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Article history: A high strength Al–Zn–Mg alloy AA7039 was friction stir welded by varying welding and rotary speed of
Received 27 July 2011 the tool in order to investigate the effect of varying welding parameters on microstructure and mechan-
Accepted 28 October 2011 ical properties. The friction stir welding (FSW) process parameters have great influence on heat input per
Available online 26 November 2011
unit length of weld, hence on temperature profile which in turn governs the microstructure and mechan-
ical properties of welded joints. There exits an optimum combination of welding and rotary speed to pro-
Keywords: duce a sound and defect free joint with microstructure that yields maximum mechanical properties. The
D. Welding
mechanical properties increase with decreasing welding speed/ increasing rotary speed i.e. with increas-
E. Mechanical
G. Fractography
ing heat input per unit length of welded joint. The high heat input joints fractured from heat affected
zone (HAZ) adjacent to thermo-mechanically affected zone (TMAZ) on advancing side while low heat
input joints fractured from weld nugget along zigzag line on advancing side.
Ó 2011 Elsevier Ltd. All rights reserved.
0261-3069/$ - see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2011.10.054
380 C. Sharma et al. / Materials and Design 36 (2012) 379–390
treatment (T6) on microstructure and mechanical properties and temperature. Dumbbell shaped tensile specimens (4 mm diameter
found that weld strength increases with increase in welding speed and 20 mm gauge length) were prepared as per the ASTM E8M-04
while PWHT deteriorates same. Therefore, this present study aims specification [22]. Electro-mechanically controlled universal test-
to experimentally examine the effect of varying welding and rota- ing machine (H25K-S, Hounsfield) was used for conducting tensile
tional speed on microstructure and mechanical properties of fric- tests at a cross head speed of 1 mm/min. Tensile tests were per-
tion stir welded joints of AA7039 aluminum alloy. formed in triplicate and average values are presented for discus-
sion. A Vickers microhardness tester (VHM-002V Walter UHL,
Germany) was employed for measuring the hardness across the
2. Material and experimental work joint with a load of 100 g and 30 s dwell time.
Samples for macro and microstructural observation of friction
The extruded plates of AA7039 of 5 mm thick in T6 condition stir welded joints were polished following conventional metallo-
were used as the base material for the present experimental study. graphic practices and etched in Keller’s reagent (2 ml nitric acid,
AA7039 is an Al–Zn–Mg alloy which gains strength from precipita- 4 ml hydrofluoric acid, and 94 ml water) for 90 s. Microstructural
tion hardening. Microstructure of as received AA7039 aluminum analysis was carried out using a light optical microscope (Leica,
alloy had equiaxed aluminum grains of average size 44.3 lm, Germany). The fracture surfaces of the tensile tested specimens
MgZn2 precipitates are embedded in the matrix of aluminum were investigated using a scanning electron microscope (SEM).
grains, i.e. a aluminum as shown in Fig. 1. The chemical composi-
tion obtained by Electron Dispersive X-ray (EDAX) analysis and
room temperature mechanical properties of AA7039 base material 3. Results and discussion
are presented in Table 1.
AA7039 aluminum alloy plates of size 300 mm 50 mm were 3.1. Macrostructure
friction stir welded (parallel to the plate extrusion direction) on a
Vertical Milling Machine (HMT India, 7 H.P. and 635 rpm) using Low magnification optical macrographs of cross section (per-
welding speed (WS) of 75, 120 and 190 mm/min and tool rotary pendicular to welding direction) of friction stir welded joints at dif-
speed (RS) of 410, 540 and 635 rpm. The developed friction stir ferent welding parameters are shown in Fig. 3. It can be observed
welded joints were designated as A, B, and C, produced using con- that all the welded joints are sound and defect free in investigated
stant rotary speed of 635 rpm and varying welding speeds of 75, range of welding parameters. All the friction stir welded joints
120 and 190 mm/min respectively. The joints produced using con- showed trapezoidal weld nugget which is different from elliptical
stant welding speed of 75 mm/min and varying rotary speeds of weld nugget as reported by Mahoney et al. [23] in case of friction
410, 540 and 635 rpm were designated as D, E, and F respectively.
Tool geometry and other welding parameters were kept constant.
Φ 20
Conventional flat shoulder and threaded pin tool made of die steel
was used for friction stir welding. The FSW tool had shoulder diam-
eter of 16 mm and cylindrical tapered pin diameter of 6 mm at top
and 4 mm at bottom, 4.7 mm in length and anticlockwise threads 15
of 1 mm pitch. Schematic diagram of FSW tool is shown in Fig. 2.
A constant tool tilt of 2.5° from the vertical axis was used.
The friction stir welded joints were then inspected visually and
by optical microscopy for any defect if present e.g. voids, root
40
flaws. Only sound and defect free friction stir welded joints were
further investigated. Mechanical properties of as welded (AW)
joints were determined by conducting tensile test at room
α Al
MgZn2 Precipitates
Φ 16 15
α Al
4.7
Φ4
Φ6
Fig. 1. Microstructure of as received AA7039 base material. Fig. 2. Friction stir welding tool.
Table 1
Chemical composition and mechanical properties of AA7039 base material.
Zigzag line a b
Zigzag line
Onion rings
500 µm 500 µm
500 µm
Fig. 4. Effect of welding parameters on the formation of onion ring and zigzag line: (a) RS 410 rpm, WS 75 mm/min (b) RS 540 rpm, WS 75 mm/min and (c) RS 635 rpm,
(b) WS 190 mm/min.
stir welded joints of 7075 T651. Dimensions of trapezoid shape of 4.24 to 4.09 mm) with increase in welding speed due to lower heat
weld nugget closely matched with tool dimensions i.e. shoulder input per unit length so reduced material flow. However, different
diameter at top (16.57 mm) and pin diameter at bottom rotary speed did not result in discernible change of size and shape
(4.24 mm) of the joints. Weld nugget is wider at upper surface than of the weld nugget.
at the bottom surface. Since upper surface is in contact with the
tool shoulder therefore experiences more frictional heating and 3.2. Formation of onion ring and zigzag line
plastic flow which results in wider weld nugget, while bottom sur-
face is in contact with backing plate which extracts heat from the The micrographs of friction stir welded joints produced using
bottom area of the joint which in turn contracts the lower portion low heat input conditions showed onion ring and zigzag line in
of weld nugget. It has been reported that flow of the material near weld nugget (Fig. 4). The formation of onion rings in the micro-
top surface layers of weld nuggets (up to a depth of about one third structure is due to flow of material in batches by rotating tool,
of weld thickness) is caused by FSW tool shoulder while that in extruding plasticized material in the form of semi cylindrical layer
sub-surface region occurs due to thread of tool pin. Therefore, flow in one rotation [14]. Onion rings have alternate bright and dark
pattern of the material near the top of the weld surface becomes rings. The gap between two consecutive rings was more at center
different from the lower part of the weld nugget [24]. The differen- than those at the outer edge. Friction stir welded joints produced
tial flow pattern of material near top surface layers from that of the using low heat input welding conditions (low rotary speed of
bottom and middle regions of the weld result in a weld nugget of 410 and 540 rpm or high welding speed of 190 mm/mm) showed
inverse trapezoid shape [25]. The overall shape and size of friction onion ring formation tendency (Fig. 4). With increase in heat input
stir welded joints varies with welding parameters. Measured width the onion rings formation tendency is reduced and eventually
of weld nugget decreased (from 16.57 to 14.84 mm at top and from these get disappeared in other welds (A, B and F) produced using
382 C. Sharma et al. / Materials and Design 36 (2012) 379–390
high rotary speed (635 rpm) and lower welding speed (75 and fatigue performance of friction stir welded joints of 7075 T6 alloy.
120 mm/min). It is imperative that proper selection of FSW parameters can effec-
At higher welding speed or lower rotary speed reduced stirring tively eliminate the formation of zigzag line; and which even can
leads to partial breaking of natural Al2O3 oxide layer and low heat change failure location from weld nugget to thermo-mechanically
input retards flowability of plastsized material. This weak flow affected zone, heat affected zone or base material thus improved
causes localized presence of broken oxide particle in the form of mechanical performance of friction stir welded joints.
dark wavy zigzag line or kissing bond defect [26] as observed in
low heat input welds (refer Fig. 4 for joints C–E). While in case of 3.3. Microstructure
high heat input welds sufficient stirring cause’s wide and diffused
distribution of oxide particles than in low heat input welds. There- Thermal and mechanical stresses caused by tool stirring and ax-
fore, no zigzag line could be observed in friction stir welded joints ial force results in the formation of weld nugget zone, thermo-
(A, B and F) produced using high heat input welding conditions mechanically affected zone and heat affected zone in friction stir
(welding speed of 75 and 120 mm/min and rotary speed of welded joints as shown in Figs. 5 and 6. The micrographs of the
635 rpm). The fracture initiate at the root along the zigzag line to center of the weld nugget zones for all conditions of welding and
cause failure from weld nugget during tensile testing of these rotary speed are shown in Fig. 5. All the weld nuggets invariably
joints. Di et al. [27] also reported that zigzag line defect reduces showed fine recrystallized equiaxed grains because of severe plas-
a b
50 µm 50 µm
c d
50 µm 50 µm
e f
50 µm 50 µm
Fig. 5. Effect of welding parameters on grain structure of weld nugget zone: Welding speed (a) 75 mm/min, (b) 120 mm/min, (c) 190 mm/min and Rotary speed, (d) 410 rpm,
(e) 540 rpm and (f) 635 rpm.
C. Sharma et al. / Materials and Design 36 (2012) 379–390 383
a b
BM
α Al
HAZ
TMAZ
MgZn2 Precipitates
WNZ
200 µm 50 µm
c d
BM
HAZ
MgZn2 Precipitates
TMAZ
α Al WNZ
20 µm 200 µm
e f
α Al
α Al
MgZn2 Precipitates
MgZn2 Precipitates
50 µm 20 µm
Fig. 6. Representative microstructure of FSW joint produced using welding speed of 120 mm/min and rotary speed of 635 rpm (a) Different FSW zones on RS showing
transition from WNZ to TMAZ, (b) RS TMAZ, (c) RS HAZ, (d) different FSW zones on AS showing transition from WNZ to TMAZ, (e) AS TMAZ (f) AS HAZ.
transformed into fine and equiaxed grain structure in weld nugget. Welding speed (mm/min) 75 120 190
As compared to the base material fewer second phase strengthen- Weld nugget grain size (lm) 13.12 9.51 7.92
ing precipitates of MgZn2 were observed in weld nugget as these Rotary speed (rpm) 410 540 635
Weld nugget grain size (lm) 7.93 10.47 13.12
are broken down and uniformly distributed by stirring tool. At
low welding speed, weld nugget is more homogeneous than those
produced using high welding speed because high heat input per
unit weld length results in more homogeneous temperature distri- It was observed that size of a aluminum present in weld nugget
bution and effective recrystallization. Image analysis of weld decreases with increasing welding speed and same trend was ob-
micrographs was done using Image J, image analyzing software served with decreasing rotary speed (Fig. 7). Because with decreas-
to determine average grain size of a aluminum present in weld ing rotary speed heat inputs per unit weld length decreases while
nugget. The determined size of grains in weld nugget of friction stir increasing welding speed shortens the available time (i.e. more
welded joints is given in Table 2. mm per tool rotation) therefore lower is the maximum annealing
384 C. Sharma et al. / Materials and Design 36 (2012) 379–390
Table 3
Tensile properties of friction stir welded joints of AA7039 aluminum alloy.
Welding parameters Yield strength (MPa) Ultimate tensile strength (MPa) Elongation (%) Energy absorbed (J) Joint efficiency (%)
Welding speed (mm/min) Rotary speed (RPM)
BM 328 414 15.1 15.05 –
A: WS 75 RS 635 217.3 354.37 21.36 18.68 85.59
B: WS 120 RS 635 218.8 352.7 20.6 19.73 85.19
C: WS 190 RS 635 226.43 317.3 9.69 8.63 76.64
D: RS 410 WS 75 245.13 275.23 7.63 3.89 66.48
E: RS 540 WS 75 247.9 346.4 15.93 12.59 83.57
F: RS 635 WS 75 217.3 354.37 21.36 18.68 85.59
Where: BM: Base material, WS: Welding speed (mm/min), and RS: Rotary speed.
C. Sharma et al. / Materials and Design 36 (2012) 379–390 385
Fig. 8. Engineering strain stress diagrams for friction stir welded joints of AA7039.
Fig. 10. Effect of rotary speed on (a) ultimate and yield strength, and (b) %
elongation and energy absorbed.
Fig. 11. Effect of (a) welding speed, and (b) rotary speed on joint efficiency of Fig. 12. Effect of welding parameters on microhardness variations across friction
friction stir welded joints. stir welded joints (a) welding speed, and (b) rotary speed.
Table 4
Effect of FSW process parameters on fracture properties friction stir welded joints of AA7039.
Welding parameters Minimum hardness (HV) Fracture location & distance from weld centre Photograph of fractured specimen
WS 75 mm/min, RS 635 rpm 89 AS HAZ. 11 mm
a b
e f
g h
Fig. 14. Effect of welding parameters on fracture morphology: Fracture surfaces of (a) base material and at welding speed of (b) 75 mm/min, and (c) enlarged view of fracture
surface showing cracked secondary precipitates at 75 mm/min, (d) 120 mm/min, and (e) 190 mm/min. Fracture surfaces at rotary speed of (f) 410 rpm, (g) 540 rpm, and (h)
635 rpm.
C. Sharma et al. / Materials and Design 36 (2012) 379–390 389
zone to retreating side heat affected zone and advancing side weld fractured surface while joints A, B and F were undergone apprecia-
nugget for joints produced at 75, 120 and 190 mm/min welding ble necking prior to failure. This may be because of confined flow-
speed. While variation in rotary speed at constant welding speed ability of plasticized material at the root of the welded joints
did not changed fracture location except for low rotary speed underneath the tool shoulder.
(410 rpm) joint which failed in advancing side weld nugget. Thus,
increase in welding speed or decrease in rotary speed shifts mini-
4. Conclusion
mum hardness region from heat affected zone to weld nugget. Liu
et al. [18] observed that fracture location of the joint gradually ap-
Al–Zn–Mg alloy AA7039 was successfully friction stir welded
proaches the weld center with increase in revolutionary pitch
employing different process parameters in order to investigate
(increasing welding or rotary speed) for friction stir welded joints
their influence on microstructure and mechanical properties of
of AA2017.
developed joints. Following conclusion can be drawn from the
present work.
3.7. Fracture surfaces
An increase in tool rotary speed and decrease in welding speed
Fracture surfaces of the broken tensile specimens were investi-
reduces zigzag line formation tendency. Average grain size of a-
gated by scanning electron microscope to carry out failure analysis
aluminum present in weld nugget decreases on increasing
and to understand the influence of microstructure on the failure
welding speed and decreasing rotary speed.
patterns of the friction stir welded joints. It was observed that
The ultimate tensile strength, % elongation, energy absorbed
welding parameters exerted significant effect on fracture pattern
and joint efficiency decrease with increase in welding speed
of friction stir welded joints. Failure occurred as 45° shear fracture
and all above joint performance parameters increase with
accompanied by limited necking in friction stir welded joints
increase in rotary speed.
welded at 75 and 120 mm/min. Fracture surface had ‘‘ ’’ like
The location of minimum microhardness zone in FSW weld
appearance without any reduction in area i.e. necking, initiated
joint of AA 7039 alloy is significantly influenced by FSW process
at the root then propagated vertically to loading axis followed by
parameters. The minimum hardness region shifts from heat
almost horizontal propagation before finally fracture in vertical
affected zone to weld nugget zone on increasing welding speed
plane for the joints produced at welding speed of 190 mm/min.
and decreasing the tool rotary speed.
At lower rotary speed of 410 and 540 rpm fracture surface had
The fracture of friction stir welded joints (A and F) produced
behavior similar to joints produced at welding speed of 190 mm/
using high heat input (high rotary speed and low welding
min while at higher rotary speed of 635 rpm had 45° shear frac-
speed) occurred from heat affected zone adjacent to thermo-
tures similar to joints produced at 75 and 120 mm/min welding
mechanically affected zone on advancing side while that of joint
speed. SEM micrographs of fractured surfaces of friction stir
developed using low heat input (C–E) fractured from the weld
welded joints are shown in Fig. 14.
nugget along zigzag line on advancing side.
Unwelded base material has undergone transgranular ductile
fracture and fracture surface covered with fine dimples of varying
Thus careful selection of FSW process parameters is required to
size and shapes (Fig. 14a). Some deep voids and enlarged dimples
(a) avoid the formation of voids or zigzag line defect (b) maximize
were also observed on the fracture surface. Careful examination of
mechanical properties and (c) regulate fracture location in friction
fractured surfaces of welded joints revealed that process parame-
stir weld joints of AA7039 aluminum alloy.
ters have noticeable effect on fracture morphology and mecha-
nism. All fractured surfaces of welded joints invariably showed
dimples of varying size and shape separated by tear ridges Acknowledgements
(Fig. 14b, d, g and h), which is an indication that most of the failure
is ductile in nature [19] except low heat input joints (C and D) pro- The authors are thankful to Dr. N.K. Jain of Indian Institute of
duced at higher welding speed of 190 mm/min and lower rotary Technology, Indore for providing support in carrying out microh-
speed of 410 rpm (Fig. 14e and f). The fracture originates from ardness characterization of welded joints. Authors are also grateful
the breakages of secondary precipitates rich in Mg and Zn to DST, Govt. of India for providing financial support through Grant
(Fig. 14c) which initiate the formation of microvoids at grain No. SR/S3/MERC/005/2009 for carrying out this work under project
boundary particles and coalesce at failure. Some flat regions with entitled ‘structural instability in friction stir welded joints of alu-
visible pores as shown in box (Fig. 14b) were also seen on fracture minum alloys and their effect on mechanical properties’’. Mr. Cha-
surface of joint A. The population of dimples diminishes with the itanya Sharma, Research scholar kindly acknowledges the MHRD,
increasing welding speed while size of dimples increase. Failure Govt. of India for awarding fellowship.
pattern was brittle in low heat input joints (C and D) and fracture
surfaces were covered with layered ledges (Fig. 14e and f). The References
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