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A Comparative Evaluation of the Wear Resistance of Various Tool Materials in Friction Stir Welding of Metal Matrix Composites

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Abstract

Friction stir welding (FSW) is the preferred joining method for metal-matrix composites (MMCs). As a solid-state process, it precludes formation of the intermetallic precipitates responsible for degradation of mechanical properties in fusion welds of MMCs. The major barrier to FSW of MMCs is the rapid and severe wear of the welding pin tool, a consequence of prolonged contact between the tool and the harder reinforcements which give the material its enhanced strength. This study evaluates the effectiveness of harder tool materials to combat wear in the FSW of MMCs. The tool materials considered are O1 steel, cemented carbide (WC-Co) of the micrograin and submicrograin varieties, and WC-Co coated with diamond. The challenges which accompany the application of harder tool materials and diamond coatings in FSW are also discussed. This study represents the first use of diamond-coated tools in FSW and the first comparative evaluation of tool materials for this application.

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Notes

  1. Because aluminum accumulates on the probe surface during welding, inserts must be etched prior to analysis. The insert is immersed in a solution of NaOH and water until all the aluminum is eroded from the surface.

  2. Values for diamond are extrapolated.

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Acknowledgments

This study was funded by a NASA GSRP Fellowship from Marshall Spaceflight Center. Materials were provided by composites manufacturer MC21, Inc. Thanks to Dr. Art Nunes of NASA MSFC, Dr. Jim Davidson and Mick Howell of Vanderbilt University (for expertise and assistance with diamond coatings), and Bob Patchin and John Fellenstein in the Vanderbilt Physics machine shop.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Vanderbilt University, 2400 Highland Avenue, Olin Hall Room 101, Nashville, TN, 37212, USA

    T. Prater, Alvin Strauss, George Cook, Brian Gibson & Chase Cox

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  1. T. Prater
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  2. Alvin Strauss
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  3. George Cook
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  4. Brian Gibson
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  5. Chase Cox
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Correspondence to T. Prater.

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Prater, T., Strauss, A., Cook, G. et al. A Comparative Evaluation of the Wear Resistance of Various Tool Materials in Friction Stir Welding of Metal Matrix Composites. J. of Materi Eng and Perform 22, 1807–1813 (2013). https://doi.org/10.1007/s11665-012-0468-9

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  • DOI: https://doi.org/10.1007/s11665-012-0468-9

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