Femina etal. 2023, int J. Vehicle Structures & Systems, 15(1), 90-93 ISSN; 0975-3060 (Print), 0975-3540 (Online) doi: 10.4273 iss. 15.1.17 {© 2023, Carbon Magies Ltd International Journal of Vehicle Structures & Systems Available online at htts:/yantrika.comeja Mechanical Properties and Pitting Corrosion of Friction Stir Welded Aluminium Alloy 5083 (H321) K. Elsie Femina* and M. Koilraj? Dept. of Mech Engg. Vellore Institute of Tech, Chennai, Tamil Nad, Tndia SDept of Mech. Engg. Nova College of Pigg. & Tech, andiira Pradesh, India Corresponding author. Enait: koil sasephs@gmailcom ABSTRACT: In the present work, 6 min plates of Al-Mg alloy 445083-H321 was friction welded. Weld microstructures, hardness values and tensile properties were evaluated in the welded condition. Macrostructure studies reveaied that he shape of the stir zone is a basin-shaped type and it appeared more like a rectangular box and no macroscopic defect or weakiv boncied regions were observed in the weld region, which extended through the full thickness of the plates. There were 10 noticeable changes in the microstructure compared to the respective unaffected base material and there was not much of difference in the microstructures of the mgget and the base metal. The pitting corresion resuts mdicate that there was noticeable improvement in the piting potential values of the welds. The weld mugget region exhibited better Ditting corrosion resistance compared to other regions. The base material and the friction stir welded materials are far superior in resistance to salt fog corrosion. KEYWorDs: Frietion stir welding; Alumiman alloys; Corrosion CITATION: K.E, Femina and M. Koilraj. 2023. Mechanical Properties and Piting Corrosion of Friction Stir Welded Aluminium Alloy $083 (H321), Jnt. J Vehicle Structures & Systems, 15(1), 90-93, doi:10.4273/ivss.15.1.17. be the most suitable which has produced defect free 1. Introduction welds. Cunha et al [2] observed the effect FSW parameters like rotational speed, welding speed and found that high gradient was occurred within a stirred zone. Several combinations have been friction stir welded with good joint efficiencies [3-6]. Wang et al [7] hhas observed that high quality of longitudinal straight joint can be obtained by FSW. Lee et al [8] reported that it is beneficial to place the stwonger materials on the advancing side [8] and the stir zone predominantly consisted of the material that was placed on the retreating side, From the foregoing, it appears that success in dissimilar FSW requires careful judgment with respect to material placement, tool positioning aud process parameters, depending on the properties of the The strength of the aluminium alloys exceeds the strength of the mild steel. The important factors in selecting aluminium and its alloys are their high strength-to-weight ratio, resistance to corrosion by many chemicals, high thermal and electrical conductivity nontoxicity, reflectivity, appearance and case of formability, machinability and their nonmagnetic nature. The melting temperature of these alloys ranges from 482.660°C. The thermal conductivity is six times that of steel and the thermal expansion is twice that of steel and also itis nontoxic. Aluminium alloys with small amounts of copper, magnesium, silicon, manganese and other elements have very useful properties and are used as . ‘ materials to be joined. Friction stir welded joints of structural materials. ALM alloy AASOSS is the widely RASH98' (Cain eater than 90%% of the Dace meal used aluminium alloy in marine industries. The MASUD TEN Se an aluminium alloy 5083 contains about 4.5% - 5% Mg and Strength es by Atallah et al [9]. The strength of the joint was decreased with an increase in the Small amiomats of other alloying elements. Al-Mg alloys “ Sean ee cee eee Tttioal speed regtiless of the traverse rte, The dusts, in which the low weight ean be of siaificast "Asie stength ofthe joint was increased wit decrease value. Magnesium is the main alloying element in 5000 in rotational speed ce to the decrease in grain size series. These alloys are stain hard enable, moderately . high strength alloys, with very high toughness and 2 Experimental work corrosion resistance that are excellent even in salt water. ‘The material used in this study is 6mm thick sheets of ‘The Sxxx alloys have wide applications in building Al-Mg_ alloy | AASO83-H321. Hardness test_ was, bridges, storage tanks, pressure vessels, marine conducted using a Vickers hardness testing machine, applications. Rao et al [1], stated that friction stir welded where a 100 g load was applied for atime period of 15s. aluminium alloy by using different pin geometry and Welds were tested for harduess as per the welded predicted tool pin profiles mostly influenced the tensile condition. The results were averaged over a minimum ofS properties of joint. Cylindrical tool pin profile found to tests per sample; more tests were conducted as required to 90Femina etal. 2025, In. J. Vehicle Sructures & Systems, 15(1), 90-93 reduce the standard deviation. Any obviously spurious results were rejected and test was repeated. Transverse tensile specimens with a gauge length of 25mm and a width of 6mm (overall length of 100mm) were prepared from the weld coupons in an as-welded condition, Room temperature tensile tests were conducted on three samples as per ASTM E8 (2010) on a universal tensile testing machine. The wire cut EDM was used to cut the smooth profile of the tensile specimens. To minimize the machining error (noise), three specimens were prepared at each level of the designed matrix and the average of the three results is presented. The prepared tensile specimens were subjected to the tensile test and their ultimate tensile strengths were evaluated, The yield strength values presented were 0.2% proof strength values as computed by the computer program that controls the machine. A software based PAR basic electrochemical system was used for conducting potentio dynamic polarization tests, to study the pitting corrosion behaviour of the welded zone. The standard calomel electrode (SCE), carbon electrode was used as the reference and auxiliary electrodes respectively. The pitting corrosion experiments conducted in 3.5% NaCI solutions, with the adjusted value of pH to 10, The potential scan was carried out at 0.166mVisee ‘with an initial potential of 0.25 (OC) SCE to the final potential of pitting. The exposure area for these experiments was Lom The potential at which the current increases drastically was considered as the critical pitting poteatial (Epit), Specimens exhibiting relatively more positive potential, (or less negative potential) were considered as those with better pitting corrosion resistance. The salt fog apparatus was used for testing the general corrosion behaviour of the welded zone. This apparatus consists of an enclosed glass chamber with square plastic rods to hang the specimens. Two nozzles viz, one for air and one for water were present within the chamber. The air nozzle is comnected to the air compressor and the water nozzle is connected to a can containing the NaCl solution. The air compressor supplies the air to the salt fog apparatus atthe required ‘working pressure, The nozzles are placed 90° apart from fone another, such that NaCI fog is created within the chamber. The specimens were tied up in the chamber with a non-corrosive polymer thread and hung in such a ‘way that they were held at an angle of 7 to 14° parallel to the flow of the fog from the nozzles. The constant flow rate is set within few minutes and the cloud of fog is created: all the specimens are being subjected to a constant flow of NaCI droplets striking their surfaces Every 16 hours (for 48 hours) the specimens, depending upon their batch were removed from the chamber and cleaned with acetone to remove any rust that may have been formed on the surface of the specimens. 3. Results and discussion Several friction stir welding trials were performed using tral and error method on $083 plates and the welds were tested for soundness and tensile properties. The following process parameters (rotetional speed of SS0rpm, welding speed of 30mmvimimute, ratio of shoulder diameter to pin diameter of 3) were found to 91 result in the welds with good mechanical properties. Fig 1 shows the cross-sectional macrosinictures of the friction stir welded sound joints. They were found to be without voids, cracks or distortion of aluminium alloy 5083, The shape of the stir zone is a basin-shaped type and this appeared to be more like a rectangular box. No macroscopic defect or weakly bonded regions were observed in the weld region, which extended through the full thickness of the plates. Sato et al [10] reported that the formation of basin-shaped nuggct on friction stir welding of AA6063-TS plate and Rhodes et al [11] reported elliptical nugget zone in the weld of AA7075- T6S1 ig. Macrostructur of welded materials ‘The base material used in the current study contained a number of undissolved second- phase intermetallic particles, which were found to be iron! ‘manganese aluminide particles as shown in Fig, 2. In ‘TMAZ, on either side of the weld angget, there were no noticeable changes in the micro structure compared 10 the respective unaffected base material while the nugget region appeared darker due to etching and there was not nich of difference in the microstructures of the nugget and the base metal (Fig. 3). This is mainly because the ‘grain boundaries could not be clearly etched in these alloys. However, careful observation at higher ‘magnifications revealed that the nugget region contained finer recrystallized grains. Chen et al [12] reported that ‘grain orientation does not affect the teusile strength of the welded joints. Micro hardness tests were conducted across the weld (mid-section and at Imm spacing) 10 ascertain the possible microstructure/property variations across the various regions of weldment region, The results are pictorially shown in Fig. 4. The weld nugget showed a higher hardness values compared to base material as HAZ and TMAZ. Apart from this region wise hardness values are found out (Table 1) and the average hardness values are correlated to the fracture location with the macrostructure of the failed tensile specimens (Fig. 5). Lowest hardness values of the ‘welded specimens are in HAZ of retreating side where the tensile failures take place. = ig. 2: Microstructure of base materials AASOSSFemina etal. 2025, In. J. Vehicle Sructures & Systems, 15(1), 90-93 = Fig. 3: Microstructures of weld mugget (5083 $083) Fig. 4 Mlero hardness profile across the weld ‘Table 1: Micro hardness ofthe SOS’ - S083 fiction sty weld ‘Advancing side 5083 Retreating side 5 Nu Base HAZ _TMAZ IMAZ HAZ. 716 767 79.7 *S2L—«ST-L—666 787 682 805 924-836 72.2 782 765 766 905 761 3 SIs 67 74888873717 B01 74 399 4S 70S 72 659 78 891 7898.4 188 686 794 S46 162 679 789 6716 772 846 738 653 822 737 793 966 «753.683. 74 706 999 805 69.5 B12 67 BLS 732 66 787655 809 736 65.7 Average hardness value 7838 70.14 7705 8843 77.16 68.46 7808 Transverse tensile specimens with a gauge length of a width of 6mm (overall length of 100mm) were prepared from the weld coupons in as welded condition. Room temperature tensile tests were conducted on three samples as per ASTM ES on a ‘universal tensile testing machine. The results of weld transverse tensile fests are shown in Table 2. All the three welded specimens failed in the heat affected zone of reueating side and the macrosticture of the failed tensile test specimen is shown in Fig. 5. The weld specimens showed slightly lower strength compared to the base material specimens. Table 2 shows the results of FSW tensile testing specimens. The joint efficiency with, respect to proof strength and UTS are 100% and 95%, Literatures showed that this kind of joint efficiencies cannot be achieved using fusion welding processes. Another result is the high ductility exhibited by 5083- 5083 friction stir welds. This is mainly because, all the three weld regions ie., nugget, TMAZ and HAZ deform under load as the hardness differences are not significant, These joint efficiencies are much higher than the conventional fusion welding processes which achieve the joint efficiencies. The defect fice welded joints with very good mechanical properties were obtained by underwater friction stir welding of 6013 Al and AZ31 ‘Mg alloys [13]. The tensile strength of joints increases with increase in traverse speed. The defect free welded joints were obtained at the lower welding speed [14]. ig. S: Macrostructures oF 5088 S083 FSW fled sample ‘Table 2: Results of FSW tensile resting specimens T226 pro ‘Utinate ene Elongstion Falire Merial tenth Ceoath MPa) 8) oeton ihara) ‘ SOE aes 5 metal) ~ 308 38 5063-508 455 agg Wa (welds) 28 2 aueee ‘The pitting potential values of the fiction stir welds AASOS3AASOS3 are presented in Table 3. The difference in the pitting potential values of AASOS3 base etal and the friction stir weld nugget is significant. The nugget exhibits lesser resistance to pitting. corrosion. This could be due to larger number of Al-Fe-Mn inter metallic particles. In the base metal there were few of these second phase particles with big size. However. in the nugget we find more of these particles with smaller size as it can be seen fom Fig. 3. Fragmentation of these particles occurs during stirring and hence the nugget contains larger number of particles which are smaller in size resulting in lower pitting potentials. Severely deformed and stressed grain structure in TMAZ on both sides of the nugget exhibit further reduction in pitting corrosion resistance, Leite et al [15] found thet TMAZ. ‘was the zone most susceptible to pitting in friction stir welded UNS $8241 lean duplex stainless steel “Table: Pitting potential values of FSW ALSOSS-ALSO8S Material Pittng Potential Epir @aV) ‘5083 - F321 base metal 23 niV 5083 - 5085 weld nugget S58 mV TMAZHAZ advancing side S73 mV TMAZ/HAZ retveating side 563 mV ‘The base materials and welds were subjected to salt fog corrosion test, Three specimens per category were Ihung in the salt fog chamber for 48 hours and weight Joss was measured on all samples. Corrosion rate was calculated based on the average weight loss using, 1 mp; 1 mum year ~ 87.6 (W/DAT) ‘Where, W — weight loss in milligrams, D- metal density in gicm’, A = area of sample in em?, T= time hours, The 0.0254 mm'yearFemina etal. 2025, In. J. Vehicle Sructures & Systems, 15(1), 90-93 results are shown in Table 4. It can be seen that AASO83 base material is the least corrosion resistant in this atmosphere. Both 5083-5083 friction stir welds and 5083 base materials are far superior in resistance to salt fog “Table 4: General corrosion of FSW iran atoys S083 Corrosion rate (min'yeat) 16 hours 32 howrs 48 hours 0.2938 0.3487 0.7896 1403 0.457 _ 0.748 Materia’condition 5083 (base material) ‘5083 - 5083 (welded material) 4. Conclusion Friction stir welding can produce defect free butt welds, ‘AASO83-H321 plates with a joint efficiency of 100% (vith respect to proof strength) and around 95% (with respect to ultimate tensile strength). The weld nugget showed a higher hardness value when compared to base Iaterial as HAZ and TMAZ. Lowest hardiess values of the welded specimens are in HAZ of the retreating side where tensile failures take place. The shape of the stir zone is a basin-shaped type and it appeared more like a rectangular box and no macroscopic defect ot weakly bonded regions were observed in the weld region, which extended through the full thickness of the plates. There were no noticeable changes_in microstructure when compared to respective unaffected base material and there was not much of a difference in microstructure of the nugget and the base metal, The difference in pitting potential values of the base metal and the friction stir weld nugget is significant. The nugget exhibits lesser resistance to pitting corrosion. The base material and the friction stir welds are far superior in resistance to the salt fog comrosion. REFERENCES: [1] MS. Rao, BR Kumar and MM. Hussain, 2017. 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