Evaluation of Additive Friction Stir Deposition for the Repair of Cast Al-1.4Si-1.1Cu-1.5Mg-2.1Zn
Evaluation of Additive Friction Stir Deposition for the Repair of Cast Al-1.4Si-1.1Cu-1.5Mg-2.1Zn
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添加剂搅拌摩擦沉积修复铸件 Al-1.4Si-1.1Cu-1.5Mg-2.1Zn 的评价
DOI：
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发表时间：
2021
期刊：
影响因子：
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通讯作者：
M. Walluk
中科院分区：
文献类型：
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作者：
P. Martin;Allen Luccitti;M. Walluk
沉积新合金以替换磨损或损坏的表面层是修复或再制造结构部件的常见策略。固态方法，例如添加剂摩擦搅拌沉积（AFSD），通过在低于熔点的温度下沉积材料来减轻与传统熔合方法相关的挑战。在这项工作中，铝合金6061-T6的AFSD作为一种手段，以填补在铸造铝合金Al-1.4Si-1.1Cu-1.5Mg-2.1Zn基板的机械加工槽进行了研究。机械加工和沉积的组合模拟了机械去除受损材料，然后使用AFSD替换的修复。通过金相检查、拉伸和疲劳试验对三种槽的几何形状进行了评价。对于本研究中使用的工艺条件和凹槽几何形状，有效修复深度限于2.3 - 2.6 mm;低于该深度，填料和基材材料之间的界面表现出与剪切变形不足相关的粘合不良。沉积的填充合金在强度和硬度方面与铸造合金基底紧密匹配。此外，完全反向轴向疲劳测试期间的疲劳寿命是根据历史数据预测的应力幅相当的疲劳寿命的66%。结果表明，有潜力利用AFSD的6061作为一个可行的修复工艺铸造Al-1.4Si-1.1Cu-1.5Mg-2.1Zn和其他可比合金。
The deposition of new alloy to replace a worn or damaged surface layer is a common strategy for repairing or remanufacturing structural components. Solid state methods, such as additive friction stir deposition (AFSD), mitigate the challenges associated with traditional fusion methods by depositing material at temperatures below the melting point. In this work, AFSD of aluminum alloy 6061-T6 was investigated as a means to fill machined grooves in a substrate of cast aluminum alloy Al-1.4Si-1.1Cu-1.5Mg-2.1Zn. The combination of machining and deposition simulate a repair in which damaged material is mechanically removed, then replaced using AFSD. Three groove geometries were evaluated by means of metallographic inspection, and tensile and fatigue testing. For the process conditions and groove geometries used in this study, the effective repair depth was limited to 2.3 – 2.6 mm; below that depth, the interface between the filler and substrate materials exhibited poor bonding associated with insufficient shear deformation. The deposited filler alloy closely matched the cast alloy substrate in both strength and hardness. In addition, the fatigue life during fully reversed axial fatigue testing was 66% of that predicted from historical data for comparable stress amplitudes. The results suggest that there is potential to utilize AFSD of 6061 as a viable repair process for cast Al-1.4Si-1.1Cu-1.5Mg-2.1Zn and other comparable alloys.