The microstructure evolution and mechanical properties of multi-layer friction stir additive manufacturing for T2 copper

Using a 2 mm thick T2 copper plate as the base material, a multi-pass five-layer Friction Stir Additive Manufacturing (FSAM) experiment was conducted, successfully producing well-formed FSAM. The microstructure of the multi-pass, multi-layer FSAM joints was characterized using optical microscopy (OM...

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Bibliographic Details
Published in:Materials today communications 2025-01, Vol.42, p.111213, Article 111213
Main Authors: Chen, Min, Chang, Zhilong, Li, Huizhao, Tao, Huwei, Jiang, Bingxin, Li, Zhihang, Zhang, Hua
Format: Article
Language:English
Subjects:
Friction stir additive manufacturing
Mechanical properties
Microstructure evolution
T2 copper
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Summary:Using a 2 mm thick T2 copper plate as the base material, a multi-pass five-layer Friction Stir Additive Manufacturing (FSAM) experiment was conducted, successfully producing well-formed FSAM. The microstructure of the multi-pass, multi-layer FSAM joints was characterized using optical microscopy (OM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM), with a detailed investigation into the microstructural evolution mechanisms and their impact on mechanical properties. The results show that the microstructure of the additive section exhibits an uneven but regular distribution. The newly added layer consists of non-uniform, non-equiaxed grains, primarily undergoing continuous dynamic recrystallization (CDRX). The Shoulder Pressure Zone (SPZ) of the underlying layer exhibits fine, uniform equiaxed grains (0.76 μm), with discontinuous dynamic recrystallization (DDRX) gradually increasing, competing with the CDRX process. This difference is primarily attributed to the variations in temperature, strain rate, and cumulative strain experienced in different additive zones. Both the average hardness (93 HV) and tensile strength of the additive region are enhanced. Finer grains correspond to higher dislocation density and increased hardness, consistent with the Hall-Petch relationship. The strengthening mechanisms for tensile strength are primarily grain boundary strengthening and dislocation strengthening. However, the microstructural heterogeneity results in a reduction in elongation. [Display omitted]
ISSN:2352-4928
2352-4928
DOI:10.1016/j.mtcomm.2024.111213