Investigation Friction Stir Welding Parameters On the Mechanical Properties of Weld Joint of ( AA 2000, 5000, 7000, or AA8000 )
DOI:
https://doi.org/10.65204/djes.v3i3.1045Keywords:
Aluminuim alloys, friction stir welding, weld jointsAbstract
This study investigates the influence of key Friction Stir Welding (FSW) parameters on the mechanical and microstructural properties of weld joints in AA2000, AA5000, AA7000, and AA8000 series aluminum alloys,Five factors were systematically varied: tool pin geometry (cylindrical, tapered, square, fully threaded, and three-flat-face), welding speed (0.5–5 mm/s), tool rotational speed (400–1000 rpm), tool tilt angle (1°–3°), and the introduction of Zn or ZnCu interlayers (0.1–0.3 mm thickness),Experiments were conducted on AA7020-T6, AA2024-T3, and AA5083-H32,Microstructural evolution was characterized by optical and scanning electron microscopy, microhardness profiles were measured via Vickers testing, and tensile and fractographic analyses were performed in accordance with ASTM E8,Statistical validity was ensured by triplicate testing and ANOVA (p < 0.05). Results show that the tapered square pin yields the most uniform material flow and reduces root-flaw defects by approximately 40%,Optimal welding conditions—speeds of 0.5–5 mm/s and 400–1000 rpm—produce ultimate tensile strengths exceeding 300 MPa with minimal heat-affected-zone softening,Incorporating a 0.2 mm ZnCu interlayer increases weld-nugget microhardness by about 15% while reducing ductility by roughly 20%,A tool tilt angle of 2°–2.5° lowers void density by 35%, notably in AA7020 joints. Based on these findings, the study recommends using a tapered square pin, a 0.2 mm ZnCu interlayer, and a 2° tilt angle to achieve an optimal balance of strength and ductility in high-strength aluminum alloy welds,Future work should explore underwater FSW or post-weld heat treatments to further enhance joint toughness and tool-material innovations (e.g., WC or PCBN) to extend tool life under high-rpm conditions.
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