US-Egypt Cooperative Research: Friction Stir Welding of Superplastic Alloys

莱昂斯描述：该奖项旨在支持南卡罗来纳州哥伦比亚市南卡罗来纳大学机械工程系的杰德·莱昂斯博士和安东尼·雷诺兹博士以及埃及开罗美国大学机械工程系哈纳迪·塞勒姆博士之间的合作项目。他们计划为运输业开发结构金属的制造技术。具体地说，将进行研究，以加深对搅拌摩擦焊(FSW)对Al-Cu-Li板材超塑成形(SPF)行为和常温性能的影响的基本了解。搅拌摩擦焊是一种新型的固态焊接工艺。它相对于传统熔焊技术的优势主要归功于不需要熔化的事实。由于需要保持动态再结晶的细晶组织，SPF合金是很好的搅拌摩擦焊候选材料。PIS的初步合作工作表明，超塑性Weldalite 049和2095铝合金在FSW后可以保持SPF行为。为了使该工艺在商业上可行，需要了解FSW工艺变量通过焊核和相邻的热机械影响区(TMAZ)对成分性能和微观结构的影响。将采用的研究技术和仪器包括仪表式搅拌摩擦焊机、用于测量拉伸性能和SPF行为的热机械测试设备、计算机视觉技术，包括数字图像相关和扫描电子显微镜(SEM)、透射电子显微镜(TEM)、光学显微镜和X射线光谱分析的微观结构表征。范围：该项目支持两个研究团队之间的合作，以开展一个重要的研究项目。美国团队将负责确定和调查FSW工艺条件并制造焊缝。他们将在不同的焊接条件下测试FSW工艺，并使用不同铜和锂含量和不同厚度的焊接剂合金。塞勒姆博士将在一名美国研究生的帮助下，进行SPF测试和透射电子显微镜调查。塞勒姆博士还将指导她在澳大利亚大学的一名研究生完成相同合金的光学和扫描电子显微镜检查。利用南卡罗来纳大学和开罗美国大学的资源，该项目有助于开发FSW/SPF组合工艺，使复杂的多板结构部件能够从定制毛坯进行净形制造。该项目将包括两名美国科学家和一名美国研究生，他们将获得国际合作研究的经验。该建议符合INT支持共同感兴趣领域的合作研究的目标。该项目得到了美国-埃及联合基金计划的支持，该计划为两国的科学家和工程师提供资助，以开展这些合作活动。

0108894LyonsDescription: This award is to support a collaborative project between Dr. Jed Lyons and Dr. Anthony Reynolds, both in the Department of Mechanical Engineering at the University of South Carolina, Columbia, South Carolina, and Dr. Hanadi Salem, Department of Mechanical Engineering, the American University in Cairo, Cairo, Egypt. They plan to develop manufacturing technologies for structural metals for the transportation industry. Specifically, research will be conducted to develop a fundamental understanding of the effects of friction stir welding (FSW) on the superplastic forming (SPF) behavior and ambient temperature properties of Al-Cu-Li sheets. FSW is a new solid-state welding process. Its advantages relative to traditional fusion welding techniques are primarily attributable to the fact that no melting is required. SPF alloys are good candidates for FSW due to the need to maintain a dynamically recrystallized fine grain microstructure. Preliminary collaborative work by the PIs indicates that SPF behavior can be retained in superplastic Weldalite 049 and 2095 aluminum alloys after FSW. An understanding of the role of FSW process variables on the constituent properties and microstructure through the weld nugget and adjacent thermo-mechanically affected zones (TMAZ) is required in order to make the process commercially viable. Research techniques and instruments to be employed include an instrumented friction stir welding machine, thermo-mechanical testing facilities for measuring tensile properties and SPF behavior, computer vision technology including digital image correlation and microstructural characterization with scanning electron microscope (SEM), transmission electron microscope (TEM) and optical microscopy and x-ray spectroscopy analysis. Scope: The project supports collaboration between two teams of investigators to carry out an important research project. The US team will be responsible for determining and investigating the FSW process conditions and for making the welds. They will test the FSW process at various conditions of weld and with various weldalite alloys with variable copper and lithium contents and different thickness. Dr. Salem will, with the assistance of a US graduate student, run the SPF tests and perform TEM investigations. Dr. Salem will also direct one of her graduate students at AUC in completing the optical and SEM examinations for the same alloys. Using the resources at both the University of South Carolina and the American University in Cairo, this project contributes to the development of combined FSW/SPF processes that enable the net-shape fabrication of complex multi-sheet structural components from custom blanks. The project will include two US scientists and one US graduate student who will gain experience in international cooperative research. The proposal meets the INT objective of supporting collaborative research in areas of mutual interest. This project is being supported under the US-Egypt Joint Fund Program, which provides grants to scientists and engineers in both countries to carry out these cooperative activities.