Friction stir welding of thixocast high performance magnesium alloys

• Grant number: 10/11391-2
• Support Opportunities: Research Grants - Young Investigators Grants
• Duration: May 01, 2011 - April 30, 2016
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Physical Metallurgy
• Principal Investigator: Haroldo Cavalcanti Pinto
• Grantee: Haroldo Cavalcanti Pinto
• Host Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
• Associated scholarship(s): 11/09324-8 - Friction stir welding of thixocast high performance magnesium alloys, BP.DD

Abstract

The aim of the present project is to investigate the friction stir weldability of novel light and recyclable high-performance materials based on the ZK60 magnesium alloy (Mg-6%Zn-1%Zr) modified with different mischmetal (RE) contents: 0.5, 1.5 e 2.5 wt%. For the production of such materials still unexplored in Brazil, it is proposed the use of a thixocasting procedure under mechanical stirring, followed by heat-treatments in the T4, T5 or T6 conditions. The ZK60 alloy represents an important matrix for the development of materials with applications in aeronautic light-weight structures. This is due to its highest specific strength among the traditional magnesium alloys, which nearly corresponds to that of the 7075 aluminum alloy. Its modification with RE additions enables the formation of intermetallics with high melting point, hot- and chemical stability, which are required to improve the mechanical strength at room and elevated temperatures, as well as the corrosion and oxidation resistance. The zirconium additions promote furthermore an effective grain refinement in magnesium castings, thus increasing the potential of the proposed alloys for a neat-net-shape processing route based on thixocasting. The effect of casting, heat-treatment and welding parameters will be quantified on the microstruture, mechanical properties, corrosion and oxidation behavior of the alloys and their weldments. It is proposed the acquisition of an X-ray diffractometer, which will enable the study of further weldment properties rarely investigated in Brazil, but particularly relevant to the performance of magnesium welds, such as: the formation of crystallographic texture in the stir zone and thermomechanical affected zones, and its influence on the mechanical properties; as well as the mechanical stress relief and its impact on the fatigue crack growth rates and corrosion behavior. This proposal is supported by Grupo Rima Industrial S/A and EMBRAER, which demonstrated great interest in this research and undertook to supply the raw materials for the alloy preparation and to take active part in the casting and welding procedures of the ZK60-RE alloys. The proponent has already experience in the welding and characterization of magnesium alloys. (AU)

Scientific publications

(10)

(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)

ERENILTON PEREIRA DA SILVA; LARISSA FERNANDES BATISTA; BRUNA CALLEGARI; RICARDO HENRIQUE BUZOLIN; FERNANDO WARCHOMICKA; GUILLERMO CARLOS REQUENA; PEDRO PAIVA BRITO; HAROLDO CAVALCANTI PINTO. Solution and ageing heat treatments of ZK60 magnesium alloys with rare earth additions produced by semi-solid casting. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 17, n. 6, p. 1507-1512, 2014-12-00. (11/09324-8, 10/11391-2)

ERENILTON PEREIRA DA SILVA; VERONA BIANCARDI OLIVEIRA; VICTOR FERRINHO PEREIRA; OMAR MALUF; RICARDO HENRIQUE BUZOLIN; HAROLDO CAVALCANTI PINTO. Microstructure and Residual Stresses in a Friction Stir Welded Butt Joint of as-cast ZK60 Alloy Containing Rare Earths. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 20, n. 3, p. 775-779, 2017-04-27. (11/09324-8, 10/11391-2)

GARCIA, JOSE; PINTO, HAROLDO; RAMOS-MOORE, ESTEBAN; ESPINOZA, CARLOS; OSTBY, JONAS; COELHO, RODRIGO. In-situ high temperature stress analysis of Ti(C,N) coatings on functionally graded cemented carbides by energy dispersive synchrotron X-ray diffraction. INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS, v. 56, p. 27-34, APR 2016. (10/11391-2)

COELHO, R. S.; CORPAS, M.; MORETO, J. A.; JAHN, A.; STANDFUSS, J.; KAYSSER-PYZALLA, A.; PINTO, H.. Induction-assisted laser beam welding of a thermomechanically rolled HSLA S500MC steel: A microstructure and residual stress assessment. MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING, v. 578, p. 125-133, AUG 20 2013. (10/11391-2)

VALES, S.; BRITO, P.; PINEDA, F. A. G.; OCHOA, E. A.; DROPPA, JR., R.; GARCIA, J.; MORALES, M.; ALVAREZ, F.; PINTO, H.. Influence of substrate pre-treatments by Xe+ ion bombardment and plasma nitriding on the behavior of TiN coatings deposited by plasma reactive sputtering on 100Cr6 steel. Materials Chemistry and Physics, v. 177, p. 156-163, JUL 1 2016. (12/10127-5, 10/11391-2)

DA SILVA, ERENILTON PEREIRA; BATISTA, LARISSA FERNANDES; CALLEGARI, BRUNA; BUZOLIN, RICARDO HENRIQUE; WARCHOMICKA, FERNANDO; REQUENA, GUILLERMO CARLOS; BRITO, PEDRO PAIVA; PINTO, HAROLDO CAVALCANTI. Solution and Ageing Heat Treatments of ZK60 Magnesium Alloys with Rare Earth Additions Produced by Semi-Solid Casting. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 17, n. 6, p. 1507-1512, NOV-DEC 2014. (11/09324-8, 10/11391-2)

DA SILVA, ERENILTON PEREIRA; BUZOLIN, RICARDO HENRIQUE; ALFARO, ULISES; REQUENA, GUILLERMO; PINTO, HAROLDO CALVALCANTI. Microstructure and mechanical behavior of similar butt-joints of ZK60 and ZK60-1.5RE magnesium alloys produced by linear friction stir welding. JOURNAL OF MAGNESIUM AND ALLOYS, v. 9, n. 5, p. 1782-1796, SEP 15 2021. (10/11391-2, 11/09324-8)

SILVA, E. P.; BUZOLIN, R. H.; MARQUES, F.; SOLDERA, F.; ALFARO, U.; PINTO, H. C.. Effect of Ce-base mischmetal addition on the microstructure and mechanical properties of hot-rolled ZK60 alloy. JOURNAL OF MAGNESIUM AND ALLOYS, v. 9, n. 3, p. 995-1006, MAY 15 2021. (11/09324-8, 10/11391-2)

BIANCARDI, OLIVEIRA VERONA; ROSA, VIERA LUCCAS; DE ABREU, LIMA BRUNO; RENATO TAVARES, AVILA PEDRO; CORREA, REGO GALTIERE; CAVALCANTI, PINTO HAROLDO; NAPOLEAO, BASTOS IVAN; PEREIRA, DA SILVA ERENILTON. Corrosion behavior of as-cast ZK60 alloy modified with rare earth addition in sodium sulfate medium. Corrosion Science, v. 158, SEP 2019. (11/09324-8, 10/11391-2)

SILVA, E. P.; MARQUES, F.; NOSSA, T. S.; ALFARO, U.; PINTO, H. C.. Impact of Ce-base mischmetal on the microstructure and mechanical behavior of ZK60 magnesium casting alloys. MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING, v. 723, p. 306-313, APR 18 2018. (11/09324-8, 10/11391-2)