Abstract
The present study efforts towards appraising the effects of corrosion on the tensile and fracture behaviour of dissimilar friction stir welding (FSW) of aluminium alloys. Three different dissimilar FSW joints obtained between AA6061-T6 and AA7075-T651, AA6061-T6 and AA2014-T6, AA7075-T651 and AA2014-T6, using threaded pin profile with three flat faces (TIF) tool at rotational speed of 1200 rpm and welding speed of 98 mm/min. The maximum joint tensile strength was achieved for AA7075-AA2014 joints followed by AA6061-AA2014 and least recorded for AA6061-AA7075 for as obtained FSW joints (non-corroded). The joints are further immersed into a corrosive solution for 1, 2, 7 and 14 days duration. The corrosion occurred all over the joint but much accelerated rate of exfoliation corrosion exists away from stir zone near the confluence of heat affected zone and base material irrespective of the advancing or retreating side. With increase in corrosion time the location of tensile failure shifted towards corroded region (AA6061-T6) instead of stir zone in dissimilar weld joint AA6061-AA2014, whereas it remained unchanged for other two joints. The fractured surfaces of AA6061-AA2014 FSW joints reveals the articulated view of pits and fracture morphology advocating the loss in YS, UTS and % elongation with increases in immersion duration.
Highlights
Aluminium alloys due to their low weight to strength ratio make them excellent for aerospace, marine and other applications
Srinivasan et al [1] studied corrosion susceptibility to stress corrosion cracking (SSC) of friction stir welded AA7075-AA6056 by performing tensile test in air and NaCl solution (3.5%). They reported that thermo-mechanically affected zone (TMAZ)/HAZ of AA7075 is susceptible to SCC, fracture location is governed by both mechanical stresses as well as corrosive environments
The maximum ultimate tensile strength (UTS) and yield strength (YS) was achieved for AA7075-AA2014 as compared to AA6061-AA2014 and AA6061-AA7075 dissimilar welds without any corrosion treatment whereas minimum % elongation is noted for AA7075-AA2014 joints compared to other two cases
Summary
Aluminium alloys due to their low weight to strength ratio make them excellent for aerospace, marine and other applications. Friction stir welding (FSW) evolved as a promising solid-state joining process for aluminium and other alloys. Srinivasan et al [1] studied corrosion susceptibility to stress corrosion cracking (SSC) of friction stir welded AA7075-AA6056 by performing tensile test in air and NaCl solution (3.5%). They reported that TMAZ/HAZ of AA7075 is susceptible to SCC, fracture location is governed by both mechanical stresses as well as corrosive environments. Birbilis et al [2] investigated the electrochemical and metallurgical behaviour of Al7Cu2Fe particles in AA7075-T651 alloys They found that 65% of the constituent particle population is of Al7Cu2Fe and are of comparatively large size. Marlaud et al [3] quantified corrosion susceptibility of
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