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Friction Stir Processing ofAluminum Casting Alloys:
Microstructure Manipulation/SurfaceComposite Fabrication
Ning Ning SunSunAdvisor: D. Advisor: D. ApelianApelian
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Born in Qingdao, east coast ofChina (known for TsingTao Beer)
B.S. in MSE (July 2007), fromHefei University of Technology
M.S. Candidate ACRC(started September 2007)
Interests:• Western and Chinese music• Piano• Jogging
NING SUN
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QINGDAO, CHINA
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Outline
• BackgroundPrinciples, Applications, Challenges
• Objectives• Experimental Plan• Expected Outcomes• Schedule
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Background
FSP is a relatively new processingmethod that was developed in 1997by R.S. Mishra et al* based on the
principles of friction stir welding (FSW-invented by TWI (UK) in 1991)
* High strain rate superplasticity in a friction stir processed 7075 Al alloy
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Background
Credit: J.-Q.Su et al.
A rotating, non-consumable tool, comprising of a profiled pin and a larger shoulder plunges into the surface of the work-piece, and then travels along the work-piece
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Background
Characteristics of FSP
• Solid-state• Thermo-mechanical in nature• Severe plastic deformation experienced
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Background
Credit: I.Charit and R.S. Mishra
Grain size refinedfrom 200 µm to0.5 µm-12 µm.
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Background
Grain Boundary Misorientation Angle Shiftsfrom a Low Value to a High One
a) b)
Credit: OIM result from W.M. Thomas et al
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Background
High Strain Rate Superplasticity Achievedat Low Temperatures
Data of Mishra et al’s work in comparison with Xing’s
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Background
Hardness Data (2014 Al alloy)
Credit: Y.J. Kwon et al
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Background
Tensile Data (2014 Al alloy)
Credit: Y.J. Kwon et al
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Background
Fatigue Data (A356)
Credit: By S.R. Sharma et al
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Background
• Tool geometry• Tool wear• Overlapping• Microstructural stability
INFLUENCING PROCESSING PARAMETERS
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Outline
• Background• Objectives• Experimental Plan• Expected Outcomes• Schedule
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Objectives
Explore and Evaluate the Feasibility ofFriction Stir Processing in AluminumAlloys, Specifically To:
1. Manipulate the microstructure to refine or strengthen locally
2. Investigate the potential of FSP to form a particle-reinforcedzone in standard Al cast components, by mixing and creatingstrengthening particles, and establish optimum processingconditions; i.e., local composite fabrication via FSP
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Experimental Plan
Alloys: work-piece material
• A356(6Si,0.2Fe,0.2Cu,0.1Mn,0.4Mg,0.1Zn,0.2Ti,other)
• A380(9Si,2.0Fe,3.0Cu,0.5Mn,0.1Mg,3.0Zn,0.5Ni,0.35Sn,other)
• A206(0.1Si,0.15Fe,4.2Cu,0.3Mn,0.3Mg,0.01Zn,0.2Ti,other)
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Experimental Plan
FSP machine
HAAS Mill DrillCenter
> 10,000 RPM> 2000 IPM
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Experimental Plan
Tool material:
Tool steel
Tool geometry:
Shoulder: 18mm Diameter Pin: Tilt angle ≈ 2.5-3 degree with
different tool shapes
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Experimental Plan
Max diameter(mm)
Min diameter(mm)
Screw
Column 8 8 Y
Column 8 8 N
Taper 8 6 Y
Taper 8 6 N
Tool Shapes
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Experimental Plan
Second Phase Particles Consideredfor Localized Composite Fabrication
> SiC
> TiC
> Cr3C4
> Al2O3
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Experimental Plan
Processing:
• Confirm microstructure evolution during FSP
• Surface composite fabrication via FSP
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Experimental Plan:microstructure evolution
Confirm Microstructure Evolution During FSP:
500, 800, 1250, 1750, 2000 (rpm)
100, 150, 200 (mm/min)
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Experimental Plan:composite fabrication
Particle-reinforced Zone Developed by:
• Mixing-in strengthening particles
• Forming strengthening particles by in-situ chemical reactions
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Experimental Plan
Mixing-in Strengthening Particles:
I. Filling into the groove on the surface of the work-piece
II. Painting slurry onto the surface of the particle-reinforced zone
III. Injecting powder into the FSP zone
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Experimental Plan
Forming Strengthening Particles by in-situChemical Reactions:
I. Alloy + Reactant + Catalyst Particles + Secondary product
II. Pin tool + Reactant + Catalyst Particles + Secondaryproduct
III. Reactant (1) + Reactant (2) + Catalyst Particles + Secondaryproduct
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Experimental Plan
FSP Parameters for Surface Composite Fabrication:
500 rpm, 800 rpm
20 mm/min, 80mm/min
H 1mm, 1.7mm, 2.3mmH
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Outline
• Background• Objectives• Experimental Plan• Expected Outcomes• Schedule
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Expected outcomes
Microstructure Evolution During FSP
Grain size refined from several hundred µm orseveral ten µm … to 0.5 µm-12 µm
Grain boundary misorientation angle shiftsfrom low to high
Enhanced mechanical properties
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Expected outcomes
Surface Composite Fabrication via FSP
Particle reinforced zone is created via FSP
Structural integrity at localized interface
Enhanced mechanical properties
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Schedule
Sep '07-Dec'07
Jan '08-May'08
Jun '08-Dec'08
Jan '09-March '09
April '09-June '09
Critical Lit Review (I) (I)
Project Planning (I)
Finalize Exp. Plan (I) (I)
Execute Exp. Part I (II) (II)
Execute Exp. Part II (II) (II) (II)
Modeling (III) (III) (III)
Thesis Write-up (IV)
Thesis Defense (IV)
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Thank you for theopportunity andyour attention