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Parametric effect on mechanical, microstructural and corrosion behaviour of friction stir welded AA5083-AA7075 alloys

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Abstract

Aluminium alloys AA5083 and AA7075 were welded using friction stir welding (FSW) with three different welding speeds of 50, 100, and 150 mm/min at a constant rotation speed of 1000 rpm in a butt joint configuration. The microstructural characteristics were investigated utilizing scanning electron microscope (SEM), optical microscope (OM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction analysis (XRD). Mechanical properties were assessed through tensile and hardness tests, while the fracture surface of the tensile-tested samples was analysed using FE-SEM. Furthermore, corrosion behaviour was studied to comprehend the impact of intermetallic compounds (IMCs) on dissimilar joining. The examination of the microstructure in the base metals (BM) revealed a notable difference in the average grain size between AA7075 and AA5083, measuring 40 μm and 25 μm, respectively. Additionally, the types of precipitates differed between the two alloys. The stir zone (SZ) exhibited significant grain refinement, with an average grain size of 2 μm at a welding speed of 50 mm/min, which increased to 6 μm as the welding speed was raised to 150 mm/min. The dissimilar joints displayed ultimate tensile strengths ranging from 160 to 200 MPa and tensile strains ranging from 11.2 to 16.4%. The fracture surface of the dissimilar joints predominantly exhibited a brittle/ductile fracture mode. The sample S1 yielded the maximum hardness value of 200 Hv. Conversely, the lowest hardness value of 141 Hv was recorded for sample S2. As per the results of EIS plots and polarization curves the sample S1 showed the better corrosion resistance than other two samples i.e., S2 and S3.

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  1. Department of Mechanical Engineering, JNTUH College of Engineering Science and Technology Hyderabad, Kukatpally, Telangana, 500085, India

    J. Ashok & A. V. S. S. Kumara Swami Gupta

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Ashok, J., Gupta, A.V.S.S.K.S. Parametric effect on mechanical, microstructural and corrosion behaviour of friction stir welded AA5083-AA7075 alloys. Int J Interact Des Manuf (2024). https://doi.org/10.1007/s12008-024-01850-x

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