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Influences of Process Parameters on Morphology and Mechanical Properties of FSW-T-Joint of 2024/5083 Al Alloy Sheets

  • Research Article-Mechanical Engineering
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Abstract

T-joints of dissimilar Al alloys are mainly prepared by mechanical connection in industry, which significantly increases the structural weight and is prone to stress concentration. In this paper, friction stir welding (FSW) technology was used to fabricate the T-joint consisting of 2024-T4 (skin) and 5083-O (stringer), and influences of process parameters on morphology and mechanical properties were investigated. In addition, the integrity and fracture characteristics of the welded joint were studied. The results showed that tunnel defects were easy to form at lower rotation speed or higher welding speed (V). Increasing the rotation speed (N) was instrumental in eliminating the tunnels, promoting the full mixing of the materials and forming "onion ring" structure; EBSD results show that the grain of the weld was obviously refined, and the dynamic recrystallization in the upper region is more sufficient than the lower region. The defects of fillet weld affected the mechanical properties of stringer whose fracture feature was ductile shear fracture, but the strength of the skin was not influenced by the defects and its fracture mode was dimple fracture. Ultimate tensile strength along the skin was up to 86% (403 MPa) of the base metal (BS) when N/W = 1200/60; Ultimate tensile load along the stringer was up to 118% (4575 N) of the BS when N/V = 1200/20. In summary, the reliable T-connection of dissimilar aluminum alloys required more heat input and the large fillet radius will improve the reliability of the connection although it narrowed the process window.

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Funding

We are grateful for the financial support from the Funding of JiangSu Innovation Program for college student (Grant No. 202110287046Z).

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Authors and Affiliations

  1. College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, 29 Jiangjun Road, Nanjing, 210016, People’s Republic of China

    Tao Sun, Yifu Shen, Ruiyang Ni, Wentao Hou, Yinfei Yan & Fujun Cao

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  1. Tao Sun
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  2. Yifu Shen
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Correspondence to Yifu Shen.

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Sun, T., Shen, Y., Ni, R. et al. Influences of Process Parameters on Morphology and Mechanical Properties of FSW-T-Joint of 2024/5083 Al Alloy Sheets. Arab J Sci Eng 47, 15195–15208 (2022). https://doi.org/10.1007/s13369-021-06494-7

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