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Microstructure, Thermal Stability During Creep and Fractography Study of Friction-Stir-Processed AA2024-T3 Aluminum Alloy
Microstructure, Thermal Stability During Creep and Fractography Study of Friction-Stir-Processed AA2024-T3 Aluminum Alloy
https://doi.org/10.1007/s11665-020-04696-y 1059-9495/$19.00
(Submitted September 19, 2019; in revised form February 18, 2020; published online February 27, 2020)
Friction stir processing (FSP) makes it possible to obtain a stir zone with very fine grain size with the aid of
severe plastic deformation. Yet using FSP, it is impossible to obtain a uniform cross section as far as the
microstructure and mechanical properties are concerned. To reduce the effect of this limitation, in the
current study, the material was processed on both sides, thus yielding a wider, rectangular and more
homogenous stir zone. In a recent publication, the authors focused on the mechanical properties, thermal
stability and transmission electron microscopy (TEM) study of friction-stir-processed AA2024-T3, com-
paring this alloy to the parent material. While the previous study mentioned focused on the parent and on
the as friction-stir-processed material, the current study focuses on post-creep specimens and hence com-
pletes the previous one with microstructural processes occurring during creep. The current paper com-
pletes the above precipitate analysis using electron-dispersive x-ray spectroscopy (EDS) mapping of the
various precipitates reported after exposure to creep temperatures. The TEM study reported in the current
paper revealed the formation of dislocation structures during creep, in parallel to the dynamic recrystal-
lization (DRX) reported by the authors in the past. In addition, fractography study indicated premature
cracking as the prevailing failure mechanism as well as in the case of friction stir welded creep specimens.
Fig. 5 EDS mapping of a specimen that crept 53 min under 25 MPa at 315 °C: (a) HAADF-STEM micrograph showing 1—grain boundary
decoration, 2—rod-shaped precipitates, 3—nano-sized precipitates; (b) HAADF-STEM micrograph of the ROI; (c) qualitative EDS mapping
showing Cu concentration; (d) qualitative EDS mapping showing Mg concentration
the friction-stir-processed material the minimum creep rate was 1. The high stress exponent n in the power law describing
1.0 9 10 5 s 1 and the whole test, until fracture occurred, took the minimum creep rate dependence on applied stress,
0.42 h. In principle, the higher creep rates of the fine-grained which is well above the n = 2 value typical of GBS-con-
FSW material could be attributed to the occurrence of grain trolled creep (Ref 13).
boundary sliding (GBS). Yet, there are several reasons to rule
out any significant role of GBS, namely:
detected in zone 3 (see Fig. 7d), this is due to plastic tate statistics, that both the h and the S sequences take
deformation bands resulting from the heavy plastic deformation place during exposure to creep temperature
during FSP. 3. The TEM study provided evidence for sub-grain forma-
tion during creep inside the grains that had undergone
DRX during the FSP. This in turn indicates that, in addi-
tion to precipitation processes, both DRX and sub-grain
5. Conclusions formation occur during creep. However, further research
is still required in order to clarify whether these two
1. AA2024-T3 underwent friction stir processing on both
mechanisms act simultaneously or one after another.
sides, thus yielding a wider, rectangular and more
4. Cracking was found to take place during creep of the
homogenous stir zone.
friction-stir-processed material as well as in the case of
2. Precipitate analysis conducted by using EDS mapping
the friction stir welded material, hence reducing creep
provided evidence, which relied on quite broad precipi-
resistance.