High-speed friction stir butt welding of 25.4&nbsp;mm thick 7175-T79 aluminum alloy

Reza-E-Rabby, Md.; Das, Hrishikesh; Wang, Tianhao; Komarasamy, Mageshwari; Whalen, Scott A.; Grant, Glenn J.

doi:10.1016/j.mfglet.2023.08.140

High-speed friction stir butt welding of 25.4 mm thick 7175-T79 aluminum alloy

Journal Article · Fri Aug 25 00:00:00 EDT 2023 · Manufacturing Letters

DOI:https://doi.org/10.1016/j.mfglet.2023.08.140· OSTI ID:2229624

^[1]; Das, Hrishikesh ^[1]; ^[1]; Komarasamy, Mageshwari ^[1]; ^[1]; Grant, Glenn J. ^[1]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

This presents the first experimental demonstration of friction stir butt welding of 25.4 mm thick high-strength, precipitate-strengthened 7XXX aluminum alloy at a welding speed above 500 mm/min and penetration depth greater than 10 mm. Tool pin threads that terminate away from the shoulder region, helped mitigate nearby stress concentration during tool traversing, enabling a higher welding speed while avoiding pin fracture near shoulder. Two kinds of welds—one-sided with full penetration of the plate thickness and double-sided with partial penetration of the plate thickness—were conducted. Significant grain refinement (grain size 1.3 ± 0.8 µm) was evident at the junction of double-sided friction stir welding (FSW) compared to other regions of weld-nugget or base material. Cross-weld tensile testing with digital image correlation revealed high local strains at the junction of double-sided FSW before macro-yield. This strain concentration impeded the typical early necking on advancing/retreating sides of FSW joints, improving the yield strength of as-welded double-sided FSW by 20–24% over slow- to medium-speed one-sided FSW. In conclusion, the joint efficiency of as-welded, double-sided high-speed FSW was about 76% with respect to the base material’s ultimate tensile strength.

View Accepted Manuscript (DOE)

Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE Office of Fossil Energy and Carbon Management (FECM)

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2229624

Alternate ID(s):: OSTI ID: 2369687

Report Number(s):: PNNL-SA--184859

Journal Information:: Manufacturing Letters, Journal Name: Manufacturing Letters Vol. 38; ISSN 2213-8463

Publisher:: Society of Manufacturing Engineers, ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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42 ENGINEERING
Friction stir welding (FSW)
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double-sided FSW
full penetration
partial penetration
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thick AA7175-T79

High-speed friction stir butt welding of 25.4 mm thick 7175-T79 aluminum alloy

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