Regularities of Friction Stir Processing Hardening of Aluminum Alloy Products Made by Wire-Feed Electron Beam Additive Manufacturing

Tatiana Kalashnikova,Evgeny Kolubaev,Denis Gurianov,Evgeny Knyazhev,Sergey Nikonov,Kirill Kalashnikov,Andrey Chumaevskii,Valery Rubtsov,Alexander Panfilov

doi:10.3390/met12020183

Tatiana Kalashnikova, Evgeny Kolubaev + Show 7 more

Open Access

https://doi.org/10.3390/met12020183

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Journal: Metals	Publication Date: Jan 19, 2022
Citations: 7	License type: CC BY 4.0

Affiliation: Institute of Strength Physics and Materials Science

Abstract

Friction stir processing of additive workpieces in the sample growth direction (the vertical direction) and the layer deposition direction (the horizontal one) was carried out. The hardening regularities of aluminum-silicon alloy A04130 and aluminum-magnesium alloy AA5056 manufactured by electron beam additive technology were studied. For each material, 1 to 4 subsequent tool passes were performed in both cases. It was found that the formation of the stir zone macro-structure does not significantly change with the processing direction relative to the layer deposition direction in additive manufacturing. The average grain size in the stir zone after the fourth pass for AA5056 alloy in the horizontal direction was 2.5 ± 0.8 μm, for the vertical one, 1.6 ± 0.5 μm. While for the alloy A04130, the grain size was 2.6 ± 1.0 μm and 1.8 ± 0.7 for the horizontal and vertical directions, respectively. The fine-grained metal of the stir zone for each alloy in different directions had higher microhardness values than the base metal. The tensile strength of the processed metal was significantly higher than that of the additively manufactured material of the corresponding alloy. The number of tool passes along the processing line is different for the two selected alloys. The second, third and fourth passes have the most significant effect on the mechanical properties of the aluminum-magnesium alloy.

Highlights

Aluminum-silicon alloy A04130 and aluminum-magnesium alloy AA5056 are structural materials widely used in the aircraft, spacecraft, vehicle and marine industries [1,2].Since these industries are constantly developing, introducing advanced technologies into the manufacturing process of such enterprises is always a critical task
Optical macro-photographs of the structures after the friction stir processing (FSP) show that the stir zone, formed by the first tool pass, changes with each subsequent one
The macro-images of A04130 alloy samples (Figure 3) show a similar formation of the stir zone (SZ) from the first to the fourth pass. It is especially noticeable on the samples processed in the horizontal direction

Summary

Introduction

Aluminum-silicon alloy A04130 and aluminum-magnesium alloy AA5056 are structural materials widely used in the aircraft, spacecraft, vehicle and marine industries [1,2].Since these industries are constantly developing, introducing advanced technologies into the manufacturing process of such enterprises is always a critical task. One of the most promising technologies from this point of view is electron beam additive manufacturing (EBAM) of large-sized products, which is based on the principle of metal wire melting in a molten pool. This method is very effective in producing high-quality components of different materials: titanium alloys [3,4], steels [5], copper alloys [6], aluminum alloys [7,8]. As a result of FSP, the structure of metals significantly changes relative to the base metal, which is the main factor affecting the mechanical characteristics [16]

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