ), as observed in other works [¹²,¹⁸]. The asymmetry of microhardness profiles can be understood from the point of view of the hardening mechanisms of each of the alloys used and the mixing pattern of welded joints. In HAZ of the advancing side (AS), the AA6063-T6 alloy softened due to its aging treatment. Considering that the microhardness measurements were performed more than a week after the FSW process. It is possible that the temperature peaks reached and the recrystallization led to coalescence and dissolution of the precipitates found, decreasing the microhardness of the welded zone [²¹-²⁴,⁴⁰]. Similarly, the phenomenon was observed in the HAZ of the retreating side (RS) where the AA5052-H32 free stored energy, the majority in accumulated deformation form [³⁵,³⁶]. When the R-ratio increases, the hardness in the stir region is increased, such as is the case of the welded joints with 900/30 and 900/36. These welded joints presented mixing patterns with marked crosslinking of layers of both plasticized base materials in the SZ, which favors the hardness values in the agitation zone [³²].

Figure 5
Cross-section microhardness profiles of studied FSW welded joints.

Figure 6 shows summarized results of yield strength (S_y), ultimate strength (S_u), and percentage elongation (ε) of each combination of FSW process parameters. All welded joints displayed similar values of S_y, ranging from 94.5 to 106 MPa, which represent approximately 51% and 40% regarding S_y of AA5052-H32 and AA6063-T6, respectively. Welded joints with the rotational speed of 900 rpm presented similar values of S_u and ε. On the other hand, the highest efficiency and ductility were presented by the welds with the R-ratios of 1800/112 and 1800/163 rev/mm, while the lowest efficiency and ductility were obtained with 1800/252 rev/mm. Table 3 is shown the comparative summary of the mechanical properties of welded joints and respective joint efficiencies regarding the base materials.

Figure 6
Tensile strength test results on FSW welded joints.

The highest joint efficiency was observed in welded joints with R-ratio of 1800/112 and 1800/163, being 67.5% and 67.7%, respectively. These results are similar to those obtained by [¹⁸], in which the highest efficiencies shown were 72.4% in FSW joints of AA5083-H12 and AA6061-T6, and they were 10% greater than TIG welded joints with the same base alloys.

Failures of all tensile specimens occurred at the center of the stir zone (SZ), which is consistent with some discontinuities found at the root of the welded joints and the presence of the remnant line that formed at the junction boundary of the two materials [¹²,¹⁷,⁴¹]. In this work, the welding process was carried out without axial force control, which could produce the formation of discontinuities, such as cavities in welded joints [⁴²]. Mechanical properties were affected by the formation of cavities, and the generation of the "zig-zag" or "S" shaped remnant line generated in some of the joints [³²]. The remnant line could contain an oxide layer that favors the formation of micro-cracks around. which has been reported by other works [²¹,⁴¹].

Figure 7 shows an analysis of the fracture surfaces of the failure of tensile specimens welded joints obtained with 1800/112 and 900/30 R-ratio. In the first case (Figure 7a), is observed a heterogeneous fracture surface, which shows three types of fracture. In the region of the bead face: (A) a fracture without any apparent deformation, which presented some scattered cavities which could be kissing bond, lack of fill, or plasticized material. Region (B) presented dimples with heterogeneous shapes, which could have been caused by their own coalescence [¹¹]. Region (C) shows a possible quasi-cleavage micro mechanism, possibly originating from the flow of plasticized material at the root of the welded joint [⁴³]. In this welded joint there is a wide area corresponding to region B, in which a ductile fracture predominates. Figure 7b shows the heterogeneous fracture surface presented by the FSW-900/30 joint. It can be observed that in the zone of the chord face (A) there is a mixed fracture behavior, in which it is possible to distinguish a region where no deformation occurred and another region with the formation of dimples [¹¹]. In region (B), a ductile fracture behavior can be observed due to the formation of dimples that present coalescence along the surface [¹¹] also, it is possible to observe particles inside, which correspond to the second phases [⁴²]. In region (C), it is possible to observe the fracture in the form of quasi-cleavage influenced by the flow of plasticized material [⁴³], combined with the deformation of some zones that resemble dimples, indicating certain ductility in the fracture. In this welded joint, several failure micromechanisms are present with a considerable proportion of ductile fracture.

Figure 7
Fracture surface analysis of tensile test specimens. A: face, B: center, and C: the root of welded.

Because in this work was not possible to measure experimentally thermal cycles, it is necessary to establish relationships between process parameters and mechanical properties. For this, it is going to use the concept of "heat pseudo-index" [⁴], which relates to the square of rotational speed (ω) and welding speed (v) values as shown in Equation 1.

$w=\mathrm{}\frac{{\omega }^2}{v}\mathrm{}$ (1)

Using values of process parameters shown in Table 4 and typical formulation of analysis of variance ANOVA [⁴⁴], there were calculated the effects and significance of heat pseudo-index, rotation speeds, and combinations of the previous two on S_u values of each FSW welded joint. The ANOVA analysis results are shown in Table 5.

Table 4
Tensile strength properties of welded joints vs. base materials.

ω (rpm)	v (mm.min-1)	$S_y$ (MPa)	$S_{ut}$ (MPa)	$\epsilon$ (%)	Joint efficiency
900	56	104	135	4.8	57.4
900	36	99	131	4.59	55.7
900	30	106	138.5	4.53	58.9
1800	252	101.5	117	3	49.8
1800	163	94.5	159	7.9	67.7
1800	112	96	158.5	7	67.5

Table 5
Summary of analysis of variance (ANOVA) for $S_{ut}$ at 95% confidence.

Source of variation	Sum of squares	Degrees of freedom	Mean square	F0	P-value
A: $\mathit{\omega }$ – rotational speed	300	1	300	16.5	0.0066
B: $\mathit{w}$ – pseudo heat index	1172.7	2	586.3	32.3	0.0006
AB: $\mathit{\omega }\mathit{w}$ – combination	1208	2	604	33.3	0.0006
Error	109	6	18.2
Total (corrected)	2789.7	11

From the results shown in Table 5, it is deduced that the pseudo heat index – w and the combination of rotational speed and the pseudo heat index are the most significant variables for obtaining maximum values of Su. This analysis is coherent with the results shown in Table 4 and the obtained results in other works [²⁵].

4 Conclusions

According to the results and analysis obtained in this work, it is possible to elucidate the following remark conclusions:

A process window was determined to generate free-discontinuities and reasonable values of mechanical properties of dissimilar welded joints between AA6063-T6 and AA5052-H32 aluminum alloys was developed. Minimization of macroscopic discontinuities of welds was possible using a balance of rotation and welding speed values, aiming to produce a sufficient operating temperature that guarantees a better mixing of the base materials. The mixing pattern determined the location of tensile test failure, which always was observed in the stir zone, and was related to emerging of the remnant line.

Both, the pseudo heat index and the rotation speed had a significant effect on the measured mechanical properties, which affects also the microstructure of the welded joint. It was evidenced that an increase in the heat index improved mechanical properties in the stir zone. The speed combinations (R=ω⁄v) that obtained a higher value of ultimate tensile strength was1800/163 rev/mm, with 159 MPa. The maximum joint efficiency obtained was 68%.

Acknowledgements

The authors wish to be grateful to Universidad de Córdoba for financial supporting this investigation through FI-06-19 project, to Universidad del Valle and Instituto Tecnológico Metropolitano by using of welding and microscopy facilities.

• How to cite:
  Osorio Díaz MA, Franco Arenas A, Unfried-Silgado J. Effects of process parameters on mechanical properties and microstructure of AA6063-T6 and AA5052-H32 dissimilar friction stir welded joints. Soldagem & Inspeção. 2024;29:e2911. https://doi.org/10.1590/0104-9224/SI29.11

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• Editor:
  Marco Antonio Osorio Díaz.

Publication Dates

• Publication in this collection
  14 Oct 2024
• Date of issue
  2024

History

• Received
  03 Mar 2024
• Accepted
  18 June 2024