April 19, 2023
Conference Paper

High speed butt joining of 1” thick 2139-T8


Thick plate (=1”) butt joining of Al alloys is challenging due to high tool forces, uneven material flow, and heat distribution in the through-thickness direction. Tool design and welding parameters used for executing thick plate butt joining have remained mostly static over the past decade. Reported welding speeds that produce viable joint strength (mostly on 6xxx alloys) typically range below 100 mm/min (4inches /min). Researchers at Pacific Northwest National Laboratory (PNNL) in association with Ground Vehicle Systems Center (US Army GVSC) have been working to demonstrate greater joining efficiency at higher welding speeds in a 1” thick AA2139-T8 plate. Using innovative tool features and effective force and temperature control a joint efficiency of 80% was demonstrated at a welding speed of 7 inches /min (178mm/min).

Published: April 19, 2023


Das H., P. Upadhyay, M. Reza E Rabby, U. Okeke, and M. Mcdonnell. 2023. High speed butt joining of 1” thick 2139-T8. In TMS 2023: Friction Stir Welding and Processing XII Symposium held at the TMS Annual Meeting and Exhibition, March 19-23, 2023. San Diego, CA. Minerals, Metals and Materials Series, edited by Y. Hovanksi, et al, 209–215. Cham:Springer. PNNL-SA-178259. doi:10.1007/978-3-031-22661-8_19