Macro-performance evaluation of friction stir welded automotive tailor-welded blank sheets: Part I - Material properties

Abstract In order to evaluate the macroscopic performance of friction stir welded automotive tailor-welded blank (TWB) sheets, the hardening behavior, anisotropic yielding properties and forming limit diagram were characterized both for base (material) and weld zones. In order to describe the Bauschinger and transient hardening behaviors as well as permanent softening during reverse loading, the modified Chaboche type combined isotropic–kinematic hardening law was applied. As for anisotropic yielding, the non-quadratic anisotropic yield function, Yld2000-2d, was utilized for base material zones, while isotropy was assumed for weld zones for simplicity. As for weld zones, hardening properties were obtained using the rule of mixture and selectively by direct measurement using sub-sized specimens. Forming limit diagrams were measured for base materials but calculated for weld zones based on Hill’s bifurcation and M–K theories. In this work, four automotive sheets were considered: aluminum alloy 6111-T4, 5083-H18, 5083-O and dual-phase steel DP590 sheets, each having one or two thicknesses. Base sheets with the same and different thicknesses were friction-stir welded for tailor-welded blank (TWB) samples.

[1]  J. Jeswiet,et al.  Tensile testing for weld deformation properties in similar gage tailor welded blanks using the rule of mixtures , 2001 .

[2]  W. Hosford.  A Generalized Isotropic Yield Criterion , 1972 .

[3]  J. Robson,et al.  Modelling of heterogeneous precipitate distribution evolution during friction stir welding process , 2006 .

[4]  Chongmin Kim.  Modeling tensile deformation of dual-phase steel , 1988 .

[5]  Drawability assessment of BCC steel sheet by using elastic/crystalline viscoplastic finite element analyses , 2001 .

[6]  R. H. Wagoner,et al.  Properties of Friction-Stir Welded Aluminum Alloys 6111 and 5083 , 2008 .

[7]  P. Withers,et al.  Physically-based constitutive modelling of residual stress development in welding of aluminium alloy 2024 , 2004 .

[8]  M. Tumuluru,et al.  Resistance spot welding of coated high-strength dual-phase steels , 2006 .

[9]  W. Wen,et al.  The effect of cold rolling and annealing on the serrated yielding phenomenon of AA5182 aluminum alloy , 2004 .

[10]  R. H. Wagoner,et al.  Forming of tailor-welded blanks , 1996 .

[11]  Carla Gambaro,et al.  Friction stir welding of dissimilar Al 6013-T4 To X5CrNi18-10 stainless steel , 2005 .

[12]  R. H. Wagoner,et al.  The Mechanism of Grain Coarsening in Friction-Stir-Welded AA5083 after Heat Treatment , 2011 .

[13]  Frédéric Barlat,et al.  Work-hardening model for polycrystalline metals under strain reversal at large strains , 2007 .

[14]  Rajiv S. Mishra,et al.  Friction Stir Welding and Processing , 2007 .

[15]  Z. Marciniak,et al.  Limit strains in the processes of stretch-forming sheet metal , 1967 .

[16]  R. H. Wagoner,et al.  Effect of stress-strain-law transients on formability , 1986 .

[17]  P. S. Bate,et al.  Reversibility in the work hardening of spheroidised steels , 1986 .

[18]  William F. Hosford,et al.  Upper-bound anisotropic yield locus calculations assuming 〈111〉-pencil glide , 1980 .

[19]  F. Barlat,et al.  Plane stress yield function for aluminum alloy sheets—part 1: theory , 2003 .

[20]  Bart Peeters,et al.  Work-hardening/softening behaviour of b.c.c. polycrystals during changing strain paths: I. An integrated model based on substructure and texture evolution, and its prediction of the stress–strain behaviour of an IF steel during two-stage strain paths , 2001 .

[21]  P. Prangnell,et al.  An examination of the mean stress contribution to the Bauschinger effect by neutron diffraction , 1995 .

[22]  R. M. Leal,et al.  Material flow in Friction Stir Welding , 2008, Microscopy and Microanalysis.

[23]  R. Mishra,et al.  Abnormal grain growth in friction stir processed alloys , 2008 .

[24]  J. Chaboche.  Time-independent constitutive theories for cyclic plasticity , 1986 .

[25]  R. Hill,et al.  On discontinuous plastic states, with special reference to localized necking in thin sheets , 1952 .

[26]  R. Miranda,et al.  Process Developments and Materials Characterization in FSW/P , 2022 .

[27]  R. E. Dick,et al.  Plane stress yield functions for aluminum alloy sheets , 2002 .

[28]  Hiroyuki Kokawa,et al.  Microstructural evolution of 6063 aluminum during friction-stir welding , 1999 .

[29]  Kwansoo Chung,et al.  Macro-performance evaluation of friction stir welded automotive tailor-welded blank sheets: Part II – Formability , 2010 .

[30]  Kwansoo Chung,et al.  Spring-back evaluation of automotive sheets based on isotropic-kinematic hardening laws and non-quadratic anisotropic yield functions: Part II: characterization of material properties , 2005 .

[31]  G. Haidemenopoulos,et al.  Aluminum and Aluminum Alloys , 2004 .

[32]  Frédéric Barlat,et al.  Spring-back evaluation of automotive sheets based on isotropic-kinematic hardening laws and non-quadratic anisotropic yield functions: Part I: theory and formulation , 2005 .

[33]  Farhang Pourboghrat,et al.  Wrinkling control in aluminum sheet hydroforming , 2005 .