Assessment of the Thermomechanical Behavior and Microstructure of AA 7075-T6 Aluminum Alloy Lap Joints at Optimal Predicted FSW Process Parameters

Abstract

The lap joints of AA 7075-T6 aluminum alloy were assembled using the friction stir welding (FSW) technique. Experimental studies were performed to characterize the thermomechanical properties of these welds. The main goal of this research was to comprehensively assess the thermomechanical behavior of AA 7075-T6 aluminum alloy under FSW conditions. Tests were carried out at a tool rotational speed of 1320 rpm and at two advancing speeds of 70 mm/min and 120 mm/min, selected based on a previous study aiming to optimize the heat input during the FSW process. The experimental investigations involved the characterization of temperature profiles during welding, mechanical properties such as microhardness and tensile strength, and microstructure examination at the two advancing speed conditions. This study revealed that the welding speed has an obvious influence on the material thermal behavior during the FSW process. Indeed, the peak temperature obtained with a lower welding speed (70 mm/min) was higher by almost 10% compared to that obtained with a higher speed (120 mm/min). Moreover, by increasing the welding speed, the mechanical characteristics, such as microhardness and tensile strength, were increased by almost 5% for the mean microhardness and 6% for the ultimate tensile strength. Additionally, the microstructure examination demonstrated that, by decreasing the welding speed, more interaction between the tool and the material is observed, resulting in a deeper stir zone due to increased heat dissipation downwards into the material, affecting the thermal profile and influencing the resulting mechanical properties of the welded joint.