Abstract
The aim of this study is to determine the sheet metal formability of AA-5083-O sheets processed by the Friction Stir Processing (FSP). The FSP process was studied and a FSP tool was built. Processing quality was verified by the metallography in the processing region, which established the voids presence. Tensile tests were carried out on FSP and non-FSP specimens, and the results showed that FSP specimens have 30% greater resistance than non-FSP ones. The formability of FSP sheets was produced in MSC-MARC and Abaqus and these software products were compared by using the nonlinear FEM code. The Forming Limit Diagram was built with the results from both software products. A device to process FSP sheet metals was developed and the sheets were processed to validate the results from the software. The tools made for the bulge tests were circular and ellipse-shaped. After the bulge tests, the commercial sheets showed close approximation to those obtained from the software. The FSP sheets broke when inferior pressure was applied because of the defects in the FSP process. The results of the FSP presented the same formability of commercial sheets, however, with 30% greater strength.
Highlights
The Friction Stir Welding (FSW), patented in 1991 by the TWI Institute, is a method used to join two parts, defining a welding joint, with better mechanical properties than the original parts
As the Friction Stir Processing (FSP) is an attractive way to refine grains, many studies on Superplasticity obtained from FSP joints were developed
A FSP tool was developed with AA-5083-O aluminum alloy, so as to define suitable conditions to establish a friction stir process window: 500 rpm and 65 mm/min, 328 rpm and 88 mm/min, and 328 rpm and 65 mm/min
Summary
The Friction Stir Welding (FSW), patented in 1991 by the TWI Institute, is a method used to join two parts, defining a welding joint, with better mechanical properties than the original parts. Heat and friction are generated by the tool, which is inserted between the parts defining the plasticity condition. The tool is removed from the parts and the regions welded are solidified and remain joined [1,2,3]. As the Friction Stir Processing (FSP) is an attractive way to refine grains, many studies on Superplasticity obtained from FSP joints were developed. The grain size obtained from a typical FSP joint is about 1 to 5 μm and the extra fine grains range from 30 to 180 nm. The grain size is a relevant factor to obtain superplastic materials [4]
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