Friction stir welding of AA5456 aluminium alloy with different thicknesses was investigated for single- and double-pass lap joint configurations. The influences of tool tilt angle in first and second passes, and rotational and welding speeds in second pass on metallurgical structure and joint strength were studied. The results indicated that tilt angle significantly influences material flow and imperfection formation, and accordingly controls the weld mechanical properties. The best results were achieved by tilt angle of 5° for single pass, and tilt angle, rotational speed and traverse speed of 5°, 250 rev min− 1 an 50 mm min− 1 respectively for double-pass. The characteristics of hooking and cold lap defects were used as criteria to recognise the influence of processing conditions on joint performance.
BirolY. and KasmanS.: ‘Effect of welding parameters on microstructure and mechanical properties of friction stir welded EN AW 5083 H111 plates’, Mater. Sci. Technol., 2013, 29, 1354–1362.
2.
FondaR., PaoP., JonesH., FengC., ConnollyB. and DavenportA.: ‘Microstructure, mechanical properties, and corrosion of friction stir welded Al 5456’, Mater. Sci. Eng. A, 2009, A519, 1–8.
3.
BirolY.: ‘Evolution of grain structure across joints in friction stir welded EN AW 5083 H111 plates during thermal exposure’, Mater. Sci. Technol., 2013, 29, 1283–1289.
4.
BozkurtY., SalmanS. and ÇamG.: ‘Effect of welding parameters on lap shear tensile properties of dissimilar friction stir spot welded AA 5754-H22/2024-T3 joints’, Sci. Technol. Weld. Join., 2013, 18, 337–345.
5.
İpekog˘luG., ErimS. and ÇamG.: ‘Investigation into the influence of post-weld heat treatment on the friction stir welded AA6061 Al-alloy plates with different temper conditions’, Metall. Mater. Trans. A, 2014, 45A, 864–877.
6.
ÇamG., GüçlüerS., ÇakanA. and SerindagH.: ‘Mechanical properties of friction stir butt-welded Al-5086 H32 plate’, Materialwiss. Werkstofftech., 2009, 40, 638–642.
7.
SimarA., BréchetY., de MeesterB., DenquinA., GallaisC. and PardoenT.: ‘Integrated modeling of friction stir welding of 6xxx series Al alloys: process, microstructure and properties’, Prog. Mater. Sci., 2012, 57, 95–183.
8.
İpekog˘luG. and ÇamG.: ‘Effects of initial temper condition and postweld heat treatment on the properties of dissimilar friction-stir-welded joints between AA7075 and AA6061 aluminum alloys’, Metall. Mater. Trans. A, 2014, 45A, 3074–3087.
9.
İpekog˘luG., ErimS. and ÇamG.: ‘Effects of temper condition and post weld heat treatment on the microstructure and mechanical properties of friction stir butt-welded AA7075 Al alloy plates’, Int. J. Adv. Manuf. Technol., 2014, 70, 201–213.
10.
ÇamG. and MistikogluS.: ‘Recent developments in friction stir welding of Al-alloys’, J. Mater. Eng. Perform., 2014, 23, 1936–1953.
11.
ÇamG., IpekogluG. and Tarik SerindagH.: ‘Effects of use of higher strength interlayer and external cooling on properties of friction stir welded AA6061-T6 joints’, Sci. Technol. Weld. Join., 2014, 19, 715–720.
12.
BuffaG., CampanileG., FratiniL. and PriscoA.: ‘Friction stir welding of lap joints: influence of process parameters on the metallurgical and mechanical properties’, Mater. Sci. Eng. A, 2009, A519, 19–26.
13.
BabuS., RamG., VenkitakrishnanP., ReddyG. and RaoK.: ‘Microstructure and mechanical properties of friction stir lap welded aluminum alloy AA2014’, J. Mater. Sci. Technol., 2012, 28, 414–426.
14.
YadavD. and BauriR.: ‘Microstructural characterisation of friction stir processed aluminium’, Mater. Sci. Technol., 2011, 27, 1163–1169.
15.
EbnonnasirA., KarimzadehF. and EnayatiM.: ‘Novel artificial neural network model for evaluating hardness of stir zone of submerge friction stir processed Al 6061-T6 plate’, Mater. Sci. Technol., 2011, 27, 990–995.
BisadiH., TavakoliA., Tour SangsarakiM. and Tour SangsarakiK.: ‘The influences of rotational and welding speeds on microstructures and mechanical properties of friction stir welded Al5083 and commercially pure copper sheets lap joints’, Mater. Des., 2013, 43, 80–88.
18.
DubourgL., MeratiA. and JahaziM.: ‘Process optimisation and mechanical properties of friction stir lap welds of 7075-T6 stringers on 2024-T3 skin’, Mater. Des., 2010, 31, 3324–3330.
19.
WangM., ZhangH., ZhangJ., ZhangX. and YangL.: ‘Effect of pin length on hook size and joint properties in friction stir lap welding of 7B04 aluminum alloy’, J. Mater. Eng. Perform., 2014, 23, (5), 1881–1886.
20.
ThreadgillP., LeonardA., ShercliffH. and WithersP.: ‘Friction stir welding of aluminium alloys’, Int. Mater. Rev., 2009, 54, 49–93.
21.
YangQ., LiX., ChenK. and ShiY.: ‘Effect of tool geometry and process condition on static strength of a magnesium friction stir lap linear weld’, Mater. Sci. Eng. A, 2011, A528, 2463–2478.
22.
CederqvistL. and ReynoldsA.: ‘Factors affecting the properties of friction stir welded aluminum lap joints’, Weld. J., 2001, 80, 281–287.
23.
AWS D17.3/D17.3M:2010: ‘Specification for friction stir welding of aluminum alloys for aerospace applications’, 2009, Miami, FL, American Welding Society.
24.
CaoX. and JahaziM.: ‘Effect of tool rotational speed and probe length on lap joint quality of a friction stir welded magnesium alloy’, Mater. Des., 2011, 32, 1–11.
25.
YadavaM., MishraR., ChenY., CarlsonB. and GrantG.: ‘Study of friction stir joining of thin aluminium sheets in lap joint configuration’, Sci. Technol. Weld. Join., 2010, 15, 70–75.
26.
WanL., HuangY., WangY., LvS. and FengJ.: ‘Friction stir welding of aluminium hollow extrusion: weld formation and mechanical properties’, Mater. Sci. Technol., 2014, 1–10.
27.
ZhaoY.-H., LinS.-B., QuF.-X. and WuL.: ‘Influence of pin geometry on material flow in friction stir welding process’, Mater. Sci. Technol., 2006, 22, 45–50.
28.
ArbegastW.: ‘A flow-partitioned deformation zone model for defect formation during friction stir welding’, Scr. Mater., 2008, 58, 372–376.
29.
MenzemerC. and SrivatsanT.: ‘The effect of environment on fatigue crack growth behavior of aluminum alloy 5456’, Mater. Sci. Eng. A, 1999, A271, 188–195.
30.
IpekogluG., ErimS., KiralB. and ÇamG.: ‘Investigation into the effect of temper condition on friction stir weldability of AA6061 Al-alloy plates’, Kovove Mater., 2013, 51, 155–163.
31.
İpekog˘luG., Gören KıralB., ErimS. and ÇamG.: ‘Investigation of the effect of temper condition on friction stir weldability of AA7075 Al-alloy plates’, Mater. Technol., 2012, 46, 627–632.
32.
CantinG., DavidS., ThomasW., Lara-CurzioE. and BabuS.: ‘Friction skew-stir welding of lap joints in 5083-0 aluminium’, Sci. Technol. Weld. Join., 2005, 10, 268–280.
