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An investigation was carried out in order to examine the feasibility of producing friction stir welded FSW T-joints using the corner fillet geometry. A specific tool comprising a rotating pin (made of MP159) with a 45 degree inclination to the two parts being welded and no shoulder rotation was developed for the work. Two tools were produced for the experiments with different surface areas in order to produce differing contact conditions during welding. The shoulder and shaft components of the tool were of H13 tool steel. FSW were produced in commercial AA2024 plates (Al, 3.8-4.2%Cu, 1.2-1.8%Mg, 0.3-0.9%Mn). Plates of 120 mm in height, 240 mm long and 6 mm thickness were welded on 240 mm square plates of 8 mm thickness. A total of 32 test were performed with spindle speed 1000-2000 rpm, traverse speed from 50 to 600 mm/min and axial force 6-15 kN. Tilt angle and pin length were also varied. Temperature measurements were taken during some of the tests and metallographic inspection was performed on cross-sections of all welded specimens. A 3D FE model was implemented in order to compare experimental and predicted temperatures in the base and straightening panels.

8th International Symposium, 18-20 May 2010, Session 4A: Process Development, Paper 04