Interfacial bonding features of friction stir additive manufactured build for 2195-T8 aluminum-lithium alloy

Abstract

Friction stir additive manufacturing (FSAM) was performed successfully using 2 mm thick sheets of 2195-T8 aluminum-lithium alloy. The influence of the tool pin shape and process parameters on the interfacial bonding features among the additive manufactured layers was discussed, and the effects of interfacial defects on the performances of the additive build were analyzed based on microstructures, hardness profiles, and mechanical property evaluations. It is shown that the shape of the tool pin is one of the key factors in influencing the bonding interface between two manufactured layers. The cylindrical pin and the conical pin with three flats are not suitable for the FSAM process since very poor material mixing features are produced along the bonding interface. Although the material mixing degree of bonding interface is obviously improved at the advancing side (AS) interface of the nugget zone (NZ) by using the convex featured pin or the pin with three concave arc grooves, the material mixing degree at the retreating side (RS) interface of the NZ is always insufficient. Meanwhile, the weak-bonding defects along the bonding interfaces could be formed, which are originated from the hooking defects on the RS. The weak-bonding defects are related to the oxides and impurities existing at the original bonding interfaces as well as the insufficient stirring action of the tool pin. The back and forth double passes welding is one of the effective methods to improve the material mixing in the whole NZ and eliminate the hooking defects extending into the NZ. The welding rotation speeds of 800, 900 and 1000 rpm for giving welding speed of 100 mm/min were used in the additive manufacturing processes of 2195-T8 aluminum-lithium alloy, in which the optimum microstructure is obtained with the rotation speed of 800 rpm. The soften degree for the multilayered build is obvious, and the hardness profiles across the different bonding interfaces are always uneven. Meanwhile, compared with the AS interface, the fluctuation of the hardness value at the RS interface is greater. The mechanical properties of the multilayered build are inhomogeneous, and the maximum tensile strength of the multilayered build is only reached the 56.6% of the base metal. The mechanical properties are closely associated with the soften tendency of the material and the degree of the amelioration of weak-bonding defect along the bonding interface.