Microstructure Evolution and Fracture Behavior of (B4C+Al2O3)/Al Friction Stir Welded Joints

doi:10.1007/s40195-025-01879-1

Abstract

Abstract:

In dry storage, spent fuel is typically stored in casks constructed from neutron absorbing materials (NAMs). The (B₄C+Al₂O₃)/Al composite, which incorporates in-situ amorphous Al₂O₃ (am-Al₂O₃) formed on fine aluminum powder as a reinforcing phase, can serve as an integrated structural and functional NAM for dry storage applications. Welding is crucial in the fabrication of these casks. In this study, friction stir welding was performed on (B₄C+Al₂O₃)/Al composite sheets at a welding speed of 50 mm/min and rotation rates ranging from 500 to 1000 r/min. The microstructure of the weld joints was analyzed, and the intrinsic relationship between fracture behavior and microstructure was elucidated. Results showed that defect-free joints were achieved at rotation rates of 500 and 750 r/min, while tunnel defects were observed at 1000 r/min. The ultimate tensile strength of the joint welded at 500 r/min was 205.7 MPa, with a strength efficiency of 82%. Microstructural analysis revealed that the grains within the nugget zones (NZs) coarsened and the Al₂O₃ network was disrupted due to the welding thermo-mechanical effect, resulting in softening within the NZs. Fracture locations for all three joints were consistently observed at the NZ boundary on the advancing side (AS). Finite element simulations confirmed that cracks propagated along the NZ boundary on the AS, where stress concentration occurred during tensile testing.

Key words: Neutron absorbing materials, Friction stir welding (FSW), Microstructure evolution, Fracture behavior

B. M. Shi, Y. T. Pang, B. H. Shan, B. B. Wang, Y. Liu, P. Xue, J. F. Zhang, Y. N. Zan, Q. Z. Wang, B. L. Xiao, Z. Y. Ma. Microstructure Evolution and Fracture Behavior of (B₄C+Al₂O₃)/Al Friction Stir Welded Joints[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(9): 1513-1526.

Figures/Tables 19

Fig. 1 Appearance of cermet welding tool: a before; b after the welding processes

Fig. 2 Macrographs of (B4C+Al2O3)/Al FSW joints: a 500-50, b 750-50, c 1000-50

Fig. 3 Cross-sectional macrostructures of the FSW joints: a 500-50, b 750-50, c 1000-50 with the AS on the right

Fig. 4 Cross-sectional microhardness distribution maps of the FSW joints: a 500-50, b 750-50, c 1000-50 with the AS on the right

Fig. 5 Engineering stress-strain curves of BM and FSW joints

Table 1 Mechanical properties of BM and FSW joints

Samples	YS (MPa)	UTS (MPa)	EL (%)
BM	190.0 ± 4.0	250.3 ± 1.5	16.5 ± 2.4
500-50	143.5 ± 3.2	205.7 ± 1.2	5.0 ± 0.8
750-50	143.7 ± 4.7	202.0 ± 2.6	4.2 ± 1.5
1000-50	140.2 ± 8.4	166.3 ± 11.6	1.6 ± 0.3

Fig. 6 Fractured tensile specimens of the FSW joints: a 500-50, b 750-50, c 1000-50 with the AS on the right

Fig. 7 Cross-sectional images of (B4C+Al2O3)/Al composite sheet: a OM, b IPF images

Fig. 8 TEM images showing a the cross-sectional morphology of the (B4C+Al2O3)/Al composite, b a higher-magnification view

Fig. 9 Cross-sectional OM of the NZs of the FSW joints: a 500-50, b 750-50, c 1000-50

Fig. 10 Distribution of B4C particles in transition zones between NZs and BMs on the AS in the joints: a 500-50, b 750-50, c 1000-50

Fig. 11 IPF images of the NZs of the FSW joints: a 500-50, b 750-50, c 1000-50

Fig. 12 IPF images of both sides of the NZ boundaries on the AS: a, c, e interior side of the boundaries of the joints 500-50, 750-50, 1000-50, respectively; b, d, f exterior side of the boundaries, for the same joints

Fig. 13 TEM images of NZs in the joints a 500-50, c 750-50; b, d the high-magnification images of Al2O3 corresponding to a, c

Fig. 14 TEM images of the NZ region in the joint 1000-50: a, c images revealing two distinct morphologies; b, d corresponding Al2O3 morphology for a, c, respectively

Fig. 15 SEM fractographs of the FSW joints: a 500-50, c 750-50; b, d high-magnification images corresponding to a, c

Fig. 16 SEM fractographs of the joint 1000-50 with different morphologies a, c; b, d high-magnification images corresponding to a, c

Fig. 17 Tensile simulation of joint 500-50: a finite element model, stress distribution after b 0.5% strain, c 1% strain

Fig. 18 Tensile simulation of joint 1000-50: a finite element model, stress distribution after b 0.5% strain, c 1% strain

References 56

[1]	M. Ghayebloo, M.T. Mostaedi, H.F. Rad, Trans. Indian Inst. Met. 75, 2477 (2022)
[2]	Y. Li, W. Wang, J. Zhou, H. Chen, P. Zhang, J. Nucl. Mater. 487, 238 (2017)
[3]	K. Wang, L. Ma, C. Yang, Z. Bian, D. Zhang, S. Cui, M. Wang, Z. Chen, X. Li, Materials 16, 4305 (2023)
[4]	L. Zhao, Y. Peng, Z. Li, X. Cui, J. Wang, T. Xiong, Mater. Today Commun. 38, 108098 (2024)
[5]	Y. Xiao, S. Zhu, J. Duan, H. Wang, Z. Huang, Q. Meng, Y. Liu, Y. Pan, X. Wang, J. Qi, T. Lu, Ceram. Int. 49, 39458 (2023)
[6]	M. Chen, Z. Liu, C. Yang, P. Xiao, W. Yang, Z. Hu, L. Sun, Y. Jia, Mater. Sci. Eng. A 861, 144376 (2022)
[7]	P. Zhang, Y. Li, W. Wang, Z. Gao, B. Wang, J. Nucl. Mater. 437, 350 (2013)
[8]	H. Chen, H. Nie, J. Zhou, W. Wang, P. Zhang, Y. Zhang, J.F. Wang, R. Liu, J. Nucl. Mater. 517, 393 (2019)
[9]	Y.L. Li, W.X. Wang, H.S. Chen, J. Zhou, Q.C. Wu, Acta Metall. Sin. -Engl. Lett. 29, 1037 (2016)
[10]	H.S. Chen, W.X. Wang, Y.L. Li, P. Zhang, H.H. Nie, Q.C. Wu, J. Alloys Compd. 632, 23 (2015)
[11]	M. Balog, T. Hu, P. Krizik, M.V.C. Riglos, B.D. Saller, H. Yang, J.M. Schoenung, E.J. Lavernia, Mater. Sci. Eng. A 648, 61 (2015)
[12]	Y. Zhou, Y. Zan, S. Zheng, X. Shao, Q. Jin, B. Zhang, Q. Wang, B. Xiao, X. Ma, Z. Ma, J. Mater. Sci. Technol. 35, 1825 (2019)
[13]	J. Qin, Z. Zhang, X.G. Chen, Metall. Mater. Trans. A 47, 4694 (2016)
[14]	Y.N. Zan, X. Lei, J.F. Zhang, D. Wang, Q.Z. Wang, B.L. Xiao, Z.Y. Ma, Acta Metall. Sin. -Engl. Lett. 35, 2007 (2022)
[15]	M. Balog, P. Krizik, M. Nosko, Z. Hajovska, M.V.C. Riglos, W. Rajner, D.S. Liu, F. Simancik, Mater. Sci. Eng. A 613, 82 (2014)
[16]	Y.N. Zan, Y.T. Zhou, Z.Y. Liu, Q.Z. Wang, W.G. Wang, D. Wang, B.L. Xiao, Z.Y. Ma, Mater. Sci. Eng. A 773, 138840 (2020)
[17]	R. Butola, P. Singh, ECS J. Solid State Sci. Technol. 11, 093001 (2022)
[18]	Z. Ma, B. Xiao, J. Zhang, S. Zhu, D. Wang, Acta Metall. Sin. 59, 457 (2023)
[19]	M.A. Chen, C.S. Wu, J.Q. Gao, Trans. Nonferrous Met. Soc. China 12, 805 (2002)
[20]	Y. Li, G. Le, P. Zhang, Y. Xian, Z. Hu, X. Pang, Metall. Res. Technol. 120, 201 (2023)
[21]	R. Kesharwani, K.K. Jha, M. Imam, C. Sarkar, I. Barsoum, J. Mater. Res. Technol. 26, 3301 (2023)
[22]	M. Kang, C. Kim, J. Weld. Join. 35, 79 (2017)
[23]	L. Qi, Z. Li, Q. Zhang, W. Wu, N. Huang, Y. Li, J. Manuf. Process. 68, 1271 (2021)
[24]	L.H. Wu, P. Xue, B.L. Xiao, Z.Y. Ma, Scr. Mater. 122, 26 (2016)
[25]	S.M.M. Zamani, K. Behdinan, M.R. Razfar, D.H. Fatmehsari, J.A. Mohandesi, Int. J. Adv. Manuf. Technol. 113, 3629 (2021)
[26]	Q. Qiao, Y. Su, Z. Li, Q. Cui, H. Yu, Q. Ouyang, D. Zhang, Mater. Sci. Eng. A 782, 139238 (2020)
[27]	A. Moradi Faradonbeh, M. Shamanian, H. Edris, M. Paidar, Y. Bozkurt, J. Mater. Eng. Perform. 27, 835 (2018)
[28]	Z. Wang, B. Wang, Z. Zhang, P. Xue, Y. Hao, Y. Zhao, D. Ni, G. Wang, Z. Ma, Acta Metall. Sin. -Engl. Lett. 36, 586 (2023)
[29]	Y.L. Ma, H.B. Xu, Z.Y. Liang, L. Liu, Acta Metall. Sin. -Engl. Lett. 33, 127 (2020)
[30]	X. Meng, Y. Xie, S. Sun, X. Ma, L. Wan, J. Cao, Y. Huang, Acta Metall. Sin. -Engl. Lett. 36, 881 (2023)
[31]	W. Dong, X. Meng, Y. Xie, X. Zhang, Z. Zhang, X. Sun, R. Guo, H. Tian, Y. Huang, Sci. Technol. Weld. Join. 29, 291 (2024)
[32]	J.F. Guo, P. Gougeon, X.G. Chen, Sci. Technol. Weld. Join. 17, 85 (2012)
[33]	K. Kalaiselvan, N. Murugan, Trans. Nonferrous Met. Soc. China 23, 616 (2013)
[34]	M. Amirizad, A.H. Kokabi, M.A. Gharacheh, R. Sarrafi, B. Shalchi, M. Azizieh, Mater. Lett. 60, 565 (2006)
[35]	Y.N. Zan, B.B. Wang, Y.T. Zhou, C.L. Jia, Z.Y. Liu, Q.Z. Wang, B.L. Xiao, Z.Y. Ma, Sci. China: Technol. Sci. 63, 1256 (2020)
[36]	J.X. Cai, B.M. Shi, N. Li, Y. Liu, Z.G. Zhang, Y.N. Zan, Q.Z. Wang, B.L. Xiao, Z.Y. Ma, Acta Metall. Sin. -Engl. Lett. 37, 1411 (2024)
[37]	Y.Z. Li, Y.N. Zan, Q.Z. Wang, B.L. Xiao, Z.Y. Ma, J. Mater. Process. Technol. 273, 116242 (2019)
[38]	K. Wang, P. Dong, X. Niu, L. Qin, G. Bian, H. Zhang, Mater. Lett. 369, 136592 (2024)
[39]	X.C. Liu, C.S. Wu, Mater. Des. 90, 350 (2016)
[40]	S. Rasaee, A.H. Mirzaei, D. Almasi, S. Hayati, Trans. Indian Inst. Met. 71, 1553 (2018)
[41]	X. Meng, Y. Huang, J. Cao, J. Shen, J.F. dos Santos, Prog. Mater. Sci. 115, 100706 (2021)
[42]	Y.G. Kim, H. Fujii, T. Tsumura, T. Komazaki, K. Nakata, Mater. Sci. Eng. A 415, 250 (2006)
[43]	C. Wang, B.B. Wang, D. Wang, P. Xue, Q.Z. Wang, B.L. Xiao, L.Q. Chen, Z.Y. Ma, Acta Metall. Sin. -Engl. Lett. 32, 677 (2019)
[44]	D. Wang, B.L. Xiao, Q.Z. Wang, Z.Y. Ma, J. Mater. Sci. Technol. 30, 54 (2014) DOI
[45]	J. Jiang, F. Jiang, M. Zhang, Trans. Nonferrous Met. Soc. China 33, 1687 (2023)
[46]	A.H. Feng, B.L. Xiao, Z.Y. Ma, Compos. Sci. Technol. 68, 2141 (2008)
[47]	Z.Y. Ma, A.H. Feng, B.L. Xiao, J.Z. Fan, L.K. Shi, Trans. Tech. Publ. 539, 3814 (2007)
[48]	B. Ravi, B.B. Naik, G.R. Kumar, Mater. Today: Proc. 5, 1411 (2018)
[49]	Y.N. Zan, Y.T. Zhou, H. Zhao, Z.Y. Liu, Q.Z. Wang, D. Wang, W.G. Wang, B.L. Xiao, Z.Y. Ma, Compos. Pt. B 183, 107674 (2020)
[50]	M. Balog, C. Poletti, F. Simancik, M. Walcher, W. Rajner, J. Alloys Compd. 509, 235 (2011)
[51]	B.M. Shi, N. Li, J.X. Cai, Y. Liu, Y.N. Zan, Q.Z. Wang, B.L. Xiao, Z.Y. Ma, Ceram. Int. 50, 36166 (2024)
[52]	R. Nandan, T. DebRoy, H. Bhadeshia, Prog. Mater. Sci. 53, 980 (2008)
[53]	T.R. McNelley, S. Swaminathan, J.Q. Su, Scr. Mater. 58, 349 (2008)
[54]	M. Nosko, M. Stepánek, P. Zifcák, L. Orovčík, Š Nagy, T. Dvorák, P. Oslanec, F. Khodabakhshi, A.P. Gerlich, Mater. Sci. Eng. A 754, 190 (2019)
[55]	V.V. Bhanuprasad, M.A. Staley, P. Ramakrishnan, Y.R. Mahajan, Key Eng. Mater. 104, 495 (1995)
[56]	M. Peel, A. Steuwer, M. Preuss, P.J. Withers, Acta Mater. 51, 4791 (2003)

Microstructure Evolution and Fracture Behavior of (B₄C+Al₂O₃)/Al Friction Stir Welded Joints

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 19

References 56

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	X. W. Shang, Z. G. Lu, R. P. Guo, L. Xu. Influence of Hot Isostatic Pressing Temperature on Microstructure and Mechanical Properties of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si Alloy [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(4): 627-641.
[2]	Jian Zang, Jianrong Liu, Qingjiang Wang, Haibing Tan, Bohua Zhang, Xiaolin Dong, Zibo Zhao. Microstructure and Texture Evolution of Ti65 Alloy during Thermomechanical Processing [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(1): 107-120.
[3]	J. X. Cai, B. M. Shi, N. Li, Y. Liu, Z. G. Zhang, Y. N. Zan, Q. Z. Wang, B. L. Xiao, Z. Y. Ma. Effect of Al₂O₃ on the Mechanical Properties of (B₄C + Al₂O₃)/Al Neutron Absorbing Materials [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(8): 1411-1420.
[4]	Long Liu, Zijian Zhou, Jie Yu, Xinguang Wang, Chuanyong Cui, Rui Zhang, Yizhou Zhou, Xiaofeng Sun. Hot Deformation Behavior and Workability of a New Ni-W-Cr Superalloy for Molten Salt Reactors [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(8): 1453-1466.
[5]	Hong-Wei Zhang, Li-Wei Lan, Zhe-Yu Yang, Chang-Chun Li, Wen-Xian Wang. Microstructure Evolution and Nanomechanical Behavior of Micro-Area in Molten Pool of Selective Laser Melting (CoCrNi)₈₂Al₉Ti₉ High-Entropy Alloy [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(6): 1019-1033.
[6]	Peng Chen, Wenhao Chen, Jiaxin Chen, Zhiyu Chen, Yang Tang, Ge Liu, Bensheng Huang, Zhiqing Zhang. Microstructure Evolution and Mechanical Properties of Friction Stir Welded Al-Cu-Li Alloy [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(5): 855-871.
[7]	Hengrui Hu, Jiayu Qin, Yunpeng Zhu, Jinhui Wang, Xiaoqiang Li, Peipeng Jin. Hot Deformation Behavior and Microstructures Evolution of GNP-Reinforced Fine-Grained Mg Composites [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(3): 407-424.
[8]	Dong-Dong Zuo, Jian Chang, Hai-Peng Wang. Phase Selection and Microstructure Evolution Dependance on Composition for Zr-Fe Eutectic Alloys [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(10): 1689-1702.
[9]	Liwei Lan, Wenxian Wang, Zeqin Cui, Xiaohu Hao. Unique Duplex Microstructure and Porosity Effect on Mechanical Properties of AlCoCrFeNi_2.1 Eutectic High-Entropy Alloys Processed by Selective Laser Melting [J]. Acta Metallurgica Sinica (English Letters), 2023, 36(9): 1465-1481.
[10]	Minhao Li, Liwei Lu, Yuhui Wei, Min Ma, Weiying Huang. Deformation Behavior and Microstructure Evolution of AZ31 Mg Alloy by Forging-Bending Repeated Deformation with Multi-pass Lowered Temperature [J]. Acta Metallurgica Sinica (English Letters), 2023, 36(8): 1317-1335.
[11]	Bing-Yu Qian, Rui-Zhi Wu, Jian-Feng Sun, Jing-Huai Zhang, Le-Gan Hou, Xiao-Chun Ma, Jia-Hao Wang, Hai-Ting Hu. Evolutions of Microstructure and Mechanical Properties in Mg-5Li-1Zn-0.5Ag-0.5Zr-xGd Alloy [J]. Acta Metallurgica Sinica (English Letters), 2023, 36(2): 215-228.
[12]	Yu Chen, Jian-chao Pang, Shou-xin Li, Zhe-feng Zhang. High-Temperature Oxidation Behavior and Related Mechanism of RuT400 Vermicular Graphite Iron [J]. Acta Metallurgica Sinica (English Letters), 2022, 35(7): 1117-1130.
[13]	Junlei Zhang, Han Liu, Xiang Chen, Qin Zou, Guangsheng Huang, Bin Jiang, Aitao Tang, Fusheng Pan. Deformation Characterization, Twinning Behavior and Mechanical Properties of Dissimilar Friction-Stir-Welded AM60/AZ31 Alloys Joint During the Three-Point Bending [J]. Acta Metallurgica Sinica (English Letters), 2022, 35(5): 727-744.
[14]	Yu-Qing Mao, Ping Yang, Li-Ming Ke, Yang Xu, Yu-Hua Chen. Microstructure Evolution and Recrystallization Behavior of Friction Stir Welded Thick Al-Mg-Zn-Cu alloys: Influence of Pin Centerline Deviation [J]. Acta Metallurgica Sinica (English Letters), 2022, 35(5): 745-756.
[15]	Li Hu, Mingao Li, Qiang Chen, Tao Zhou, Laixin Shi, Mingbo Yang. Dependence of Microstructure Evolution and Mechanical Properties on Loading Direction for AZ31 Magnesium Alloy Sheet with Non-basal Texture During In-Plane Uniaxial Tension [J]. Acta Metallurgica Sinica (English Letters), 2022, 35(2): 223-234.