Microstructure and mechanical characterization of tungsten inert gas-welded joint of AA6061 and AA7075 by friction stir processing

Abstract

In this work, the effect of friction stir processing (FSP) on tungsten inert gas welding (TIG) has been observed to improve mechanical properties and wear resistance behavior of TIG-welded joint of AA7075 and AA6061. The TIG-welded joints were processed by FSP at various tool rotational speeds of 700, 800, 900, 1000, and 1100 r/min with a constant feed rate of 70 mm/min and tilt angle of 1°. The maximum joint efficiency of 92.81% was observed in TIG + FSP-welded joint with filler ER5356 at a rotational tool speed of 1100 r/min. The maximum tensile strength of 284 MPa was observed in TIG + FSP-welded joint with filler ER5356, whereas the minimum tensile strength of 124 MPa was observed in the TIG weldment with filler ER4043. The cleavage facets, tears ridges, and large dimples were observed in fractured specimens of TIG-welded joints, whereas fine and equiaxed dimples were observed in TIG + FSP-welded joints. The maximum micro-hardness of 137 HV in the stir zone was observed in TIG + FSP-welded joint at a rotational tool speed of 1100 r/min. Due to intense precipitate (MgZn2) kept in the stir zone with filler ER5356, the TIG + FSP-welded joints using filler ER5356 have superior wear resistance compared to TIG and TIG + FSP-welded joint with filler ER4043.