In this study, metal particles were added during the spot friction welding (SFW) process, a solid state sheet metal joining process, to create a localized metal matrix composite (MMC) for the improvement of lap shear strength in AISI 6111-T4 aluminum alloy sheets. The Ancorsteel® 1000 particles were compressed between the upper and lower sheets and distributed concentrically around the tool axis perpendicular to the plate surface, which formed a localized MMC and were effective as the reinforcement particles in aluminum 6111-T4 alloy sheets. Results revealed that the MMC reinforcement improved the lap shear strength of SFW joints by about 25%. An aluminum-ferrous solid solution was formed around the steel particles along the aluminum matrix interface. The load-deflection curve shows that the steel particle MMC increased both the strength and ductility of SFW joint. This is attributed to two phenomena observed on the failed lap shear tensile specimens with SFW MMC. One is the longer and more torturous crack path, and the other is the secondary crack on steel particle MMC reinforced SFW joints.
References
1.
Chawla
, N.
, and Chawla
, K. K.
, 2006, Metal Matrix Composites
, Springer
, Berlin
.2.
Suresh
, S.
, Mortensen
, A.
, and Needleman
, A.
, 1993, Fundamentals of Metal Matrix Composites
, Butterworth-Heineman
, Oxford, UK
.3.
Mishra
, R. S.
, Ma
, Z. Y.
, and Charit
, I.
, 2003, “Friction Stir Processing: A Novel Technique for Fabrication of Surface Composite
,” Mater. Sci. Eng., A
, 341
, pp. 307
–310
.4.
Wang
, W.
, Shi
, Q.
, Liu
, P.
, Li
, H.
, and Li
, T.
, 2009, “A Novel Way to Produce Bulk Sicp Reinforced Aluminum Metal Matrix Composites by Friction Stir Processing
,” J. Mater. Process. Technol.
, 209
, pp. 2099
–2103
.5.
Storjohann
, D.
, Barabash
, O. M.
, Babu
, S. S.
, David
, S.
, and Sklad
, P.
, 2005, “Fusion and Stir Welding of Aluminum-Metal-Matrix Composites
,” Metall. Mater. Trans. A
, 36A
, pp. 3237
–3247
.6.
Sun
, X.
, Stephens
, E.
, Davies
, R.
, Khaleel
, M.
, and Spinella
, D. J.
, 2005, “Effects of Failure Modes on Strength of Aluminum Resistance Spot Welds
,” Society of Automotive Engineers
, Warrendale
, PA
, SAE Technical Paper No: 2005-01-0906.7.
Thornton
, P.
, Krause
, A.
, and Davies
, R.
, 1996, “Aluminum Spot Weld
,” Weld. J.
(Miami, FL, U.S.), 75
, pp. 101s
–108s
.8.
Gean
, A.
, Westgate
, S. A.
, Kucza
, J. C.
, and Ehrstorm
, J. C.
, 1999, “Static and Fatigue Behavior of Spot-Welded 5182-0 Aluminum Alloy Sheet
,” Weld. J.
(Miami, FL, U.S.), 78
, pp. 80s
–86s
.9.
Badarinarayan
, H.
, Shi
, Y.
, Li
, X.
, and Okamoto
, K.
, 2009, “Effect of Tool Geometry on Hook Formation and Static Strength of Friction Stir Spot Welded Aluminum 5754-O Sheets
,” Int. J. Mach . Tools Manuf.
, 49
, pp. 814
–823
.10.
Freeney
, T. A.
, Sharma
, S. R.
, and Mishra
, R. S.
, 2006, “Effect of Welding Parameters on Properties of 5052 Al Friction Stir Spot Welds
,” Society of Automotive Engineers
, Warrendale
, PA
, SAE Technical Paper No: 2006-01-0969.11.
Sakano
, R.
, Murakami
, K.
, Yamashita
, K.
, Hyoe
, T.
, Fujimoto
, M.
, Inuzuka
, M.
, Nagao
, Y.
, and Kashiki
, H.
, 2001, “Development of Spot FSW Robot System for Automobile Body Members
,” Proceedings of the 3rd International Symposium on Friction Stir Welding
, Kobe
, Japan
.12.
Arul
, S.
, Miller
, S.
, Kruger
, G.
, Pan
, T.
, Shih
, A.
, and Malick
, P. K.
, 2008, “An Experimental Study of Joint Performance in Spot Friction Welding of 6111-T4 Aluminum Alloy
,” Sci. Technol. Weld. Joining
, 13
(7
), pp. 629
–637
.13.
Geni
, M.
, and Kikuchi
, M.
, 1998, “Damage Analysis of Aluminum Matrix Composite Considering Non-Uniform Distribution of SiC Particles
,” Acta Mater.
, 46
(9
), pp. 3125
–3133
.14.
Bao
, G.
, Huchinson
, J. S.
, and McKeeking
, R. M.
, 1991, “Particle Reinforcement of Ductile Matrices Against Plastic Flow and Creep
,” Acta Metall. Mater.
, 39
, pp. 1871
–1882
.15.
Whitehouse
, A. F.
, and Clyne
, T. W.
, 1993, “Effects of Reinforcement Content and Shape of Cavitation and Failure in Metal-Matrix Composites
,” Composites
, 24
(3
), pp. 256
–261
.16.
Ancorsteel® datasheet, 1001 Taylor Lane, Cinnaminson, NJ 08077-2017, www.hoeganaes.com
17.
Arul
, S. G.
, Kruger
, G. H.
, Miller
, S. F.
, Pan
, T. Y.
, and Shih
, A. J.
, 2008, “Spot Friction Weld Strength Improvement Through In-Process Metal Matrix Formation
,” Proceedings of the 2008 International Manufacturing Science and Engineering Conference, Evanston
, IL
, October 7–10.18.
North
, T. H.
, Bendzsak
, G. J.
, Li
, Z.
, and Zhai
, Y.
, 1997, “Particle Fracture, Retention and Fluid Flow in Metal Matrix Composite Friction Joints
,” Metall. Trans. A
, 28
, pp. 2371
–2384
.19.
Mitlin
, D.
, Radmilovic
, V.
, Pan
, T.
, Feng
Z.
, and Santella
, M.
, 2006, “Structure-Properties Relations in Spot Friction Welded (also Known as Friction Stir Spot Welded) 6111 Aluminum
,” Mater. Sci. Eng., A
, 441
, pp. 79
–96
.20.
Su
, P.
, Gerlich
, A.
, North
, T. H.
, and Bendzsak
, G. J.
, 2006, “Material Flow During Friction Stir Spot Welding
,” Sci. Technol. Weld. Joining
, 11
(1
), pp. 61
–71
.21.
Tozaki
, Y.
, Uematsu
, Y.
, and Tokaji
, K.
, 2006, “Effect of Welding Condition on Tensile Strength of Dissimilar FS Spot Welds Between Different Al Alloys
,” Proceedings of the 6th International Symposium on Friction Stir Welding
, Saint-Sauveur, Nr Montreal
, Canada
, October 10
–13
.22.
Lathabai
, S.
, Oainter
, M.
, Cantin
, G.
, and Tyagi
, V.
, 2005, “Friction Stir Spot Welding of Automotive Lightweight Alloys
,” Proceedings of the 7th International Conference on “Trends in Welding Research
,” Pine Mountain
, GA, ASM
, pp. 207
–212
.23.
Toda
, H.
, and Kobayashi
, T.
, 1999, “Simulation of Crack Propagating in Discontinuously Reinforced Metal Matrix Composite
,” Metall. Mater. Trans. A
, 28
A, pp. 2149
–2157
.24.
Ma
, Z. Y.
, Tjong
, S. J.
, Li
, Y. L.
, Liang
, Y.
, 1997, “High Temperature Creep Behavior of Nanometric Si2N4 Particulate Reinforced Aluminum Composite
,” Mater. Sci. Eng., A
, 225
, pp. 125
–134
.Copyright © 2011
by American Society of Mechanical Engineers
You do not currently have access to this content.
