Abstract
In this study, feasibility of dissimilar friction-stir welding between an Al-Mg alloy (AA5052-O) and an Al-Cu alloy (AA2024-T4) in the lap joint design was assessed. After establishing a suitable working window in the moderate heat inputs in the term of rotational speed (w) and traverse velocity (v) to attain a defect-free sound dissimilar weld between these alloys, the microstructural characteristics and mechanical properties were evaluated. A hardness loss in the thermo-mechanical-affected zone and heat-affected zone at the AA2024 side was noticed due to over-ageing of precipitates. The most of processed dissimilar welds were failed along the stir zone. Depending on the welding defects, different fractographic aspects were observed. The processing parameters were optimized as w = 1250 rpm and v = 160 mm/min, which its weld failed from the weakest base metal (i.e., AA5052). A joint strength ratio of ~ 99% (strength of~ 200 MPa) and a completely ductile fracture behavior with large dimple-like features were noticed.
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Rafiei, R., Shamanian, M., Fathi, M. et al. Dissimilar friction-stir lap-welding of aluminum-magnesium (AA5052) and aluminum-copper (AA2024) alloys: microstructural evolution and mechanical properties. Int J Adv Manuf Technol 94, 3713–3730 (2018). https://doi.org/10.1007/s00170-017-0964-z
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DOI: https://doi.org/10.1007/s00170-017-0964-z