TWI

An investigation is presented into the processing window for friction stir welding (FSW) of Formall 545 (equivalent to AA-5083) to age-hardened AA-6082 aluminium alloys with regard to tool rotation and traverse speeds, and into an evaluation of a number of influencing factors, including the presence of voids and flaws, microstructural variations related to softening in the TMAZ (thermomechanically affected zone) and HAZ, and residual stress distribution (as determined by synchrotron X-ray diffraction). FSW trials were conducted on butt joints between 3 mm sheet work pieces using a modified milling machine at rotation speeds of 280-840 rpm and traverse speeds of 100-300 mm/min. Weld microstructure, hardness and residual stress distributions were determined. The experimental data were rationalised with respect to the forces acting on the tool, the heat input and the temperature cycle during welding.

6th International Symposium, 10-13 Oct 2006, Session 9A: Properties, Paper 03