Strengthening strategy for high-performance friction stir lap welded joints based on 5083 Al alloy

Yujia Shen; Jijie Wang; Beibei Wang; Peng Xue; Fengchao Liu; Dingrui Ni; Bolv Xiao; Zongyi Ma

doi:10.1007/s12613-024-2847-2

Volume 31 Issue 11

Nov. 2024

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Article Navigation > International Journal of Minerals, Metallurgy and Materials > 2024 > 31(11): 2498-2507

Yujia Shen, Jijie Wang, Beibei Wang, Peng Xue, Fengchao Liu, Dingrui Ni, Bolv Xiao, and Zongyi Ma, Strengthening strategy for high-performance friction stir lap welded joints based on 5083 Al alloy, Int. J. Miner. Metall. Mater., 31(2024), No. 11, pp. 2498-2507. https://doi.org/10.1007/s12613-024-2847-2

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Yujia Shen, Jijie Wang, Beibei Wang, Peng Xue, Fengchao Liu, Dingrui Ni, Bolv Xiao, and Zongyi Ma, Strengthening strategy for high-performance friction stir lap welded joints based on 5083 Al alloy, Int. J. Miner. Metall. Mater., 31(2024), No. 11, pp. 2498-2507. https://doi.org/10.1007/s12613-024-2847-2

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Research Article

Strengthening strategy for high-performance friction stir lap welded joints based on 5083 Al alloy

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Corresponding authors:
Beibei Wang E-mail: bbwang@imr.ac.cn

Peng Xue E-mail: pxue@imr.ac.cn
Received: 10 November 2023; Revised: 12 January 2024; Accepted: 4 February 2024; Available online: 6 February 2024

Abstract

Abstract

During aircraft, ship, and automobile manufacturing, lap structures are frequently produced among Al alloy skins, wall panels, and stiffeners. The occurrence of welding defects severely decreases mechanical properties during friction stir lap welding (FSLW). This study focuses on investigating the effects of rotation rate, multipass welding, and cooling methods on lap defect formation, microstructural evolution, and mechanical properties. Hook defects were eliminated by decreasing welding speed, applying two-pass FLSW with a small welding tool, and introducing additional water cooling, thus leading to a remarkable increase in effective sheet thickness and lap width. This above strategy yielded defect-free joints with an ultrafine-grained microstructure and increased tensile shear force from 298 to 551 N/mm. The fracture behavior of FSLW joints was systematically studied, and a fracture factor of lap joints was proposed to predict their fracture mode. By reducing the rotation rate, using two-pass welding, and employing additional water cooling strategies, an enlarged, strengthened, and defect-free lap zone with refined ultrafine grains was achieved with a quality comparable to that of lap welds based on 7xxx Al alloys. Importantly, this study provides a valuable FSLW method for eliminating hook defects and improving joint performance.
- friction stir lap welding;
- defect control;
- microstructure;
- fracture mechanisms;
- mechanical properties

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