Study Fatigue Behavior of Friction Stir Welded Joints for Dissimilar Aluminum Alloys (2024 -T3 and 7020 -T6)


The aim of the present work is to investigate the fatigue behavior of friction stir welded joints for dissimilar aluminum alloys (2024 -T3 and 7020-T6). Friction stir welding (FSW) had been done for 6.6 mm thick plate by using NC milling machine with R18 tool steel of 18mm with shoulder diameter and 6mm pin diameter with different tool designs; threaded cone with double bevel, threaded cylinder with concave shoulder of 4°, and beveled cone with concave shoulder of 4°. FSW were carried out under various welding parameters, travel speed of 40, 50, 75 mm/min, rotation speed range (275-1250) rpm and tilt angle of (Ɵ = 3°) with counterclockwise revolution. Many non- destructive inspections and mechanical tests were performed to evaluate welded joints to determine the best welding parameters. Fatigue test has been done at constant stress amplitude cantilever with stress ratio of (R= -1). The results showed that maximum tensile strength and joint efficiency were 360MPa and 86% respectively for dissimilar joints which were welded at 40mm/min travel speed and 550 rpm rotation speed by using threaded cone with double bevels.