Thermodynamics guided design and processing of a WC/HEA cermet tool for high temperature friction stir welding
Friction stir welding (FSW) of high temperature materials such as ferrous alloys, Ti-alloys, and Ni-alloys is challenging due to the high costs, short tool lives, and limited availability of tool materials. Commercially available cermets such as WC/Co are relatively cost-effective, yet their perform...
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Elsevier
2025-02-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127525000383 |
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| author | Supreeth Gaddam Surekha Yadav Amit Kishan Behera Noriaki Arai Zaynab Mahbooba Shikhar Krishn Jha Qiaofu Zhang Rajiv S. Mishra |
| author_facet | Supreeth Gaddam Surekha Yadav Amit Kishan Behera Noriaki Arai Zaynab Mahbooba Shikhar Krishn Jha Qiaofu Zhang Rajiv S. Mishra |
| author_sort | Supreeth Gaddam |
| collection | DOAJ |
| description | Friction stir welding (FSW) of high temperature materials such as ferrous alloys, Ti-alloys, and Ni-alloys is challenging due to the high costs, short tool lives, and limited availability of tool materials. Commercially available cermets such as WC/Co are relatively cost-effective, yet their performance is largely compromised by subpar high temperature properties of the Co binder. To address this issue, an integrated computational materials engineering (ICME) approach was applied to design a WC/HEA cermet with high entropy alloy (HEA) binder for better mechanical properties and high temperature performance. The WC/HEA cermet was fabricated by powder metallurgy route using mechanical alloying and mixing followed by spark plasma sintering (SPS). The SPS-sintered WC/HEA cermet possessed good room temperature hardness-fracture toughness synergy and hot hardness property. FSW tools were fabricated using the WC/HEA material and the tools were benchmarked against a high strength low alloy grade 50 (HSLA-50) steel. The tools performed with no observed chemical interaction with the workpiece material. The HSLA-50 material showed improved microstructure, hardness, and tensile properties post FSW. This study is the first proof-of-concept for the design, fabrication, testing, and evaluation of a novel cermet FSW tool material with low-cost and high-performance synergy for high temperature FSW application. |
| format | Article |
| id | doaj-art-ae18cbc645ca4dbc97507147c7c57307 |
| institution | Kabale University |
| issn | 0264-1275 |
| language | English |
| publishDate | 2025-02-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj-art-ae18cbc645ca4dbc97507147c7c573072025-01-22T05:40:57ZengElsevierMaterials & Design0264-12752025-02-01250113618Thermodynamics guided design and processing of a WC/HEA cermet tool for high temperature friction stir weldingSupreeth Gaddam0Surekha Yadav1Amit Kishan Behera2Noriaki Arai3Zaynab Mahbooba4Shikhar Krishn Jha5Qiaofu Zhang6Rajiv S. Mishra7Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Advanced Materials and Manufacturing Processes Institute, University of North Texas, Denton, TX 76207, USACenter for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Advanced Materials and Manufacturing Processes Institute, University of North Texas, Denton, TX 76207, USA; Schneider Electric, Cedar Rapids, IA 52404, USAQuesTek Innovations LLC, Evanston, IL 60201, USAQuesTek Innovations LLC, Evanston, IL 60201, USAQuesTek Innovations LLC, Evanston, IL 60201, USA; EOS North America, Pflugerville, TX 78660, USACenter for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Advanced Materials and Manufacturing Processes Institute, University of North Texas, Denton, TX 76207, USAQuesTek Innovations LLC, Evanston, IL 60201, USA; Department of Metallurgical and Materials Engineering, The University of Alabama, Tuscaloosa, AL 35487, USA; Corresponding authors at: Department of Metallurgical and Materials Engineering, The University of Alabama, Tuscaloosa, AL 35487, USA (Q. Zhang) and Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA (R.S. Mishra).Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA; Advanced Materials and Manufacturing Processes Institute, University of North Texas, Denton, TX 76207, USA; Corresponding authors at: Department of Metallurgical and Materials Engineering, The University of Alabama, Tuscaloosa, AL 35487, USA (Q. Zhang) and Center for Friction Stir Processing, Department of Materials Science and Engineering, University of North Texas, Denton, TX 76207, USA (R.S. Mishra).Friction stir welding (FSW) of high temperature materials such as ferrous alloys, Ti-alloys, and Ni-alloys is challenging due to the high costs, short tool lives, and limited availability of tool materials. Commercially available cermets such as WC/Co are relatively cost-effective, yet their performance is largely compromised by subpar high temperature properties of the Co binder. To address this issue, an integrated computational materials engineering (ICME) approach was applied to design a WC/HEA cermet with high entropy alloy (HEA) binder for better mechanical properties and high temperature performance. The WC/HEA cermet was fabricated by powder metallurgy route using mechanical alloying and mixing followed by spark plasma sintering (SPS). The SPS-sintered WC/HEA cermet possessed good room temperature hardness-fracture toughness synergy and hot hardness property. FSW tools were fabricated using the WC/HEA material and the tools were benchmarked against a high strength low alloy grade 50 (HSLA-50) steel. The tools performed with no observed chemical interaction with the workpiece material. The HSLA-50 material showed improved microstructure, hardness, and tensile properties post FSW. This study is the first proof-of-concept for the design, fabrication, testing, and evaluation of a novel cermet FSW tool material with low-cost and high-performance synergy for high temperature FSW application.http://www.sciencedirect.com/science/article/pii/S0264127525000383ICME designWC/HEA cermetMechanical alloyingSpark plasma sinteringFSW toolHSLA steel |
| spellingShingle | Supreeth Gaddam Surekha Yadav Amit Kishan Behera Noriaki Arai Zaynab Mahbooba Shikhar Krishn Jha Qiaofu Zhang Rajiv S. Mishra Thermodynamics guided design and processing of a WC/HEA cermet tool for high temperature friction stir welding Materials & Design ICME design WC/HEA cermet Mechanical alloying Spark plasma sintering FSW tool HSLA steel |
| title | Thermodynamics guided design and processing of a WC/HEA cermet tool for high temperature friction stir welding |
| title_full | Thermodynamics guided design and processing of a WC/HEA cermet tool for high temperature friction stir welding |
| title_fullStr | Thermodynamics guided design and processing of a WC/HEA cermet tool for high temperature friction stir welding |
| title_full_unstemmed | Thermodynamics guided design and processing of a WC/HEA cermet tool for high temperature friction stir welding |
| title_short | Thermodynamics guided design and processing of a WC/HEA cermet tool for high temperature friction stir welding |
| title_sort | thermodynamics guided design and processing of a wc hea cermet tool for high temperature friction stir welding |
| topic | ICME design WC/HEA cermet Mechanical alloying Spark plasma sintering FSW tool HSLA steel |
| url | http://www.sciencedirect.com/science/article/pii/S0264127525000383 |
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