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The paper deals with a numerical finite element simulation of the residual stress evolution in friction stir welding of 6 mm thick aluminum alloy AA2024-T3. The transient thermal field during the welding process was calculated with the commercial code COMSOL Multiphysics 5.0. Therefore, a thermal-pseudo-mechanical (TPM) heat source was implemented. A subsequent mechanical simulation was performed with varying hardening models for different welding speeds of 60 and 300 mm/min. The influence of softening of the material, which was due to hardening precipitation dissolution associated to the heating, was also investigated. Experiments in terms of thermocouple measurements as well as Vickers hardness and X-ray measurements of the residual stresses were conducted and compared to numerically obtained results. A qualitatively as well as quantitatively good agreement was found for different applied welding speeds.
Several glazed ceramic fragments (XVIth to XVIIIth centuries) from two production centers in Portugal (Coimbra and Lisbon) were the object of this study. The ones from Coimbra comprise two sets of samples: faiences and tiles. The ones from Lisbon are only tiles (azulejos, in Portuguese). The three main divisions of such pieces are the ceramic support (body), glaze and surface decoration. The system decoration/glaze is not easy to investigate, due to the high heterogeneity resulting from the mixing procedures and firing temperatures used. Moreover, the ability of the pigment to diffuse into the base glaze varies depending on the composition of both the pigment and the glaze in terms of fusibility. In order to raster these effects, high resolution techniques are required. In this work, synchrotron micro-X-ray fluorescence (µ-XRF) analysis was performed to monitor the profiles of the characteristic elements from the colors used and the glaze in well prepared cross-sections of the samples. Key elements are: Co for blue, Mn for purple, Cu for green, Sb for yellow, Pb for the glaze and Fe for the body. The major difference observed is that faiences have glaze thicknesses between 150 and 200 µm and tiles have glaze thicknesses between 350 and 400 µm. Furthermore, in faiences all the pigments except the yellow ones are well dispersed into the glassy matrix, while in tiles, all of them are just partially diffused throughout the glaze. However, differences between the tiles from Coimbra and Lisbon were observed. In the samples from Lisbon, a higher intake from the pigment throughout the glaze is observed.
The application of magnesium (Mg) inevitably involves dissimilar welding with steel. A novel solid state spot welding method, refill friction stir spot welding (refill FSSW), was utilized to weld AZ31 Mg alloy to galvanized DP600 steel. Although Mg/Fe is an immiscible alloy system, defect-free welds with high strength were successfully obtained in a wide parameter window. The results of microstructure, interfacial reactions, and mechanical properties are reported to reveal the underlying joining mechanism. Due to the melting of Zn coating and subsequent Mg-Zn reactions, Mg-Zn eutectic and intermetallic compounds were detected within welds. Heterogeneous interfacial reactions occur along Mg/steel interface, and the relationship between interfacial structure and fracture behavior was investigated. The joining mechanism is associated with Zn coating and Fe-Al layer: 1) the presence of Zn coating is beneficial for achieving high-quality welding between Mg and steel, it protects the interface from oxidation and contributes to brazing of the weld; 2) the Al present in Mg alloy reacts with Fe, resulting in the growth of Fe-Al layer, which contributes to the diffusion bonding in the interface. The overall results clearly show that Refill FSSW is a competitive welding method for joining Mg and galvanized steel.
Cast magnesium alloys welds produced by refill friction stir spot welding (refill FSSW) show low lap shear strength (LSS) and constantly fail in stirred zone (SZ) shear mode. The cause is most probably related to the heavily textured microstructure. Here, to re-engineer the resulting microstructure, we pro- pose a novel process variant, the differential rotation refill FSSW (DR-refill FSSW). DR-refill FSSW stim- ulates discontinuous dynamic recrystallization and produces a bimodal microstructure with weakened texture. Therefore, the deformation incompatibility between SZ and thermal-mechanically affected zone is avoided. The welds have 50% higher LSS than that of standard refill FSSW welds, and fail in a different failure mode, i.e., SZ pull-out mode. DR-refill FSSW provides a new and effective strategy for improving the performance of spot welds based on microstructural engineering.