Microstructural and Mechanical Properties of Dissimilar AA7075 and AA2024 Rotary Friction Weldments
This study aims to explore the effects of various pre- and post-weld heat treatments (PWHTs) on the microstructural and mechanical properties of dissimilar aluminium alloys, namely AA7075 and AA2024, joined through rotary friction welding. The joints were rigorously evaluated through multiple charac...
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2024-11-01
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| author | Sandip Kumar Bauri Nagumothu Kishore Babu Malkapuram Ramakrishna Ateekh Ur Rehman Vanam Jaya Prasad Minnam Reddy Suryanarayana Reddy |
| author_facet | Sandip Kumar Bauri Nagumothu Kishore Babu Malkapuram Ramakrishna Ateekh Ur Rehman Vanam Jaya Prasad Minnam Reddy Suryanarayana Reddy |
| author_sort | Sandip Kumar Bauri |
| collection | DOAJ |
| description | This study aims to explore the effects of various pre- and post-weld heat treatments (PWHTs) on the microstructural and mechanical properties of dissimilar aluminium alloys, namely AA7075 and AA2024, joined through rotary friction welding. The joints were rigorously evaluated through multiple characterization methods, revealing no signs of cracking or incomplete bonding. This study observed that dissimilar joints between AA7075 and AA2024 alloys showed increased flash formation on the AA7075 side due to its lower melting point relative to the AA2024 alloy. Various zones within the weld region were identified, such as the dynamic recrystallized zone (DRZ), the thermo-mechanically affected zone (TMAZ)—which includes TMAZ-1 with elongated grains and TMAZ-2 with compressed or distorted grains—the heat-affected zone (HAZ), and the base metal (BM) zone. Of all the welding conditions examined, the post-weld heat-treated (PWHT) AA2024/AA7075 joint produced by rotary friction welding showed the highest strength, with a yield strength (YS) of 305 ± 2 MPa and an ultimate tensile strength (UTS) of 477 ± 3 MPa. This improvement in strength can be attributed to the significant strengthening precipitates of MgZn<sub>2</sub> (found on the AA7075 side), θ-Al<sub>2</sub>Cu, and S-Al<sub>2</sub>CuMg (found on the AA2204 side) formed during post-weld ageing. Notably, all dissimilar welds failed in the HAZ region on the AA2024 side due to coarse grain formation, identifying this as the weakest area. |
| format | Article |
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| issn | 2073-4352 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Crystals |
| spelling | doaj-art-297bb21d53b24360af883d21bc3d088d2025-08-20T02:00:37ZengMDPI AGCrystals2073-43522024-11-011412101110.3390/cryst14121011Microstructural and Mechanical Properties of Dissimilar AA7075 and AA2024 Rotary Friction WeldmentsSandip Kumar Bauri0Nagumothu Kishore Babu1Malkapuram Ramakrishna2Ateekh Ur Rehman3Vanam Jaya Prasad4Minnam Reddy Suryanarayana Reddy5Department of Metallurgical and Materials Engineering, National Institute of Technology, Warangal 506004, IndiaDepartment of Metallurgical and Materials Engineering, National Institute of Technology, Warangal 506004, IndiaDepartment of Mechanical Engineering, Vignan’s Foundation for Science, Technology and Research, Deemed University, Guntur 522213, IndiaDepartment of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi ArabiaDepartment of Mechanical Engineering, Jawaharlal Nehru Technological University, Kakinada 533003, IndiaProduct Application Group South, Tata Steel Limited, Jamshedpur 831001, IndiaThis study aims to explore the effects of various pre- and post-weld heat treatments (PWHTs) on the microstructural and mechanical properties of dissimilar aluminium alloys, namely AA7075 and AA2024, joined through rotary friction welding. The joints were rigorously evaluated through multiple characterization methods, revealing no signs of cracking or incomplete bonding. This study observed that dissimilar joints between AA7075 and AA2024 alloys showed increased flash formation on the AA7075 side due to its lower melting point relative to the AA2024 alloy. Various zones within the weld region were identified, such as the dynamic recrystallized zone (DRZ), the thermo-mechanically affected zone (TMAZ)—which includes TMAZ-1 with elongated grains and TMAZ-2 with compressed or distorted grains—the heat-affected zone (HAZ), and the base metal (BM) zone. Of all the welding conditions examined, the post-weld heat-treated (PWHT) AA2024/AA7075 joint produced by rotary friction welding showed the highest strength, with a yield strength (YS) of 305 ± 2 MPa and an ultimate tensile strength (UTS) of 477 ± 3 MPa. This improvement in strength can be attributed to the significant strengthening precipitates of MgZn<sub>2</sub> (found on the AA7075 side), θ-Al<sub>2</sub>Cu, and S-Al<sub>2</sub>CuMg (found on the AA2204 side) formed during post-weld ageing. Notably, all dissimilar welds failed in the HAZ region on the AA2024 side due to coarse grain formation, identifying this as the weakest area.https://www.mdpi.com/2073-4352/14/12/1011rotary friction weldingAA7075AA2024microstructurehardnessmechanical properties |
| spellingShingle | Sandip Kumar Bauri Nagumothu Kishore Babu Malkapuram Ramakrishna Ateekh Ur Rehman Vanam Jaya Prasad Minnam Reddy Suryanarayana Reddy Microstructural and Mechanical Properties of Dissimilar AA7075 and AA2024 Rotary Friction Weldments Crystals rotary friction welding AA7075 AA2024 microstructure hardness mechanical properties |
| title | Microstructural and Mechanical Properties of Dissimilar AA7075 and AA2024 Rotary Friction Weldments |
| title_full | Microstructural and Mechanical Properties of Dissimilar AA7075 and AA2024 Rotary Friction Weldments |
| title_fullStr | Microstructural and Mechanical Properties of Dissimilar AA7075 and AA2024 Rotary Friction Weldments |
| title_full_unstemmed | Microstructural and Mechanical Properties of Dissimilar AA7075 and AA2024 Rotary Friction Weldments |
| title_short | Microstructural and Mechanical Properties of Dissimilar AA7075 and AA2024 Rotary Friction Weldments |
| title_sort | microstructural and mechanical properties of dissimilar aa7075 and aa2024 rotary friction weldments |
| topic | rotary friction welding AA7075 AA2024 microstructure hardness mechanical properties |
| url | https://www.mdpi.com/2073-4352/14/12/1011 |
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