Session: 16-01-01: Government Agency Student Poster Competition

Paper Number: 150161

150161 - Investigating the Composition Distribution and Hardness of Dissimilar Al6061/al7075 Joints Produced via Additive Friction Stir Deposition 

The advancement of modern manufacturing technologies has ushered in a new era of materials engineering, where the focus is not only on individual material properties but also on creating novel, high-performance materials by joining dissimilar metals. This study delves into the use of Additive Friction Stir Deposition (AFS-D) to join Al6061 and Al7075 alloys, addressing the myriad challenges associated with dissimilar metal joints. AFS-D represents a cutting-edge solid-state joining technique that effectively mitigates issues commonly encountered in conventional material joining methods. These issues include porosity, hot cracking, and elemental segregation. By utilizing the mechanical stirring and plastic deformation inherent in AFS-D, these defects are significantly reduced, facilitating near-net shaping with minimal pre- and post-processing. This capability makes AFS-D particularly suitable for producing high-quality, defect-free joints in dissimilar aluminum alloys. This study focuses on a comprehensive analysis of the joints which involves evaluating hardness, composition distribution, corrosion resistance, and the effects of various heat treatment regimens. Hardness testing, conducted using microhardness testing equipment across different regions of the joint, reveals consistent profiles with no significant drops in hardness. This uniform hardness distribution is indicative of a well-bonded joint with minimal defects. Energy Dispersive Spectroscopy (EDS) mapping analyses were employed to assess the composition distribution and microstructural characteristics of the joints. Initial findings from these analyses confirm a homogeneous distribution of elements across the joint interface, with no significant signs of elemental segregation. Heat treatment is another focal point of this study, as it has a significant impact on the mechanical properties and microstructural stability of the joints. Various heat treatment protocols, including solution treatment followed by aging, will be applied to the joints. The effects of these treatments will be systematically studied through tensile testing, hardness measurements, and microstructural analysis. Findings can indicate the possibilities of heat treatment to enhance the mechanical properties of the joints, increasing their strength and ductility while maintaining or even improving their microstructural integrity. The comprehensive investigation into the use of AFS-D for joining Al6061 and Al7075 alloys lays the foundation for developing reliable, high-performance dissimilar metal joints. The successful application of AFS-D in this context demonstrates its potential for producing defect-free, high-quality joints and underscores its versatility and efficiency. The insights gained from this research have significant implications for aerospace, automotive, and marine industries, where the demand for lightweight, high-strength materials is ever-increasing. By optimizing processing parameters and understanding the interplay between processing, structure, and properties, this work contributes to the advancement of dissimilar metal joining technologies, paving the way for the fabrication of next-generation engineering materials.

Presenting Author: Kekeli Doe Agbewornu Southern University and A&M College

Presenting Author Biography: Kekeli Doe Agbewornu is a Research Assistant at Southern University and A&M College specializing in the field of materials science and engineering. He holds a BSc. in Metallurgical Engineering from Kwame Nkrumah University of Science and Technology - Ghana, where he focused on the physical metallurgy of ferrous and non-ferrous metals, and materials joining processes. Kekeli Doe Agbewornu's research interests include dissimilar metal joining, additive manufacturing, additive friction stir deposition (AFSD), and the characterization of microstructural and mechanical properties of advanced materials.

Authors:

Kekeli Doe Agbewornu Southern University and A&M College
Antonio Wells Southern University and A&M College
Patrick Mensah Southern University and A&M College
Congyuan Zeng Southern University and A&M College