An investigation on mechanical and microstructural evolution of stationary shoulder friction stir welded aluminum alloy AA7075-T651

The stationary shoulder friction stir welding (SSFSW) technique promotes new opportunities for welding material. In the current work, a special setup of SSFSW was designed and manufactured in only three parts according to the homemade friction stir welding (FSW) machine dimensions and specifications. This setup with minimum parts is easily adjustable beside it facilitates fast control of the tool pin length. This gives the design more advantages than the previous designs published for the same purpose. Two different parameters were used with the SSFSW setup to butt weld samples of AA7075-T6 of 5 mm thick. Various welding travel speeds of 25, 50 mm/min, and 75 mm/min and different values of Z-force of 20, 25 KN, and 50 KN were used to evaluate the effect of the SSFSW parameters on the joints’ quality and properties. The results confirmed that sound joints were produced without internal or surface defects. In addition, the joints are characterized with a smooth surface finish compared to the conventional FSW joints. A narrow heat affected zone around the nugget due to the elimination of heat generation by the shoulder. The tensile strength of welded samples increases with increasing the vertical force with the maximum tensile strength of 418.7 MPa at a rotational speed of 600 r/min, a welding speed of 50 mm/min, and 50 KN Z-force. This implies that the vertical applied force upon SSFSW is an important parameter in controlling the joint properties. Analysis of the hardness distribution across the weld cross-section shows slight reduction in the heat affected zone.