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A Numerical Simulation for Dissimilar Aluminum Alloys Joined by Friction Stir Welding

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Abstract

Dissimilar aluminum alloy sheets of 2017A-T451 and 7075-T651 (6 mm thickness) were friction stir welded in a butt weld configuration. A numerical simulation of the joining process was developed to visualize the material flow patterns and temperature distribution and to correlate the microstructure to the hardness behavior. Due to the complementary downward flow of surface material into the workpiece thickness and upward flow of mid-plane and bottom-plane material, the weld nugget is composed of alternating layers of 7075 and 2017A. These layers have unique temperature histories depending on the material’s initial location within the cross section; therefore, they also have distinctive precipitate distributions. Supersaturated surface material flows into the process zone and forms a core in which GP zones reprecipitate upon cooling. Mid-plane and bottom-plane material flow toward the workpiece surface and encompass the surface material core. Within this region, the weld temperatures overage the equilibrium θ phase in 2017A, decreasing the hardness, and at the same time, dissolve the equilibrium η/T phase in the 7075, leading to reprecipitation of GP zones upon cooling and a hardness recovery.

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Acknowledgments

This work was supported by Polish National Science Center, Grant No. 2013/11/B/ST8/04409.

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Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, College of Engineering and Computing, Miami University, Oxford, OH, USA

    Carter Hamilton (Associate Professor)

  2. Faculty of Metal Engineering and Industrial Computer Science, AGH University of Science and Technology, Kraków, Poland

    Mateusz Kopyściański (Research Scientist) & Stanisław Dymek (Professor)

  3. Department of the Testing of Materials Weldability and Welded Construction, Institute of Welding, Gliwice, Poland

    Aleksandra Węglowska (Research Scientist) & Adam Pietras (Director)

Authors
  1. Carter Hamilton
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  2. Mateusz Kopyściański
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  3. Aleksandra Węglowska
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  4. Stanisław Dymek
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  5. Adam Pietras
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Corresponding author

Correspondence to Carter Hamilton.

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Manuscript submitted November 23, 2015.

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Hamilton, C., Kopyściański, M., Węglowska, A. et al. A Numerical Simulation for Dissimilar Aluminum Alloys Joined by Friction Stir Welding. Metall Mater Trans A 47, 4519–4529 (2016). https://doi.org/10.1007/s11661-016-3617-1

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  • DOI: https://doi.org/10.1007/s11661-016-3617-1

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