Solid-State Repair of Casting Defects in ZL210 Aluminum Alloy
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JMEPEG https://doi.org/10.1007/s11665-020-05054-8
Solid-State Repair of Casting Defects in ZL210 Aluminum Alloy Zan Lv, Song Han, Wei Hu, Zhibo Dong, Ruofei Huang, and Kang Yang (Submitted August 17, 2019; in revised form February 8, 2020) Casting defects in the ZL210 aluminum alloys were repaired via a solid-state welding method named activepassive filling friction stir repairing (A-PFFSR). Effects of plunge speed on microstructures and mechanical properties of repaired joints were investigated based on a six-spiral-groove pinless tool. Casting defects were firstly machined into a tapered hole by a tapered and threaded pin. Then, the keyhole was successfully repaired by the materials surrounding the keyhole and an extra filler via the A-PFFSR. The lower plunge speed was propitious to improving frictional heat and material flow, which improved joint integrity containing surface appearance and interface joining behaviors. The maximum tensile strength of the repaired joint was approximately equivalent to that of base ZL210 alloys, realizing the quasi-repairing of the ZL210 aluminum alloys. Keywords
casting aluminum alloys, defects repairing, mechanical properties, microstructures, solid-state welding
1. Introduction Metallic materials have been extensively applied in the manufacturing fields of aerospace, railway and so on, which demand more and more attentions of heat processing techniques (Ref 1-4). When improper process parameters or technological conditions are implemented, the defects are easily formed, which are detrimental to service performances of structural parts (Ref 5-7). Meanwhile, casting aluminum alloys have been widely used in the aerospace and marine manufacturing fields (Ref 8). The casting defects, such as pores, cavities and cracks, deteriorate the service performances of casting structural parts (Ref 9-11). Although the conventional fusion welding techniques can be used to repair the defects in structural parts, they are restricted due to the pores, coarse grains and cracks induced by extremely high repairing temperature (Ref 12). Recently, a solid-state repairing method based on friction stir welding (FSW) has attracted extensive attentions (Ref 13-16). Aiming at the long volume tunnel and groove defects, Liu and Zhang (Ref 17) put forward the re-FSW method and found that a proper offset could benefit for enhancing joint quality. Ji et al. (Ref 18, 19) proposed vertical compensation friction stir welding (VCFSW) to eliminate groove, tunnel and gap defects, and then obtained a high-quality joint with good surface (Ref 19). For the small Zan Lv and Song Han have contributed equally to this work. Zan Lv, Song Han, Wei Hu, Ruofei Huang, and Kang Yang, College of Aerospace Engineering, Shenyang Aerospace University, Shenyang 110136, China; and Zhibo Dong, State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, China. Contact e-mails: [email protected] and [email protected].
Journal of Materials Engineering and Performance
volume defects, such as keyhole, c
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