Effect of multi-pass overlapping friction stir processing on fatigue behavior of Al-Cu alloy

IF 2.5 4区材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications Pub Date : 2024-08-26 DOI:10.1177/14644207241276721

Marukurthi V N V Satyanarayana, Sagar Yanda, Kethavath Kranthi Kumar, Bade Venkata Suresh, Durga Janaki Venkatesh, Rajani Kanthreddy Kolagotla, Kumar Raja Gudaru

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Abstract

More than half of mechanical breakdowns stem from fatigue failure, often occurring suddenly and without warning. Friction stir processing (FSP) enhances the material's toughness and resilience to fatigue by refining its grain structure. This study investigates how multi-pass overlapping technique impacts the fatigue crack growth rate of FSPed Al-Cu alloy. Microstructural analysis revealed that the stir region exhibited uniformly dispersed and fragmented precipitates and finely recrystallized ultrafine grains. The hardness and strength were reduced, and ductility was enhanced after FSP due to high thermal cycling. Fatigue testing demonstrated a significant increase in fatigue life and reduced fatigue crack growth rate attributable to the combined effects of precipitation and grain refinement during cooling-assisted FSP. SEM examination of fatigue fracture surfaces revealed dimples indicative of ductile failure in the rapid crack propagation zone, while the steady-state propagation region displayed striation markings and secondary fractures.

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多道重叠摩擦搅拌加工对铝铜合金疲劳行为的影响

一半以上的机械故障都源于疲劳失效，而且往往是在毫无征兆的情况下突然发生。搅拌摩擦加工（FSP）可通过细化晶粒结构提高材料的韧性和抗疲劳能力。本研究探讨了多道工序重叠技术如何影响经 FSP 处理的铝铜合金的疲劳裂纹生长率。微观结构分析表明，搅拌区呈现出均匀分散的碎片状析出物和细小的再结晶超细晶粒。由于高热循环，FSP 后硬度和强度降低，延展性增强。疲劳测试表明，疲劳寿命显著提高，疲劳裂纹生长率降低，这归因于冷却辅助 FSP 期间析出和晶粒细化的共同作用。对疲劳断裂表面进行的扫描电子显微镜检查发现，在快速裂纹扩展区出现了表明韧性破坏的凹陷，而在稳态扩展区则出现了条纹和二次断裂。

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来源期刊

Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 工程技术-材料科学：综合

CiteScore

4.70

自引率

8.30%

发文量

166

审稿时长

3 months

期刊介绍： The Journal of Materials: Design and Applications covers the usage and design of materials for application in an engineering context. The materials covered include metals, ceramics, and composites, as well as engineering polymers. "The Journal of Materials Design and Applications is dedicated to publishing papers of the highest quality, in a timely fashion, covering a variety of important areas in materials technology. The Journal''s publishers have a wealth of publishing expertise and ensure that authors are given exemplary service. Every attention is given to publishing the papers as quickly as possible. The Journal has an excellent international reputation, with a corresponding international Editorial Board from a large number of different materials areas and disciplines advising the Editor." Professor Bill Banks - University of Strathclyde, UK This journal is a member of the Committee on Publication Ethics (COPE).