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Advanced Materials Processing and Joining Laboratory Tuesday, February 27 th, 2007 Friction Stir Welding of Bulk Metallic.

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Presentation on theme: "Advanced Materials Processing and Joining Laboratory Tuesday, February 27 th, 2007 Friction Stir Welding of Bulk Metallic."— Presentation transcript:

1 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Friction Stir Welding of Bulk Metallic Glasses Presented by Lily Ma MS Student- Materials Engineering and Science Rakesh C. Suravarapu MS Student- Materials Engineering and Science Stanley M. Howard Professor, Department of Materials and Metallurgical Engineering William J. Arbegast Director, Advanced Material Processing Center Katharine M. Flores Assistant Professor, Department of Material Science and Engineering Ohio State University

2 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Objective  Establish a FSW processing window for BMG Vitreloy 106A to maintain its amorphous nature

3 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Fracture toughness – ~15 to 20 MPam 1/2 Applications – automotive and aerospace structures, biomedical devices, machinery structure materials, and sporting gears Figure 1: Combination of strength and Toughness compared with selected engineering materials. (Flores, K.M et al. 2003 ) Background

4 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Materials 2.8Nb 10.3Al 12.8Ni 15.6Cu 58.5Zr Atomic Percent Element Composition of Vitreloy 106A Figure 2 Time temperature transformation diagram of the bulk metallic glass – Vitreloy106A. (Hays, C.C et al. 2001) Crystalline Amorphous 200 Tg = 400 o C T liq = 830 o C Temperature ºC 500 600 700 800 300 900 400

5 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 0.39” 0.6” 0.39” 0.6” 1.84” 1.78” Sample C Sample B Sample A Samples and Campaign Conditions Table 1: Summary of the campaign conditions Preheated friction stir welding Yes C Campaign III Series of four linear friction stir welds No CCampaign II Friction stir plunging No BCampaign I N/A AReference Process Preheated SampleDescription

6 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Campaign I – Friction stir plunging 500RPM800RPM Friction stir plunged sample Sample B Copper Plates PCBN Pin Tool Clamping and weld setup Two plunges on Sample B: 500RPM and 800RPM PCBN pin tool was used Sample B was placed on the copper plates for rapid cooling

7 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Campaign II – Friction stir welding (no preheating) Table 2: Processing parameters used in Campaign II Pin Tool Weld No. Weld Length (inches) Weld Speed (in/min) Spindle Speed (RPM) Forge Depth (inx10 -3 ) Plunge Rate (in/min/s) Forge Force (pounds) Atmosphere PCBN11.001.050050.130882Air PCBN20.651.0500150.130950Air W-Re30.350.5300100.1302070Argon W-Re40.850.580010 - 160.065647Argon Clamping and weld setup 1 st & 2 nd welds without Argon blanket

8 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 3 rd & 4 th welds with Argon blanket Weld-2 Friction stir welded sample Weld-4 Weld-1 Weld-3Weld-2 Campaign II cont’d

9 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Pin tool wear Before After PCBN 2 Weld 2 PCBN 1 Weld 1 W-Re 1 Weld 3 W-Re 2 Weld 4 W-Re 3 Pre-Heated Weld W-Re – 38002.0Pre-heated weld W-Re – 28000.5Weld 4 (No Preheating) W-Re – 13000.5Weld 3 (No Preheating) PCBN – 25001.0Weld 2 (No Preheating) PCBN – 15001.0Weld 1 (No Preheating) Pin Tool Used Spindle Speed (RPM) Weld Speed (IPM) Weld No. Table 5: Processing parameters used in Campaign III

10 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Campaign III – Pre-heated friction stir welding Table 4: Processing parameters used in Campaign III Pin Tool Weld No. Weld Length (inches) Weld Speed (inches/min) Spindle Speed (RPM) Forge Depth (inches) Plunge Rate (inches/min/sec) Forge Force (pounds) W-Re51.02.08000.0100.0652000 Quenching with Liq Nitrogen after the weld Weld-5 Friction stir welded sample Clamping and weld setup Pre-heating plate

11 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Pin tool wear Before After PCBN 2 Weld 2 PCBN 1 Weld 1 W-Re 1 Weld 3 W-Re 2 Weld 4 W-Re 3 Pre-Heated Weld W-Re – 38002.0Pre-heated weld W-Re – 28000.5Weld 4 (No Preheating) W-Re – 13000.5Weld 3 (No Preheating) PCBN – 25001.0Weld 2 (No Preheating) PCBN – 15001.0Weld 1 (No Preheating) Pin Tool Used Spindle Speed (RPM) Weld Speed (IPM) Weld No. Table 5: Processing parameters used in Campaign III

12 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Campaign II – Surface XRD Scan 1 Scan 2 Scan 3 Scan 4 Scan 5 Scan 6 Scan 7 Scan 8 Scan 9 Friction stir welded sample Weld-2 Weld-4 Weld-1 Weld-3Weld-2 1 2 3 9 8 7 6 4 5 Weld No. Pin Tool IPMRPM Weld #1 PCBN – 1 5001.0 Weld #2 PCBN – 25001.0 Weld #3W-Re3000.5 Weld #4 W-Re8000.5 Two-Theta (deg.) Intensity (Counts)

13 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Weld-5 10 Spot 10 Campaign III – Surface XRD Weld 5 Weld No. Pin Tool IPMRPM Pre-heated Weld #5 W-Re8002.0

14 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 DSC Campaign II and III – 450 o C to 550 o C 100% Crystalline 95% Crystalline 59% Crystalline 57% Crystalline 62% Crystalline 29% Crystalline 0% Crystalline Percent Crystalline 21.22 J/g 25.02 J/g 56.4 J/g 68.01 J/g 70.5 J/g 96.5 J/g 102.1 J/g Parent Metal Weld #2 – Campaign II Weld #1 – Campaign II Weld#5 – Campaign III Weld #4 – Campaign II Weld #3 – Campaign II Crystallized Sample Exo Up Temperature ( o C)

15 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Weld 2: Off weld / On weld Weld 5: Off weld / On weld

16 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Comparison of crystallinity XRD Location Crystallinity, (%) Surface XRD Cross section XRD DSC Crystallized Bulk Metallic Glass Sample100 Weld 4 (Campaign II)6053 42 Weld 1 (Campaign II)534139 Weld 3 (Campaign II)512895 Weld 5 (Campaign III - Pre Heated)516156 Weld 2 (Campaign II)35246.9 Amorphous Bulk Metallic Glass -Parent Metal000

17 Advanced Materials Processing and Joining Laboratory Xiaoqian.Ma@Hardrockers.sdsmt.edu Tuesday, February 27 th, 2007 Vitreloy can be plasticized by friction stir plunging while maintaining amorphous condition Pre-heating resulted in superior plasticization Process window appears to have 800 RPM and 2 IPM (initially) Pre-heating with quenching is recommended primarily for the weld quality and pin tool life Conclusions

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