Research Papers

A Microstructure and Microhardness Characterization of a Friction Plug Weld in Friction Stir Welded 2195 Al-Li

[+] Author and Article Information
D. F. Metz, E. R. Weishaupt, M. E. Barkey, B. S. Fairbee

 Aerospace Engineering and Mechanics Department,The University of Alabama, Tuscaloosa, AL 35487

J. Eng. Mater. Technol 134(2), 021005 (Mar 27, 2012) (7 pages) doi:10.1115/1.4006066 History: Received April 14, 2011; Revised January 30, 2012; Published March 26, 2012; Online March 27, 2012

In this study, extruded 2195-T8 plugs that were friction welded into the friction stir weld of 2195-T8 base metal plates were examined. This study characterizes the resulting microstructure and microhardness of the plug weld interfaces with the friction stir welded material and base metal in an effort to identify the extent of the thermal, thermomechanical, and mechanical effects introduced by the friction plug welding process. A zone of recrystallized material was observed around the plug weld circumference. The thickness of the recrystallized layer was measured to be 30–122 μm. The hardness measured near the plug weld interface was found to be 110–130 HK100g , or approximately 35% less than the base metal hardness. By characterizing the hardness of these zones, insight can be gathered into the transformation of material from the friction plug welding process around the fusion zone, and areas that may control the fatigue behavior of the joint.

Copyright © 2012 by American Society of Mechanical Engineers
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Figure 1

Friction stir welded 2195-T8 Al–Li plates with FSW keyhole defect (A), FSW (B), unfinished plug in FSW following joining (C), and FPW after removal of excess plug material (D)

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Figure 2

Detailed keyhole defect (a), FSW (b), unfinished plug joint (c), and semifinished plug joint (d)

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Figure 10

Montage of 270 deg section

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Figure 9

Montage of 240 deg section

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Figure 8

Montage of 0 deg section

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Figure 7

(a) Hardness results for the 0 deg/180 deg plane. (b) Hardness results for the 30 deg/210 deg plane. (c) Hardness results for the 60 deg/240 deg plane. (d) Hardness results for the 90 deg/270 deg plane. (e) Hardness results for the 120 deg/300 deg plane. (f) Hardness results for the 150 deg/330 deg plane.

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Figure 6

Average recrystallized layer thickness

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Figure 5

Recrystallized zone measurement at minor diameter location for 0 deg sample

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Figure 4

Sectioning diagram of specimen

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Figure 3

Schematic and nomenclature of plug



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