NASA/TM--1999-209876

Friction Metal
(MSFC Project
J.A. Lee, Marshall

Stir Welding Matrix

for Aluminum (MMC's)

Fund Final Report, Discretionary

Composites

Center Director's No. 98-09)

R.W. Space Carter, Flight and J. Ding Center, Marshall

Space

Flight

Center,

Alabama

December

1999

The NASA

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NASA

/ TM--1999-209876

Friction Stir Welding for Aluminum Metal Matrix Composites (MMC's)

(MSFC Project
J.A. Lee, Marshall

Center Director's No. 98-09)

R.W. Space Carter, Flight and J. Ding Center, Marshall

Discretionary

Fund

Final

Report,

Space

Flight

Center,

Alabama

National Space Marshall

Aeronautics Administration Space Flight

and

Center

MSFC,

Alabama

35812

December

1999

Acknowledgments
The Principal Investigator, Jonathan Lee, wishes to thank Robert Carter and Jeff Ding for their assistance in performing the fiiction slir welding. Furthermore, the authors would like to acknowledge the financial support fiom the Center Director's Discretionary Fund (CDDF) program officc at MSFC and to Mark van dcn Bcrgh, fi'om DWA Aluminum for supplying mosl of thc composite matcrial panels used in this study. Composites, Inc.,

Available fl'om:

NASA Center fl_l"AcroSpacc 7121 Standard Drive Hanover, MD 21076-1320 (301) 621-0390

Information

National

Technical

Information

Service

5285 Port Royal Road Springficld, VA 22161 (703) 487-4650

TABLE

OF CONTENTS

i. 2.

INTRODUCTION POTENTIAL 2.1 Solidification 2.2 Chemical

.......
"'''''''''' ........ '''.*... ......Hi, ..... ... ...... . .... . .... .....o.. .... .... . ........

1 2 2
.....

ISSUES Effects

IN JOINING

MMC'S
............. ...., ................ .... .... . .... ..... ,,.o_o......... ....

.........

. .........

,.

......

o,,

....

,,,,

....

..,,

.....

*,,,,**.,,,,

,,,,,,,,,,,,,,.,

....

**,

......

,,,***...,

Reactions
..... ..,,.,,.,. ..... ..,,.,,,,,,, ,,,,,, ,., ..... .,,, .... ,,.. ........... ,, .... ,,.,. .......... .. ....... 1.,

2 2 3 5 5 6 8 12 12 13 13 15 15 15 16 18 19 20

2.3 Joint Preparation 2.4 Qualitative 3. FRICTION

...................................................................................................................... Rating ...................................................................................... OF A1 6092/17.5 SiCpFF-6 MMC'S ............................................. : .......

Performance

STIR WELDING

3. I Background 3.2 Experimental 3.3 Results ....

....

.............................................................................................................................. Procedures
.**,, ..............

.........................................................................................................
,,,,., .... , ....................... .,.,.. .......... , .... , .... , .... . ...... ,, ................. , .... ** .... ,

4.

FSW

OF FUNCTIONAL

GRADIENT

A1 MMC

TO AI-Li 2195 .................................................

4. I Background 4.2 Experimental 4.3 Results

......................

.............................................................................................................................. Procedures
. ....................

.........................................................................................................
. ........ .................**... ....*..... .... ........... .... . ..... ......... ........

5.

TECHNOLOGY 5.1 Performance 5.2 Potential 5.3 Other

ASSESSMENT Limitations

AND

POTENTIAL ...................
......

APPLICATIONS

.....................................

of FSW for MMC Techniques

.................

........

...

.......

......................

Applications Joining

Flanges

................................................................................ Flanges ...........................................................

Potential

for MMC

6. 7.

CONCLUSIONS

..................................
.. .................. . .............. .....o .......... . ......... .. .... . .... . .... . .... . ......

RECOMMENDATIONS
......... . .......... . .... ..... ......... ***. ........... ... .... .... ........... ..... ..... o ........ .....**.......

REFERENCES

....................................................................................................................................

111

LIST

OF FIGURES

Classification Schematic FSW

of selected drawing

joining

methods

for MMC's

....................................................

4 5 6 7

2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

of FSW process

................................................................................. design .......................................................... materials ......................................

in action

and the pin tool's of hardness values

geometric for candidate

Comparison Cross-sectional Change Hardness

coating

view of an FSW joint

for MMC's

(x 10) ................................................ edge boundary .....................

8 9 11 12

in SiC particle measurement of FGM

sizes and distribution across

at the HAZ's

the HAZ ........................................................................... plates ............................................................................ welded to A1-Li 2195 ................................. ............................... ...............

Development FGM

for MMC edge

with 18.5-percent welding reinforced

reinforcement

13 14 16

Unsuccessful MMC flanges

of 50-percent

SiC MMC

plate to A1-Li 2195

with 50-percent

SiC particulate

for fuel line system

iv

LIST OF TABLES

Chemical Typical Empirical MMC joint MMC joint FSW

compositions properties parameters strength strength

of 6092 AI alloy

as the matrix with

material

.......................................... ........................

7 7 8 10 I0 15

2. 3. 4. 5. 6.

of 6092 AI reinforced developed results results using using

17.5-percent

SiC particulate

for FSW of MMC's uncoated B4C-coated for joining

..........................................................

pin tool ............................................................ pin tool ........................................................ MMC's ...........................................................

advantages

and limitations

LIST

OF ACRONYMS

AND

SYMBOLS

A! A1-Li A1203 AI4C 3 B4C CIJ FGM FSW HAZ HRC GMAW GTAW IFW ipm MMC MSFC NPA RSP SBIR Si SiC TWI UTS WC

aluminum aluminum-lithium aluminum aluminum boron oxide carbide

carbide joining gradient stir welding zone "C" scale material

cast-insert functional fi-iction

heat-affected hardness gas metal

Rockwell

arc welding arc welding welding

gas tungsten inertia friction

inch per minute metal matrix composite Flight Center

Marshall nanophase resistance

Space

aluminum spot welding Innovative Research

Small Business silicon silicon carbide

The Welding ultimate tungsten

Institute strength

tensile carbide

vi

TECHNICAL MEMORANDUM

FRICTION

STIR

WELDING

FOR ALUMINUM Discretionary

METAL Fund Final

MATRIX Report,

COMPOSITES Project No. 98-09)

(MMC'S)

(MSFC

Center

Director's

1. INTRODUCTION

methods utilize

In order to fabricate must be developed a variety of nonmetallic (AI203) MMC's

certain structures from metal matrix composites (MMC's), effective joining to join MMC's to the same or to different monolithic alloys. Since MMC's reinforcements such as silicon carbide (SIC), boron carbide (B4C), limitaimpose

aluminum oxide tions for joining

' graphite, etc., these nonmetallic reinforcements will naturally using conventional methods for monolithic metals.

This report joining a variety

describes

an investigation reinforced

into the use of the friction with discontinuous

stir welding

(FSW)

process gradient

for

of AI MMC's

SiC particulate

and functionally

material (FGM). FSW consolidating materials forces. The process rotating of a special around thereby

is a fairly new solid state welding process for joining around the bond line using thermal energy produced the need along for gas shielding to slowly the bond occurs solidification is feasible plunge or filler metal. into the MMC

metals by plasticizing and from localized friction The FSW process at the bond sound up and forced point consists line. to flow welds reactions. surface

does not require and moves forward

pin tool that is positioned tips, forming

As the tool rotates the rotating with MMC's

line, the material well below defects

is heated

a solid state joint. temperature

FSW has the potential

for producing

because

the processing

the melting and undesirable

of the metal,

reducing Preliminary

the reinforcement-to-matrix results show that FSW

chemical

to weld A1 MMC's

to MMC's

or to aluminum-

lithium (AI-Li) 2195 if the SiC reinforcement is <25 percent by volume. Tensile strength, hardness, and microstructure of these welds were characterized in both the as-welded and post heat treatment conditions. However, a softening factors in the heat-affected strength. zone (HAZ) was observed is made and is known from a low-cost to be one of the steel tool H-13 major limiting for joint The pin tool's material

material, and the wear was excessive such that the pin tool length had to be manually adjusted for every 5 ft of weldment. Initially, B4C coating was developed for pin tools, but it did not show significant improvement Therefore, in wear FSW resistance. Basically, articles FSW is applicable mainly for butt joining MMC joining of flat plates. ranging from techniques. of cylindrical such as a flange to a duct, with practical diameters

2-5 in., must be fully demonstrated

and compared

with other proven

2. POTENTIAL

ISSUES

IN JOINING

MMC'S

2.1

Solidification

Effects

In general,

MMC's

utilize

a variety

of nonmetallic

reinforcements

with a typical

volume

fraction

ranging from 5 to 60 percent. For this reason, there are several potential joining issues that are peculiar to MMC's such as the solidification effects. Since most nonmetallic reinforcements have different densities ahead Under from the metal state. of the solidification the molten state, matrix, front, this can lead to pronounced critical solidification resulting metal in nonuniformity High viscosity particle segregation effects when the matrix region. not by in Most and is in the molten Below a certain temperature, reinforcements viscosity can be pushed and does

of the reinforcement has a higher can often to control

in the weld

the composite

rnetal weld matrix. which effects

pool generally

flow as well as the unreinforced convection distributions most fusion mechanism welding fusion in the MMC's. packing

lead to a lower heat transfer microstructures and commonly and the stress encountered

in the weld pool, Solidification techniques. density welding

can affect the resulting are difficult problems may result

Solidification

in dissolution

of the reinforcements and laser-beam conditions

and nonuniform conventional welding complex

due to the migration as miniature

of the reinforcement electron-beam castings

into the weld regions. welding, boundary

techniques be considered

such as arc welding,

can fundamentally solidification

with different

effects. 2.2 Chemical Reactions

In the past, there success welding ments cooling metal metal metal cesses tal data the very welding on some types for MMC's

were some of particulate

fusion

welding

techniques

that have been the major matrix

used with moderate difficulty with fusion reinforceupon types of and particulate

reinforced contact reactions.

MMC's. between

However, a molten-metal

is that prolonged chemical

can lead to undesirable to precipitate the molten down matrices carbides metal

For instance, carbon to form

liquid phase AI will react with SiC the silicon (Si) content will react with A1 or certain phases. In the presence the joint compatibility Most For example, and increase the chemical and process by most welds to MMC's.

reinforcement

the aluminum matrix.

carbide

(A14C3) and increase or graphite detrimental gases

Similarly,

at high processing can decompose cracking and joint energy

temperatures with the release strength processes joining

of moisture, susceptibility of the fusion proin experimenwith high

of hydrocarbon method is material absorbed

to corrosion

degradation.

Consequently, applied fusion

to reinforcement are high thermal suggested narrow speed

for a specific

specific. nonmetallic

that are not easily is preferentially flux. Therefore, to reduced in order

that the laser energy weld regions control

reinforcements

of high heat

must be automated chemical reaction.

and temperature

undesirable

2.3 Joint

Preparation

Because wear resistance;

of their nonmetallic and high brittleness

reinforcements, to machine,

MMC's

tend to have low ductility; standard steel cutting

high surfacetools and saw

cut, or drill using

blades.Most MMC's with high reinforcement olumerangingfrom 40 to 60 percentwill behavemore v like ceramicthanmonolithic metalsandcanbecome difficult to cutor machine.In preparation an for MMC joint prior to welding,the cuttinganddrilling parameters suchasspeed andforce mustbecarefully controlledin orderto avoidcompositepaneltearoutor crack.To avoidexcessive tool wear,it is a commonpracticefor diamond-or diamond-like-coatedteeltoolsto beemployedfor MMC's. s

2.4 Qualitative
Figure groups: joining lacking. mentally. combination 1 shows that the major (2) fusion, joining

Performance for MMC's

Rating can be classified it is important technical joining into three to realize details main that the

methods and many

(1) Solid state, technology

and (3) other for MMC's, knowledge

processes.

Presently, important

is not mature

are still including experion the joining

I Consequently, As a general

the precise

of the adaptability

of a specific factor which

joining

method,

FSW in this study,

is a specific

material factors:

and process-dependent of any joining (I) The volume percent

must be determined will depend of reinforcements,

rule, the adaptability

techniques amount

for MMC's and types

of the following

(2) the metal matrix meIting point, and (3) the thermal energy management process. A brief summary of these three factors is given as follow:

fi'om the selected

Since

MMC's

utilize

a variety

of nonmetallic

reinforcements, techniques

the higher to adapt.

the reinforcement

volume reinforced

fraction,

the less likely

for standard

metal joining

Discontinuously

MMC's are easier to join than continuously reinforced MMC's using fibers which are prone to matrix fiber debonding, delamination, nonuniform fiber packing density, and migration of fibers bundled into the weld regions.

The prolonged able chemical the metal factor. fusion matrix

contact reactions

time between

a molten-metal compatibility matrix

matrix

and a reinforcement temperature

can lead to undesirincreases. Therefore, most of the

that are accelerated chemical the metal

as the molten-metal melting

reinforcement

is a materialtemperature,

and temperature-dependent the less likely

For this reason, the higher techniques are to adapt.

Although energy method improve

high thermal

energy

is required

for most conventional the use of an automated input

joining joining

processes, process process

excessive

thermal joining

input is undesirable.

Therefore,

or a special

that can offer a well-controlled, thermal-energy the joining adaptability for MMC's.

in a minimum

time will likely

MMC JoiningMethods

I [
Inertia Friction Welding Frictioin Stir Welding Ultrasonic Welding Diffusion Bonding Laser Beam Welding Electron BeamWelding Gas Metal Arc Welding GasTungsten Arc Welding ResistanceSpot Welding CapacitorDischarge Welding

I O*_er_oce_e_l
Brazing Soldering Adhesive Bonding Mechanical Fastening Cast-Insert Joining Transient Liquid Phase Rapid Infrared Joining for MMC's.

Figure

1.

Classification

of selected

joining

methods

3.

FRICTION

STIR

WELDING

OF Ai 6092/17.5

SiCp/T-6

MMC's

3.1

Background

Welding by many

FSW is a relatively new joining Institute (TWI) of Cambridge, researchers.3-5 However,

process that was originally developed and patented by The England." Since 1993, FSW has been studied and demonstrated in conventional terms as a combination as a solid state of The process is considered or filler metals.

FSW can best be described

extrusion and forging of metals process, and it does not require

at elevated temperatures. the need for gas shielding

Figure 2 is a schematic describing the FSW process. FSW consists of a rotating and nonconsumable pin tool that is slowly plunged into the bond line until the pin tool's shoulder is in intimate contact with the workpiece. line begins This heat source As the tool rotates is developed mainly and moves forward along the bond line, the material deformation while at the bond backside. the keeping to heat up, forcing it to flow around the rotating friction tip to consolidate and plastic on the pin tool's

due to the local

pin tool's shoulder in intimate contact at all times with the workpiece. The workpieces must be securely clamped to a backing anvil in a manner that prevents them from moving and being forced apart at the abutting joint faces. Interestingly, FSW has the potential for welding MMC's temperature occurs well below the metal's melting point, thereby eliminating and undesirable chemical reactions. disadvantages which will be briefly Rotationof Tool and VerticalForce FrictionHeated MetalBy Pin Tool Workpiece Workpiece However, reviewed as with all welding in this study. processes, because the processing the solidification defects FSW has its advantages and

Friction Stir Welding Pin and ShoulderTool

Side View

FrontView

Plasticized Metal LayerBeneath Shoulderand Around Pin Tool

FrictionStir WeldingCharacteristics Rotatingsteel pin and shouldertool friction heatsthe abutting faces.As the tool movesalong theseam line, plasticizedmetal is mechanically stirred and weldedtogetherby forging. Processingtemperatureoccurs well below metal melting point. No toxic fumes, heat,and arc flashes.

Regionof Welded Metal Seam

+
Figure

Direction of Travel

2. Schematic

drawing

of FSW

process.

3.2

Experimental

Procedures

The pin tools used were

specifically

designed

for this study

to accommodate in plate thicknesses and 10-24 unified the optimum proprietary

the 0.125-in.-thick prior to welding. coarse left-handed of by designed information.

plates, and the tool length can be manually adjusted for variation As shown in figure 3, the tools had a 0.475-in.-diameter shoulder threads 0.120 Robert on the pin. A computer in. for making Carter, an optimum the Co-Principal simulation Investigator, was used to determine and does not contain full-penetration

pin tool length design

weld. This pin tool was independently

Figure

3. FSW in action

and the pin tool's

geometric

design.

Due to the highly For this reason,

abrasive

nature

of this particular identical

MMC,

excessive

pin tool wear was expected. wear-resistant coating were of

two sets of pin tools having

geometry

but different

applied. Both sets were fabricated from H-13 tool steel that was heat treated to 53-55 Hardness Rockwell "C" (HRC) scale. One set was then coated with B4C to achieve a surface hardness value 93-95 HRC. The other tool set was left uncoated. superior lubricity, low-cost The B4 C was chosen good corrosion, Figure process. 4 shows as a coating a hardness for outstanding was applied coating initial trials materials wear resistance, that were and chemical B4C coating resistance. comparison was chosen

due to its potential The coating of several for the

using a low-temperature, considered due to its low cost factor. in figure control 3, FSW milling

for this study. Furthermore,

As shown computer numerical

was performed machine

using

the Kearney

& Trecker

five-axis welding,

horizontal the panels were

that was modified

for FSW. After

x-rayed, and root side die-penetrated tests were performed. machined into tensile specimen coupons and microstructure tensile tested in as-welded conditions and in post heat-treated and consisted by age hardening tions were recommended then water quenching. by the manufacturer It was followed

The welded panels were then cut and analysis specimens. The specimens were T6 conditions. of solution heat The T6 condition treating specificaat 1,030 F for 3 hr,

at 325 F for 8 hr and then air cooled.

Coating Materials Diamond Boron Carbide Titanium Carbide Silicon Nitride Chromium High-Speed Steel

HardnessValues in Rockwell "C" Scale 100

95 9o 9o 7o 6o

Figure

4. Comparison

of hardness

values

for candidate

coating

materials.

The MMC particulate treatment supplier,6 which condition some DWA Aluminum table 2 shows

material Composites, prior

used in this study distributed Chatsworth, Table Inc. Inc.,

was a 6092 A1 alloy reinforced throughout CA, the matrix. The

with material

17.5-percent was supplied plates

SiC by and

is homogeneously to welding.

in the form of 6x12x0.125-in. the chemical properties compositions were which provided

with T6 heat

I shows

of 6092 Ai alloy, by the material

of the physical

and mechanical

DWA Aluminum Table

Composites,

1. Chemical

compositions
Element Silicon Magnesium Copper Manganese Chromium Zinc Titanium Iron Oxygen Aluminum

of 6092

Al alloy as the matrix

material.

Compositions (wt. %) 0.4-0.8 0.8-1.2 0.7-1.0 0.15 (max.) 0.I5 (max.) 0.25 (max.) 0.I5 (max.) 0.3 (max.) 0.05-0.5 Balance

Table

2. Typical

properties

of 6092 A1 reinforced
Property

with

17.5-percent

SiC particulate.

Value/Description 6092/SiC/17.5p-T6 17.5% SiC Particulates 0.101 67 57 8 9.3 82 T-6

Material Descriptor Reinforcement Type Density (Ib/in3) Ultimate tensile strength (ksi) Yield strength (ksi) Elongation (percent) CTE(ppm/F) Hardness (Rockwell "B") Temper

Table this study be noted tools were data using generate

3 lists the FSW sound parameters

parameters These

and their description parameters were used for a feasibility to develop

that were experimentally as guidelines study before and have welding not been parameters

developed fully optimized.

for It should

to yield that these

welds.

for FSW of MMC's.

were chosen of the study parameters.

Tool wear was monitored the chosen data using

by measuring

pin tool dimensions The B4C-coated

and after each

weld. The uncoated and to generate part of this study to

used in the beginning the chosen Table

acceptable tools were

set of parameters.

used in the latter

3. Empirical

parameters Value 4 ipm 1,350rpm 2.5 deg 0.010in. 0.005in,

developed

for FSW Description

of MMC's.

FSWParameters Travel peed s Rotatingspeed Leadangle Plungedepth Penetration ligament

Inch-per-minute horizontal peed s Rotatingspeedof pin tool Pintool's tilting anglefrom verticalplane Shoulder lengthplungesbelowcrownside Distance between of pin and backing tip anvil

3.3 3.3.1 Microstructure No evidence optical microscopy the welds Analysis of cracking was found within

Results

the cross-sectional easily revealed alloys,

view of the welds that the crown the crown

as observed FSW

by in an

at x 400. However, In comparison

visual

inspection

side (top side) of

was quite coarse.

with monolithic

side of a typical

AI alloy has a highly polished, machined appearance. tently gave the crown side a unique appearance_that typical adhere anomaly lower welding, der. Once surface shows surface of concrete. This coarse appearanc well with the AI at the surface of the weld was partially allowing overcome lubricity, the material were already to coaiesee beginning

The welds performed with MMC material consisis rernin]sc-ent 0_ what one would expect to see for a

e was caused.= =bY-_ fact that the SiC particles .=. = the did not adjacent to thg tool shoulder. It was noticed that the tOOlS which However, had a higher edge hardness and a of much better. after only a few inches appeared

with the use of B4C-coated

the SiC particles the coating anomaly

to wear the B4C off the outer reappeared. using This coarseness on the tensile pin tool. influence

of the tool shoulto be only a Figure 5

was worn

off, the coarseness

and did not seem to have any significant view of an FSWjoint

properties.

the cross-sectional

an uncoated

Figure

5. Cross-sectional

view of an FSWjoint

for MMC's

(x 10).

It was noticed "stuck" beneath pressure Such

that on the root side of some

MMC

welds,

occasionally

some

panels

were actually

to the backing anvil after being welded. This phenomenon the pin and adjacent to the backing anvil became welded created craters by the welding places where were identified surface Figure process using in this zone. a conventional which an interesting Observations anvil material "stuck" defects to the backing

occurred when the material directly to the anvil due to the heat and extreme of intermittent when technique, influence at the edge smaller concentration "craters" on the root the workpiece was removed.

side indicated small appeared properties Evidently, the center HAZ.

die-penetrated microstructure particle

and these defects the mechanical of the HAZ at x 400. toward of the

to be very shallow of the welds. of the HAZ. the SiC particles

may not significantly

6 shows

were broken

up by the pin tool and became

as they traveled at the edge

Also, there

was a lack of high-volume

(a) Cross-sectional iew of FSWjoint (Magnification:x 4). v Figure 6. Change in SiC particle

(b) Microstructureof FSWjoint (Magnification:x 400). at the HAZ's edge boundary.

sizes and distribution

3.3.2

Tensile In order

Strength to access measured

Measurements the joint at room efficiency as follows. temperature, when UTS of welds and 61.9 the parent of MMC of these MMC Using tested was 41.4 performed using welds, tensile tested strength was measured ultimate tensile condition. back to the 4 ksi when Tables and

the joint strength Tensile original tested

efficiency (UTS), strength

was calculated

the uncoated ksi when

tool, the average

in the as-welded and age hardening tools

of 54.7 ksi was obtained The average condition efficiency, data for FSW

after heat treatment

T6 condition. in the as-welded the tensile the joint value

with B4C coated in the postheat-treated an uncoated

was 43.3

ksi when tested panels material's

T6 condition. determined

and 5 show To evaluate It was noted experimental joint

and coated

pin tool, respectively. to be =60 ksi. From to alter the condithe

UTS was experimentally reported percent coating was achieved

that this value percent

is = 10 percent

less than the UTS value of 61-72 pin tool. In general,

in the literature.

of 60 ksi, the joint

efficiency

in the as-welded

tion and 92-100 efficiency

after heat treatment. with an uncoated

the pin tool does not seem

in comparison

Table 4. MMC

joint

strength

results

using

uncoated

pin tool.

JointProperty Modulus(Msi) Yieldstrength(ksi) Tensile strength(ksi) 2-in. elongation(%)

As-Welded HeatTreated 11.13 27.7 41.4 2.49 12,28 49.1 57.7 2.07

Table

5. MMC joint

strength

results

using

B4C-coated

pin tool.

JoinlProperty Modulus(Msi) Yieldstrength(ksi) Tensile strength(ksi) 2-in. elongation(%)

As-Welded HealTreated 10.44 27.4 43.5 2.72 12.83 55.1 61.9 2.00

3.3.3

Hardness Hardness

Measurements measurement performed In general, it becomes and tensile was taken strengths across the crown pin tools. side of the weld zone the hardness greatly in the HAZ energy input as shown in figure 7.

These cluded ment joining FSW 3.3.4

welds

were

with B4C-coated coating obvious

From

measurement,

it was condue to measurefor most including

that the yield profile

were also reduced

by overheating is required is undesirable,

the FSW process. processes, in this study.

of the pin tool does not seem to alter pin tool. Although thermal thermal energy that any excessive

the HAZ hardness

in comparison

with an uncoated

Pin Tool Wear The pin tool's wear was found to be most significant form. on the outer =0.0005 edge of the tool shoulder was removed by 0.010 in./ft of of =5 ft or and

on the major weld. head

diameter

of the pin's manageable for every

thread without

On the average, pin tool length length

in. of material was reduced

from the tool shoulder This wear was and manually less. In other words,

per linear foot of weldment, manual 5 ft of welds,

and the pin diameter

adjustment

for weldment

the pin tool's

must be removed

from the welding

adjusted

for the next weld session.

10

FSW Pin To_ Weld Centerline

PlateA Heat Affected Zone

Postheat Treatment 90 "" 80' 7060504O 3O 0

//

"*_

. As-Welded " ""

i,#'/_"

o.2 '0.4

016 0.8
gislance (in.) across

112

Figure

7.

Hardness

measurement

the HAZ.

!1

4. FSW

OF FUNCTIONAL

GRADIENT

AI MMC

TO AI-Li

2195

4.1 Previous ment method volume to increase studies of several adaptability which methods

Background MMC's joining have shown that the higher the reinforcein order joining as listed

of joining metal

fraction the joining

the less likely

for standard by decreasing

techniques

to adapt. 7 Therefore, line, a unique (CIJ) technique

the reinforcement to the cast-insert

at the bond joining

was developed

was somewhat

similar

in figure 1. The CIJ is a method inserts or metallic-like materials conventional Using infiltration the welding joining technique.8

of near net- shape casting of MMC components with built-in metallic to provide a site joining with another metal or MMC using any

the CIJ concept, edges of the plate

several as shown

MMC

plates volume

were produced fraction 8. These using FGM

through MMC

the near net-shape material contain

pressure along

process,

with low reinforcement by volume

thin strips of "insert" plates everywhere

in figure which

up to =50-percent except near the

SiC particulate

reinforcement

is uniformly

distributed

edges of the plate. Along these edges, the reinforcement 18.5, and 27 percent by using a special ceramic preform thickness FGM of 0.25 in. One of the objectives to A1-Li 2195. of this project

concentration level can be made to drop to 5, material called Saffil paper with a typical was to investigate the feasibility of FSW these

plates

..0.0e.th.ss I IF-..e-,h5.erce. I
Reinforcement Material SiC Reinforcement

T
4 in.

T
0.25 in.

:.:!.i !;ili;ili!ii!iiiiiiii i!iii ;! {; i;i;i}};.}}.iiiiii

il;;i;ii!iiii
12in.

i : :i:ii

Figure

8. Development

of FGM

for MMC

plates.

12

4.2 4.2.1 Pin Tool Geometry

Experimental

Procedures

From the previous study particulate, a slight modification

of FSW of 0.125-in.-thick for the pin tool geometry thread

MMC plates reinforced with 17.5 percent SiC was performed. All pin tools were threaded length of 0.230 in. The pin tool's

with a unified fine 20-pitch, left-handed shoulder diameter was 0.738 in.

with a nominal

4.2.2

Welding The

Parameters material on FSW thickness of AI-Li for all welds 2195 speed-_ made was 0.250 plates for welding in. The 2195 plunge initial welding thicknesses were given in. parameters of 0.250 as folin.

nominal based

were developed lows: Spindle

to AI-Li 2195 developed

with identical

By trial and error,

a set of welding

parameters

to 2195

speed--700

rpm, travel

ipm, and shoulder 4.3 Results

depth--0.010

4.3.1

Welding

Trial No. 1 (2195

to 50-Percent

SiC FGM

With 5-Percent for welding travel speed and promote

Saffil 2195

Edge) to 2195. It was from 4 to Visual inspecthe pin tool of the pin tool

This weld was initiated observed that the weld 3.4 ipm at ---3.5 in. into the weld tion of this weld shoulder property length 4.3.2 from the crown values did not plunge and stiffness and plunge Welding Based Spindle depth

using the parameters enough, in order to increase

developed heat input because problem. With

was not "hot"

and the transverse appeared

was reduced weld quality. However, adjustment

side (.top side)

to be of good

quality.

far enough would

into the material, plate. this typical

of the unexpected that a slight

high wear-resistant

from the MMC overcome

It is expected

Trial No. 2 (2195 on the results

to 50-Percent

SiC FGM

18.5-Percent were adjusted

Saffil

Edge) as follows: inspection showing

of welding

trial No. 1, new parameters ipm, and shoulder to be of very good

and given

speed--700

rpm, travel

speed--3.5

plunge quality.

depth--0.015 Figure

in. Visual

of this weld from the crown side appeared the result of this welding trial.

9 is a photograph

3cYJ ),--"
Figure 9. FGM with 18.5-percent edge reinforcement welded to A1-Li 2195. 13

4.3.3

Welding

Trial No. 3 (2195 was performed material

to 50-Percent based

SiC FGM

With

27-Percent

Saffil

Edge) of the

This weld

on the same parameters consolidation. the heat input

used in weld No. 2. The beginning by excessive speed heat input The was increased from

weld had an excessive

loss due to "flash." in a lack of material in order to reduce

This was caused

to the 2195 3.5 to

side of the weld and resulted 4 ipm at 1.5 in. into the weld

to the 2195

side. At 6 in. into the weld the

pin tool broke off due to excessive mismatch in the ductility or plastic conductivity Marshall dissimilar FSW. 4.3.4 Welding Trial No. 4 (2195 between Space Flight material the MMC Center properties

loading force. It was speculated zone side due to the difference material. diverse, Indeed, for FSW of A! to copper more

that this situation was caused by a in forging temperature and thermal experiments performed at as (Cu) were not successful. very difficult to perform Therefore, a sound

and the 2195

previous

(MSFC) become

it will become

to 50-Percent using

SiC With

No FGM) as weld No. 2. The weld was unsuccessful of the plate. In this weld the pin broke off

This weld was performed due to very high reinforcement after only 1.5 in. of weld. Another after <1 in. of weld. It is speculated match in the plastic zone

the same parameters at the welding edge

volume

trial was performed with a similar result: the pin tool broke off again that with the 50-percent SiC reinforcement, there is a large misthe MMC and 2195 material, thus making this weld nearly

size between

impossible. Similarly, a previous experiment performed at MSFC for FSW of A1 to Cu was not successful due to the same reasons. Therefore, as stated in the paragraph above, as dissimilar material properties become showing more diverse, the result it will become very difficult welding to perform a sound FGM. FSW. Figure 10 is a photograph of this unsuccessful trial without

Figure

10. Unsuccessful

welding

of 50-percent

SiC MMC

plate to A1-Li 2195.

14

5. TECHNOLOGY

ASSESSMENT

AND

POTENTIAL

APPLICATIONS

5.1

Performance

Limitations

of FSW

As with all welding processes, FSW has specific advantages in table 6. The FSW process may be considered as a joining method

and limitations for MMC's, that utilizes a combination

as listed of

extrusion or forging of metals at elevated temperatures. Therefore, as dissimilar material become even more diverse, it will become more difficult to perform a sound FSW.

properties

Table

6. FSW

advantages

and limitations
Advantages

for joining

MMC's.

Operate below melting point to prevent undesirablechemical reactions No solidification defects between reinforcement and metal Perform at ambient conditions with no toxic fumes Minimum shrinkage, distortion, and residual stress Simple control process without gas shielding or filler material PerformanceLimitations Process portability is limited by the need for heavy and large backing anvil Pin-tool wear may be severe for MMC with reinforcement of >20 percent Sound weld for AI MMC to 2195 AI alloy limited to reinforcment of <25 percent Limiting joint strength to <65 percent due to high processing temperature Welding MMC flat plate or large curvature surface only

The adaptability the volume process. volume welded FSW was found percent In this study, fraction. would Above make that a higher

of FSW it was

or any of the solid state joining of reinforcements, resistance that the FSW process pin tool wear to apply. mismatch strengths

techniques

for MMC's energy input

will depend

on

amount,

the types found

and the thermal for MMC's may become the MMC energy

from the joining SiC by it to be was a importantly, alloy process

was limited

to =25-percent Most

this value, material

too severe.

properties

between

and the monolithic by the FSW in the HAZ.

FSW mainly

very difficult for butt joining

The thermal

created greatly

also high enough is applicable

that the yield and tensile

were also reduced Therefore,

Historically, (e.g., with

of flat plates.

FSW of cylindrical

articles

flange to a duct) with diameters ranging from 2-5 other conventional joining techniques as described 5.2 5.2.1 Potential Applications Potential

in. must be fully demonstrated in figure i. for MMC Flanges

and compared

Applications

rocket

There are several MSFC engines such as the X-33

ongoing vehicle's

activities in the development of MMC's Aerospike and X-34's Fastrac engine.9

for advanced liquid In most of these MMC

15

applications,

it was found

that FSW

either

cannot

be applied

efficiently

or will not be required,

with the

exception of the potential application of joining an MMC flange state-of-the-art fuel line flanges which are made with AI MMC's particulate. For reference, these typical flanges a 4-in.-diameter port hole. Each of these MMC

to an A1 duct. Figure 11 shows the reinforced with 50-percent SiC or B4C

are 1.90 _n. high and have a 6.5-in. outside diameter with flanges would weigh =913 g. The future fuel line duct is the feasibility assessment of contained value reached

proposed to be either A1-Li 2195 alloy or the nanophase A1 (NPA) alloy. For this reason, of FSW of MMC plates to A1 2195 plates was investigated in this study as a preliminary FSW of MMC <25-percent 50-percent flanges to A1 ducts. It was found that FSW was fairly to weld when good when reinforcement volume fraction. and it was nearly impossible the reinforcement

the MMC

Figure

11. MMC

flanges

reinforced

with 50-percent

SiC particulate

for fuel line system.

5.2.2

Functional

Gradient

Material to improve being Matrix the joining under process for the MMC flanges is to develop flanges (SB1R) articles using volume preform methods them as well as phase are thin level to be

One innovative with FGM the FGM 2 contract produced features flat plates for MSFC through

method are currently with Metal

in order

to reduce

the volume made

fraction

at the bond

line. These Innovative

FGM

a Small Business process

Research FGM volume

Cast Composites,

Inc., Waltham,

MA. These

a net-shape,

pressure-infiltration

with low reinforcement

strips of "insert" material along the welding edges. Along the bond lines, the reinforcement can be made to drop from 50 percent to 27, 18.5, and 5 percent by using a special ceramic material layer called Saffil. Most importantly, for joining Potential FGM of MMC Joining technology flanges. Techniques for MMC Flanges it may allow is applicable of <2-5 may allow other joining used more effectively than FSW 5.3 It is speculated methods to be used butt joining Other

that if FGM in addition There However, are several depending

is applied cylindrical

for the development flanges. articles material having

of MMC's, FSW diameters techniques

other joining mainly for not been for are

to FSW for MMC

Historically, small welding

of flat plates. flanges,

in. have

fully demonstrated. FGM of MMC

solid state and fusion

that may be applied If the ducts

on the duct's

and performance

requirements.

16

madefrom NPA,thenonly solid stateweldingtechniques canbe appliedto maintaina low processing temperature NPA.If the ductsaremadefrom anAI-Li alloy suchas 2195,thenfusionwelding for processes maybe used,depending theflangedesignandrequirements. uggestionsor solid state on S f welding techniques which maybeapplicablefor MMC flangesareinertia friction welding (IFW) and diffusion bonding.Suggestionsor fusionprocesses f arelistedasgasmetalarc welding(GMAW), gas tungstenarc welding(GTAW),andresistance spot welding(RSP).Thesewelding techniques arecapable for welding eitherflat platesor cylindrical articlesthathavea smallradiusof curvature.In this study,a literaturesurveyfor welding MMC cylindrical articlesrevealed that IFW andGMAW wereusedsuccessfullyin thepastfor welding of cylindrical MMC components monolithicalloys.Therefore,a to summaryof thepotentialwelding techniques thatmay beapplicablefor NASA'sapplicationsareshown below.
5.3.1 Inertia Friction Welding

Interestingly, cylindrical monolithic the composite objects AI could base

IFW has proven that have a small exhibit material. Yield an excellent

very successful radius.J0-1;'

in the past for making that some strength tensile joint

sound

MMC joints between

for and

It was noted in cross-weld

of the welds of 83 percent

MMC of parent

room-temperature values

of the value of

strength

of up to 90 percent

material value have been obtained by IFW. In fact, the cylindrical geometry of the duct and flange to be mated would directly allow the use of this technique with potentially very little preparation and no speciaI keeping tacting exhibits ducts. tooling. Basically, the method Then, state weld. is simply described as making are brought one workpiece together under to be rotated a compressive materials flanges MMC and conand and the other stationary. force to form several a solid important the two workpieces that make

IFW has been widely it a viable

used for joining candidate

dissimilar

characteristics

for welding

5.3.2

Gas Metal

Arc Welding

results

This fusion welding process can be used for low volume fi'om A/can International have shown that it was possible to monolithic
A1203

reinforcement of MMC. Experimental to weld 4-in.-diameter (10-cm) MMC 13-15 It was noticed demonstration to foxed MMC that the MMC AI, because of several 6061 AI yokes. assembly matethis seamless The for

driveshafts type tubes

A] yokes reinforcement

for automotive was much

applications. easier

rial at 20-percent

to weld than the um'einforced Furthermore, welded

of reinforcement

made

the weld

pool more viscous. in.) were wire was used

with wall thicknesses

of 2 mm (0.08

successfully in the standard

GMAW process with 5356 AI filler full-scale component demonstration.

driveshaft

fixtures

17

6. CONCLUSIONS

FSW

can be applied Above previous

for discontinuously FSW is difficult low ductility,

reinforced to apply high forging performed

MMC"s temperature,

when

the reinforcement

is <25 perhigh For conductivity.

cent by volume. wear resistance, similar reasons,

this level,

due to the material's

high brittleness,

high stiffness,

and low thermal

FSW experiments was found

at MSFC even when

for A1 to Cu were not successful. reinforcement adjusted was limited for every to 17.5 per-

The pin tool's cent SiC by volume, However, higher be machined excessive

wear

to be excessive, length for future

such that the pin tool's high fracture

had to be manually to prevent

5 ft of weld. off due to

tool wear resistance

materials

such as tungsten-carbide,

etc., must be able to

and may require force.

toughness

the pin tool from breaking

welding

In this study, wear against MMC's. as diamond

cost-effective High

B4 C coating

did not work for the H-13 better further investigation of thermal

steel tool to prevent coating

pin tool such

processing like materials

cost but potentially may need

wear-resistance for FSW.

materials

and diamond

FSW has shown a softening factors in the HAZ strength. for joint

to release The joint

an excessive efficiency

amount

energy

for welding

MMC.

Evidently, limiting for

was observed

for all of the welds of 65 percent

in this study, which was achieved

is one of the major

in the as-welded

condition

6092/SiC/20p-T6. Historically, have a large radius FSW may become metal ducts. If FGM in addition techniques for welding applications. is utilized for the development flanges. MMC of MMC's, survey it may allow suggested In particular, other joining methods potential to be used welding FSW is applicable of curvatures. very difficult mainly for butt joining that below for small of flat plates certain small circular and of curved values MMC for radius flanges plates that

It is speculated to apply,

of curvature

in particular

to cylindrical

to FSW for MMC small

for MMC flanges cylindrical

A literature components

that there

are other

such as the 1FW and GMAW.

IFW has been

used successfully

such as tubes

and driveshafts

for automotive

18

7.

RECOMMENDATIONS

It is recommended the bond line in order approach that could allow

that FGM be developed the joining potential other

as a method for MMC methods

to reduce flanges.

the reinforcement FGM ducts, effectively

volume

at

to improve

processes

is an innovative and tubes

material

MMC joining objects

to be used more flanges,

than FSW,

particularly for joining small cylindrical diameters ranging from 2 to 5 in.

such as MMC

with practical

flanges radius

It is recommended and ducts. These of curvature.

that IFW, GMAW, GTAW, and RSP be developed for joining of MMC welding techniques are capable of welding cylindrical articles with a small survey for welding MMC cylindrical articles revealed that IFW and components cylindrical MMC

A literature

GMAW were used such as driveshafts

successfully and extensively in the past for welding and thin-walled tubes to monolithic alloys.

MMC's

It is recommended with >25-percent

that higher pin tool wear-resistant materials reinforcement. However, high wear-resistant well and have good fracture toughness

or coatings be developed for pin tool materials must also to prevent breaking off under high

exhibit the ability to machine FSW welding force.

It is recommended

that FSW

of cylindrical

articles

such as MMC diameters techniques

flanges

to A1 ducts,

with

realistic NASA propulsion hardware applications for practical demonstrated and compared with other proven MMC joining

ranging from 2-5 in., be fully for cylindrical articles.

I9

REFERENCES

Lee, J.A.: "Section: be published

1.2.8.4

Joining

Methods

for MMC,"

In: Metal

Matrix

Composite

Handbook,

to

by the Department et al." "Friction W.M.:

of Defense. Stir Welding," "Friction U.S. Patent 5,460,317. Aluminum Alloys," Welding Journal,

2. 3.

Thomas, Dawes,

W.M.;

C.J.; and Thomas, March O.T.; 1996.

Stir Process

Welds

pp. 41-45, 4. Midling,

"Material Fourth

Flow Behavior

& Microstructural Alloys,

Integrity

of Friction September

Stir Butt 1994. of

Weldments," 5. Rhodes, C.G.;

Inter. Conf. Aluminum

pp. 451-458,

Mahoney, Metall.,

M.W.; et al.: " Effects Voi. 36, pp. 69-75, van den Bergh

of Friction 1997.

Stir Welding

on Microstructure

7075 Al," Script. 6. Database provided

by Mark

from DWA Aluminum Joining

Composites,

Inc. " 21st Conf. on

Lee, J.A.: "Technology Composites, Materials

Assessment and Structures,

of Commercial Cocoa Beach,

Techniques 27-31,

for MMC, 1997.

FL, January Gr/Mg 7-9, MMC 1993.

Lee, J.A.; and Kashalika, NASA Conf. 3249,

U.: "Casting

of Weldable

with Built-in

Metallic

Inserts,"

Voll 1, p. 371, Anaheim, Applications of Al MMC

December

9.

Lee, J.A." "Potential 23rd Conf.

for NASNs Cocoa Alloy

Advanced Beach,

Propulsion FL, January

Systems," 25, 1998.

on Composites,

Materials P.: "Joining

and Structures, Aluminum

10. Gittos,

M.; and Threadgill, 1992.

MMC,"

Bulletin

5, TWI J., pp. 104-105,

September/October 11. Abeam, Marietta

J.S.; and Cooke, Co., Report:

D.C.:

"Joining

Discontinuous September

SiC Reinforced 1, 1985. 6061-T6/A1203

A1 Composites,"

Martin

NSWC-TR-86-36, Friction Institute, Welding June

12. Cola, M.J.; et al.: "Inertia MR9108, 13. Altshuiler, Materials, Edison Welding

of Aluminum 1991.

MMC,"

Research

Report

B.; Christy, ASM

W.; and Wiskel,

B.: "GMA

Welding Park,

of Al-Alumina OH, 1990.

MMC,'"

Weldability

of

International,

pp. 305-309,

Materials

2O

14. Lienert,T.; Lane,C.; andGould, J.: "SelectionandWeldabilityof A1

Vol. 6, pp. 555-559, 15. Schwartz, Materials Materials Park, OH, 1995. Matrix Materials," ASM

MMC,"

ASM

Handbook,

M.M.: "Joining of Composite Park, OH, 1995.

hlternational,

pp. 98-100,

21

REPORT

DOCUMENTATION

PAGE

Form Approved

OMBNo.0704-0188

Public reporting burden for this collection of information is eslirnated 1oaverage 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and compleling and reviewing the collection of information Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing Ihis burden, Io Washington Headquarters Services, Direclorate ier Information Operation and Repods, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503 1. AGENCY USE ONLY (Leave Blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED

December
4. TITLE AND SUBTITLE

1999

Technical

Memorandum
NUMBERS

5. FUNDING

Friction Stir Welding (MMC's)

for Aluminum

Metal Matrix Composites

(MSFC Center Director's Discreli0nar_' Ft, nd Final Report, Pro iect No. 98-09)
6. AUTHORS

J.A. Lee, R.W. Carter, and J. Ding

7. PERFORMING ORGANIZATION NAMES(S) AND ADDRESS(ES) 8. PERFORMING REPORT ORGANIZATION

NUMBER

George C. Marshall Space Flight Center Marshall Space Flight Center, Alabama 35812

M-953

9. SPONSORING/MONITORING

AGENCY

NAME(S)

AND

ADDRESS(ES)

10. SPONSORING/MONITORING AGENCY REPORT NUMBER

National

Aeronautics DC

and Space Administration NASA/TM--1999-209876

Washington,

20546-0001

11.

SUPPLEMENTARY

NOTES

Prepared
12a.

for Materials

Processes
STATEMENT

and Manufacturing

Department,

Engineering
12b.

Directorate
CODE

DISTRIBUTION/AVAILABILITY

DISTRIBUTION

Unclassified-Unlimited Subject Category 29 Nonstandard Distribution

13, ABSTRACT (Maximum 200 words)

This technical

memorandum

describes

an investigation

of using

fi'iction

stir welding

(FSW)

process

for

joining a variety of aluminunl metal matrix composites (MMC's) reinforced with discontinuous siliconcarbide (.SIC) particulate and functional gradient materials. Preliminary results show that FSW is feasible [o weld aluminum MMC to MMC or to aluminum-lithium 2195 if the SiC reinforcement is <25 percent by volume fraction. However, a softening in the heat-affected zone was observed and is known to be one of the major limiting factors for joint strength. The pin tool's material is made fi'om a low-cost steel tool H-13 material, and the pin tool's wear was excessive such that the pin tool length has to be manually adjusted for every 5 ft of weldment. Initially, boron-carbide coating was developed for pin tools, but it did not show a significant improvement in wear resistance. Basically, FSW is applicable mainly for butt joining of flat plates. Therefore, FSW of cylindrical articles such as a flange to a duct with praclical diameters ranging from 2-5 in. must be fully demonstrated and compared with other proven MMC joining techniques for cylindrical articles.

14.

SuBJEcT

TERMS

i15, NUMBER

OF PAGES

friction stir welding, metal matrix cornposiles, silicon-carbide, functional gradient materials, wear-resistant coating, ah|rnint, na-lithium 2195, flanges, ducts, pin tool,.joining technologies
17. SECURITY OF REPORT CLASSIFICATION 18. SECURITY OF THIS CLASSIFICATION PAGE 19. SECURITY CLASSIFICATION

28
16. PRICE CODE

A03
20. LIMITATION OF ABSTRAC'T

OF ABSTRACT

Unclassified
NSN 7540-01-280-5500

Unclassified

Unclassified

Unlimited
Standard Form 298 (Rev. 2-89) Prescribed by ANSI Std 239-18 298-102