TY - JOUR

T1 - Process parameter assessment on the dissimilar deposition of AA2024-T351 on AA7475-T761 by friction surfacing

AU - Brandes, Amanda Catarina

AU - Roos, Arne

AU - Klusemann, Benjamin

AU - Martins, Juliana de Paula

AU - dos Santos, Jorge Fernandez

AU - Carvalho, André Luis Moreira

N1 - Funding Information: The authors would like to thank the C2PA consortium for R&D in friction processing for funding this research. Publisher Copyright: © 2023 Published by Elsevier B.V.

PY - 2023/11/1

Y1 - 2023/11/1

N2 - Friction surfacing as a solid-state deposition process allows the joining of materials with different chemical and physical properties at temperatures below their respective melting points. This experimental work focuses on generating sound, defect-free metallurgical joints between single friction surfacing deposits and substrate surfaces from dissimilar Al alloys of the 2xxx and 7xxx series. In this context, the influence of axial force and deposition speed on surface morphology and deposit geometry of the two heat-treatable Al alloys AA7475 as substrate and AA2024 as deposit are investigated. Process parameter variation shows that an increase in axial force from 8 to 12 kN, in conjunction with a deposition speed of 8 mm/s, leads to smooth surface morphology and consistent deposit width along its length. The AA2024 deposits consist of fine-grained microstructure with higher hardness at the top and lower hardness at the deposit-substrate interface. The joining mechanism is by interdiffusion, with a 7.5 μm thick diffusion zone across the dissimilar interface. Three-point bending tests reveal excellent bonding in the lateral surface of the advancing side due to the absence of delamination for all conditions tested. Minor delamination appears predominantly on the retreating side region for process parameter sets with low axial force. Tensile test results reveal that the AA2024 deposit on the AA7475 substrate presents an ultimate tensile strength equivalent to the AA7475-T651 base material and an increase of 37 % in ductility.

AB - Friction surfacing as a solid-state deposition process allows the joining of materials with different chemical and physical properties at temperatures below their respective melting points. This experimental work focuses on generating sound, defect-free metallurgical joints between single friction surfacing deposits and substrate surfaces from dissimilar Al alloys of the 2xxx and 7xxx series. In this context, the influence of axial force and deposition speed on surface morphology and deposit geometry of the two heat-treatable Al alloys AA7475 as substrate and AA2024 as deposit are investigated. Process parameter variation shows that an increase in axial force from 8 to 12 kN, in conjunction with a deposition speed of 8 mm/s, leads to smooth surface morphology and consistent deposit width along its length. The AA2024 deposits consist of fine-grained microstructure with higher hardness at the top and lower hardness at the deposit-substrate interface. The joining mechanism is by interdiffusion, with a 7.5 μm thick diffusion zone across the dissimilar interface. Three-point bending tests reveal excellent bonding in the lateral surface of the advancing side due to the absence of delamination for all conditions tested. Minor delamination appears predominantly on the retreating side region for process parameter sets with low axial force. Tensile test results reveal that the AA2024 deposit on the AA7475 substrate presents an ultimate tensile strength equivalent to the AA7475-T651 base material and an increase of 37 % in ductility.

KW - AA2024

KW - AA7475

KW - Diffusion

KW - Dissimilar deposition

KW - Friction surfacing

KW - Mechanical properties

KW - Engineering

UR - http://www.scopus.com/inward/record.url?scp=85178164269&partnerID=8YFLogxK

U2 - 10.1016/j.jmrt.2023.11.178

DO - 10.1016/j.jmrt.2023.11.178

M3 - Journal articles

AN - SCOPUS:85178164269

VL - 27

SP - 7593

EP - 7605

JO - Journal of Materials Research and Technology

JF - Journal of Materials Research and Technology

SN - 2238-7854

ER -