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Optimizing the welding performance of 2024-T351 aluminum alloy through friction stir welding technology

Ali Aenas Laith, Naif Sara Kareem

Archives of Engineering Knowledge

2024

T. 10, Nr 1

125--129

This study investigates the impact of friction stir welding (FSW) parameters, specifically the rotational speed of the welding tool and the linear welding speed, on the bonding efficiency and mechanical performance of high-strength aluminum alloy joints. The research focuses on alloy 2024-T351, with a thickness of 7.1 mm, widely utilized in aerospace applications due to its excellent strength-to-weight ratio. However, welding this alloy using conventional fusion methods such as TIG, MIG, and laser welding presents considerable challenges, includ ing the formation of defects and loss of mechanical properties.To overcome these limitations, FSW was employed using a conventional milling machine, with two rotational speeds (800 and 1100 RPM) and three linear welding speeds (28, 40, and 56 mm/min). Tensile test specimens were prepared according to standard procedures, and tensile tests were conducted at room temperature to evaluate the welded joints’ mechanical integrity. The obtained results were compared with the tensile strength of the base metal to determine bonding efficiency. The findings revealed that increasing the rotational speed while reducing the linear welding speed negatively impacted the tensile strength and bonding efficiency of the joints. However, improved ductility was observed at specific speed combinations, indicating an optimal balance between heat input and material flow. The highest bonding efficiency of 87.4% was achieved at a rotational speed of 800 RPM and a linear speed of 28 mm/min, highlighting the importance of precise parameter selection for enhancing weld quality in alloy 2024-T351.