Papers by Author: Hiroyuki Kokawa

Abstract: The Texture Developed in High-Temperature β Phase during Friction Stir Welding of Ti-6Al-4V Was Studied. It Was Demonstrated that 0002 and 1120 Pole Figures Calculated from α Phase May Be Employed for Interpretation of Material Flow in the β Phase. Together with Orientation Measurements in Retained β Phase, this Approach Was Shown to Be a Very Simple and Effective for the Texture Analysis. The β Texture Was Found to Be a Mixture of {hkl}<111>-Fiber Texture and D₂(112)[111](Simple-Shear Texture Component.

Abstract: The authors have developed a new friction-stir welding (FSW) tool that enables to weld high-softening-temperature materials (HSTMs), such as steels, titanium and zirconium alloys. The new tool is made of a Co-based heat-resistant alloy strengthened by precipitating intermetallics, Co₃(Al,W), with a L1₂ structure at high temperatures. The Co-based alloy tool exhibits yield strengths higher than 500 MPa at 1000 deg C, so it might have a great potential as a tool material for FSW of HSTMs. In this study, the feasibility of using the Co-based alloy tool with various HSTMs was examined. Changes in the tool shape during FSW and the weld appearances produced with the Co-based alloy tool will be briefly shown.

Abstract: The principal features of material flow during friction stir welding (FSW) were illustrated via textural measurements in magnesium alloys. The straining state in the stir zone was demonstrated to be close to the simple-shear deformation with the shear plane/direction aligned with the local surface of the welding tool. Due to the unique nature of FSW process as well as specific character of the welding tool geometry, texture distribution in the stir zone was shown to be inherently inhomogeneous. The impact of this effect on mechanical properties is briefly considered.

Abstract: Invar 36 alloy is increasingly used as a structural material for manufacture of liquefied natural gas (LNG) transporters and storage tanks. However, the conventional arc welding of Invar 36 alloy has high susceptibility of hot-cracking. As a high-energy-beam welding process, laser welding could be effective for producing defect-free Invar 36 weld. In the present study, defect-free Invar 36 weld was successfully produced by Nd:YAG laser welding. The microstructure and mechanical properties of weld were also tested.

Abstract: Four kinds of the welding tools made of PCBN, W, WC and Al2O3 were applied to FSW of 304 stainless steel, and then the wear and reaction between the tool debris and the steel matrix were examined for each tool material. Severe tool damage was found in W, WC and Al2O3 tools after FSW, while the PCBN tool was hardly worn. Formations of Cr-rich borides, ferrite phases containing the high W contents and Cr-rich carbides were found in the stir zones produced using PCBN, W and WC tools, respectively. It was suggested that formation of those phases could be expected by calculation using the thermochemical database.

Abstract: The “stop-action” technique was employed to study grain structure evolution during friction-stir welding of AZ31 magnesium alloy. The grain structure formation was found to be mainly governed by the combination of the continuous and discontinuous recrystallization but also involved geometric effect of strain and local grain boundary migration. Orientation measurements showed that the deformation mode was very close to the simple shear associated with the rotating pin and material flow arose mainly from basal slip.

Abstract: To improve intergranular corrosion resistance of 304 stainless steel, a novel method, laser surface remelting combined with annealing treatment was adopted, which resulted in a high population of low  CSL boundaries, especially, twin boundaries (3) on the surface of the processed specimens. The grain boundary character distribution and effect of laser processing parameters on it were investigated. The experimental results showed that the maximum frequency of the low  CSL boundaries could attain 88.6% under the optimal processing conditions. The high fraction of the low  CSL boundaries led to a high corrosion resistance to intergranular corrosion.

Abstract: An AC magnetic field (0.5Tesla) is applied with the field direction perpendicular to the rolling direction during annealing of a 76% cold-rolled IF steel sheet. Microstructure and texture evolution in the as-annealed specimens were determined using SEM based OIM technique. It is found that the recrystallization is noticeably retarded by AC magnetic field annealing. At the early stage of recrystallization (annealing at 650°C for 30min), the development of (111) <123> orientations was favored by the AC magnetic field. With progress of recrystallization (annealing at 700°C and 750°C for 30min), the applied AC magnetic field suppressed the development of γ-fiber recrystallization textures to some extent.

Abstract: Friction stir spot welding (FSSW), developed based on principle of friction stir welding, has been paid attention as a new solid-state spot welding process. Since FSSW can produce high-quality weld in Al alloys more easily than resistance spot welding, this process has been already used for construction of Al components in the automotive industries. Despite the large industrial interests in FSSW, fundamental knowledge on welding phenomena of this process has not been fully understood. In this study, FSSW phenomena, such as the consolidation mechanism, the microstructural evolution and the material flow, were examined in Al alloy 6061. This study clarified that the elliptical zone found in the vicinity of the pin hole on the cross section was characterized by the initially lapped surface of two sheets. Moreover, the following material flow was proposed; capture of the upper material with the threads on the pin surface, spiral flow along the tool rotation, and then release at the tip of the pin.

Abstract: Superplasticity in an Al-6%Cu-0.45%Mg-0.4%Mn-0.16%Sc-0.12%Zr alloy subjected to intense plastic straining through equal-channel angular extrusion (ECAE) was studied in tension at strain rates ranging from 5.6×10-4 to 5.6×10-3 s-1 in the temperature interval 350-450°C. The alloy had a non-uniform microstructure with an average crystallite size of 1.2 m. The volume fraction of high-angle grain boundaries was about 57%. In spite of small crystallite size the alloy shows moderate superplastic properties. The highest elongation-to-failures of 320% appeared at a temperature of ~425°C and an initial strain rate of ~1.410-3 s-1, where the strain rate sensitivity coefficient, m, was about 0.33. The relationship between superplastic ductilities and microstructure stability is analyzed.