Achieving 100 %-efficiency joint in rotary friction welding of thin-walled Al alloy drive shafts via high friction pressure and short-time post-weld heat treatment
Rotary friction welding (RFW) was employed to join large diameter thin-walled Al–Mg–Si–Cu alloy drive shafts. The coupling effects of friction pressure and post-weld heat treatment (PWHT) on the microstructure evolution and mechanical properties of the RFWed joints were investigated. Increasing the...
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Elsevier
2025-07-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425016175 |
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| author | Kailiang Chen Zexi Wu Chunhui Ma Licheng Sun Wuran Lei Ke He Xiaoxue Chen Yanquan Wu Chunbo Zhang Jun Zhou Huihong Liu Yongbing Li |
| author_facet | Kailiang Chen Zexi Wu Chunhui Ma Licheng Sun Wuran Lei Ke He Xiaoxue Chen Yanquan Wu Chunbo Zhang Jun Zhou Huihong Liu Yongbing Li |
| author_sort | Kailiang Chen |
| collection | DOAJ |
| description | Rotary friction welding (RFW) was employed to join large diameter thin-walled Al–Mg–Si–Cu alloy drive shafts. The coupling effects of friction pressure and post-weld heat treatment (PWHT) on the microstructure evolution and mechanical properties of the RFWed joints were investigated. Increasing the friction pressure effectively enhanced the hardness of the softest area in heat affected zone (HAZ), due to the reduction in the peak welding temperature, which inhibited the annihilation of dislocation and the dissolution of precipitates and dispersions, thereby maintaining a high density of dislocations and an abundance of Q′ phases, β′ phases and α-Al(MnFe)Si dispersions in the softest area of the joints. Furthermore, higher friction pressure increased the cooling rate, resulting in no GP zones/pre-β'' phase precipitating during the cooling process, thereby retaining solute atoms within the Al matrix after RFW. Consequently, the combination of high friction pressure and short-time low-temperature PWHT at 180 °C for 60 min successfully improved the hardness of the softest area due to the precipitation of substantial spherical GP zones/pre-β'' phases using the solute atoms dissolved from Q′ and β′ phases at the abundant residual dislocations serving as nucleation sites. A high-performance RFWed joint of Al alloy exhibiting 100 % joint efficiency was therefore achieved for the first time in the large diameter thin-walled drive shafts. |
| format | Article |
| id | doaj-art-6f29d61e2a3b465f9dd19d73bed1ae9e |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-6f29d61e2a3b465f9dd19d73bed1ae9e2025-08-20T03:24:30ZengElsevierJournal of Materials Research and Technology2238-78542025-07-01372539255310.1016/j.jmrt.2025.06.195Achieving 100 %-efficiency joint in rotary friction welding of thin-walled Al alloy drive shafts via high friction pressure and short-time post-weld heat treatmentKailiang Chen0Zexi Wu1Chunhui Ma2Licheng Sun3Wuran Lei4Ke He5Xiaoxue Chen6Yanquan Wu7Chunbo Zhang8Jun Zhou9Huihong Liu10Yongbing Li11Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai, 200240, PR China; State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, 200240, PR ChinaShanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai, 200240, PR China; State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, 200240, PR China; Corresponding author. Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai, 200240, PR China.Process Research Institute, SINOTRUK Jinan Power Co., Ltd, Jinan, 250200, PR ChinaShanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai, 200240, PR China; State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, 200240, PR ChinaSINOTRUK (Jinan) Driving Shaft Co., Ltd, Jinan, 250000, PR ChinaProcess Research Institute, SINOTRUK Jinan Power Co., Ltd, Jinan, 250200, PR ChinaProcess Research Institute, SINOTRUK Jinan Power Co., Ltd, Jinan, 250200, PR China; Corresponding author.Harbin Welding Institute Limited Company, Harbin, 150028, PR ChinaHarbin Welding Institute Limited Company, Harbin, 150028, PR ChinaHarbin Welding Institute Limited Company, Harbin, 150028, PR ChinaShanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai, 200240, PR China; State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, 200240, PR China; Corresponding author. Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai, 200240, PR China.Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, Shanghai Jiao Tong University, Shanghai, 200240, PR China; State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, 200240, PR ChinaRotary friction welding (RFW) was employed to join large diameter thin-walled Al–Mg–Si–Cu alloy drive shafts. The coupling effects of friction pressure and post-weld heat treatment (PWHT) on the microstructure evolution and mechanical properties of the RFWed joints were investigated. Increasing the friction pressure effectively enhanced the hardness of the softest area in heat affected zone (HAZ), due to the reduction in the peak welding temperature, which inhibited the annihilation of dislocation and the dissolution of precipitates and dispersions, thereby maintaining a high density of dislocations and an abundance of Q′ phases, β′ phases and α-Al(MnFe)Si dispersions in the softest area of the joints. Furthermore, higher friction pressure increased the cooling rate, resulting in no GP zones/pre-β'' phase precipitating during the cooling process, thereby retaining solute atoms within the Al matrix after RFW. Consequently, the combination of high friction pressure and short-time low-temperature PWHT at 180 °C for 60 min successfully improved the hardness of the softest area due to the precipitation of substantial spherical GP zones/pre-β'' phases using the solute atoms dissolved from Q′ and β′ phases at the abundant residual dislocations serving as nucleation sites. A high-performance RFWed joint of Al alloy exhibiting 100 % joint efficiency was therefore achieved for the first time in the large diameter thin-walled drive shafts.http://www.sciencedirect.com/science/article/pii/S2238785425016175Al alloy drive shaftsRotary friction weldingLow-temperature weldingMicrostructure regulationDislocation densityHigh-performance joint |
| spellingShingle | Kailiang Chen Zexi Wu Chunhui Ma Licheng Sun Wuran Lei Ke He Xiaoxue Chen Yanquan Wu Chunbo Zhang Jun Zhou Huihong Liu Yongbing Li Achieving 100 %-efficiency joint in rotary friction welding of thin-walled Al alloy drive shafts via high friction pressure and short-time post-weld heat treatment Journal of Materials Research and Technology Al alloy drive shafts Rotary friction welding Low-temperature welding Microstructure regulation Dislocation density High-performance joint |
| title | Achieving 100 %-efficiency joint in rotary friction welding of thin-walled Al alloy drive shafts via high friction pressure and short-time post-weld heat treatment |
| title_full | Achieving 100 %-efficiency joint in rotary friction welding of thin-walled Al alloy drive shafts via high friction pressure and short-time post-weld heat treatment |
| title_fullStr | Achieving 100 %-efficiency joint in rotary friction welding of thin-walled Al alloy drive shafts via high friction pressure and short-time post-weld heat treatment |
| title_full_unstemmed | Achieving 100 %-efficiency joint in rotary friction welding of thin-walled Al alloy drive shafts via high friction pressure and short-time post-weld heat treatment |
| title_short | Achieving 100 %-efficiency joint in rotary friction welding of thin-walled Al alloy drive shafts via high friction pressure and short-time post-weld heat treatment |
| title_sort | achieving 100 efficiency joint in rotary friction welding of thin walled al alloy drive shafts via high friction pressure and short time post weld heat treatment |
| topic | Al alloy drive shafts Rotary friction welding Low-temperature welding Microstructure regulation Dislocation density High-performance joint |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425016175 |
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