Investigation of Friction Stir Welding of AA2024-T4 Thin Sheets for Industrial Applications

Abstract

The welding of aluminum alloys thin sheets is a complicated process no matter what the technology used. A 2024-T4 AL sheets of 1.2mm thickness were welded using stir welding method and then examined for their mechanical and microstructure characteristics. The process included the use of specifically designed fixture along with cylindrical tool. Thin sheets welding of aluminum alloy is a complicated process either in conventional or newly developed methods. In this approach the friction stirs welding (FSW) is used. Tensile test and microstructure test were conducted to analyze final product properties. The cylindrical rotating tool was used to create a joint which is specifically useful in the welding of aluminum alloys in particular. It was found that All tested samples were defects free. Mechanical properties show that ultimate tensile strength of samples is below the base metal. Two rotational speed were applied (900 and 1400) rpm with welding feed rate of (20, 40 and 80) mm/min respectively. The tool has a 1.2mm diameter pin of 1 mm height and 8mm shoulder diameter. A rotation speed of (900) rpm and feed rate of (40) mm/min gave the best quality product in which an increase of (72%) in ultimate tensile strength was observed.