Friction stir lap welding (FSLW) with linear speed of 1m/min or higher can open up opportunities for industrial implementation of FSLW. This paper will provide an overview of several challenges and mitigation strategies to produce effective joints between several Al alloys. FSLW of Al alloys at high speed presents challenges including interface hook features and defects at the interface. Combination of 5xxx, 6xxx and 7xxx Al alloys were joined and characterized. Load bearing capacity in excess of 80% of base material strength has been demonstrated at the welding speed of 2m/min for 6xxx and 5xxx similar lap joints. The effects of parameters like welding speed, RPM, tool geometry in material flow features, void volume, and hook geometry is investigated and this knowledge base is applied to improve the joint strength of 7xxx series lap welds.
Revised: February 12, 2020 |
Published: March 11, 2019
Citation
Upadhyay P., X. Li, and T.J. Roosendaal. 2019.High-Speed Friction stir lap welding of Al alloys. In Friction Stir Welding and Processing X. The Minerals, Metals & Materials Series, edited by Y. Hovanski, et al, 67-75. Cham:Springer.PNNL-SA-140140.doi:10.1007/978-3-030-05752-7_7