Friction Stir Welding of AA2024-T3 plate – the influence of different pin types

Abstract. Some aluminium alloys are difficult to join using traditional fusion (melting and solidification) welding techniques. Friction Stir Welding (FSW) is a solid-state welding technique that can join two plates of material without melting the workpiece material. This proecess uses a rotating tool to create the joint and it can be applied to alumium alloys in particular. Macrostructure, microstructure and micro hardness of friction stir welded AA2024-T3 joints were studied. The influence of tool pin profile on the microstructure and hardness of these joints was examined. Square, triflute and tapered cylinder pins were used and results from each weldment are reported. Vickers micro hardness tests and grain size measurements were taken from the transverse plane of welded samples. Distinct zones in the macrostructure were evident. The zones were identified by transitions in the microstructure and hardness of weld samples. The zones identified across the sample were the the unaffected parent metal, the Heat Affected Zone (HAZ), the Thermo-Mechanicaly Affected Zone (TMAZ), and the Nugget Zone (NZ). Measured hardness values varied through each FSW zone. The hardness in each zone was below that of the parent material. The HAZ had the lowest hardness across the weld profile for each pin type tested. The cylindrical pin consistently produced tunnel and joint-line defects. Pin profiles with flat surface features and/or flutes produced consolidated joints with no defects.