Weld distortion and thinning critically affect the quality of friction stir welded (FSW) thin-walled sheets. Here, in-situ rolling FSW (IRFSW) was proposed to join 7075-T6 sheets with co-controlling distortion and weld thinning. The novel IRFSW tool was composed of inner and outer double-shoulders and circumferential rolling balls. The double-shoulder structure suppresses material overflow and the rolling balls regulate surface residual stress. The IRFSW process produced defect-free joints with minimal thinning (0.03 mm), whose surface finish was improved by 80.7%, and the longitudinal and transverse distortions of the IRFSW joint were reduced by 83.7% and 62.1% compared with those of the conventional joints. The ultimate tensile strength of the IRFSW joint reached 483 ± 2 MPa, retaining 86.1% of the base material's tensile strength. This study will provide powerful technical strategy and theoretical support for achieving low distortion and micro-thinning friction stir welding of thin sheets.
JiSWangJZhangZ, et al.Achievement of nearly-equal-strength repaired exceeded tolerance hole of 2024 aluminum alloy by ultrasonic-assisted radial-additive friction stir repairing. Chinese J Aeronaut2025; 38: 103620.
6.
ZhangZLuKJiS, et al.A novel reverse-flow friction stir lap welding of 2024 aluminum alloys based on a right-left thread X-shape pin. J Mater Sci Technol2025; 228: 92–106.
7.
GaoCYuHGuB, et al.The deformation analysis of friction stir welding with different clamping distances for large thin-walled joints. Sci Technol Weld Join2023; 28: 415–423.
KimYGFujiiHTsumuraT, et al.Three defect types in friction stir welding of aluminum die casting alloy. Mater Sci Eng A2006; 415: 250–254.
10.
SattariSBisadiHSajedM. Mechanical properties and temperature distributions of thin friction stir welded sheets of AA5083. Int J Mech Appl2012; 2: –6.
11.
KimKHBangHSKaplanAFH. Joint properties of ultra thin 430M2 ferritic stainless steel sheets by friction stir welding using pinless tool. J Mater Process Technol2017; 243: 381–386.
12.
ScialpiADe GiorgiMDe FilippisLAC, et al.Mechanical analysis of ultra-thin friction stir welding joined sheets with dissimilar and similar materials. Mater Des2008; 29: 928–936.
13.
HuangYMengXXieY, et al.Improving mechanical properties of composite/metal friction stir lap welding joints via a taper-screwed pin with triple facets. J Mater Process Technol2019; 268: 80–86.
14.
WuHChenYCStrongD, et al.Stationary shoulder FSW for joining high strength aluminum alloys. J Mater Process Technol2015; 221: 187–196.
15.
SejaniDLiWPatelV. Stationary shoulder friction stir welding – low heat input joining technique: a review in comparison with conventional FSW and bobbin tool FSW. Crit Rev Solid State Mater Sci2022; 47: 865–914.
16.
YangKNianSJiS, et al.Research on ultrasonic-stationary shoulder assisted friction stir lap welding of thermoplastic polymer and aluminum alloy. Compos Part B Eng2024; 286: 111797.
17.
ZhangHWangMZhouW, et al.Microstructure-property characteristics of a novel non-weld-thinning friction stir welding process of aluminum alloys. Mater Des2015; 86: 379–387.
18.
MarquesMJRamasamyABatistaAC, et al.Effect of heat treatment on microstructure and residual stress fields of a weld multilayer austenitic steel clad. J Mater Process Technol2015; 222: 52–60.
19.
ZhouGLiuXJinC, et al.Welding deformation controlling of aluminum-alloy thin plate by two-direction pre-stress method. Mater Sci Eng A2009; 499: 147–152.
20.
WenSWColegrovePAWilliamsSW, et al.Rolling to control residual stress and distortion in friction stir welds. Sci Technol Weld Join2010; 15: 440–447.
21.
AltenkirchJSteuwerAWithersPJ, et al.Residual stress engineering in friction stir welds by roller tensioning. Sci Technol Weld Join2009; 14: 185–192.
22.
DengQFuRJingL, et al.Influence of cold-rolling and annealing treatments on microstructure and mechanical properties of friction stir-welded Al–Cu joints. Sci Technol Weld Join2016; 21: 614–623.
23.
IlmanMNMuslihMRPriyantoTH, et al.Diminishing residual stress and distortion by in-situ rolling tensioning to increase fatigue performance of friction stir welded AA2024-T3 joints. Int J Fatigue2025; 190: 108659.
24.
HuangYXieYChenJ, et al.Wire-based friction stir additive remanufacturing of 2219 aluminum alloy components. Int J Adv Manuf Technol2025; 137: 6029–6041.
25.
HuangYWanLLvS, et al.In situ rolling friction stir welding for joining AA2219. Mater Des2013; 50: 810–816.
26.
HuangYXWanLLvSX, et al.New technique of in situ rolling friction stir welding. Sci Technol Weld Join2012; 17: 636–642.
27.
WangWMengXXieY, et al.High corrosion resistance of aluminum alloy friction stir welding joints via in situ rolling. Coatings2024; 14: 1604.
28.
Avettand-FenoelM-NTaillardR. Heterogeneity of the nugget microstructure in a thick 2050 Al friction-stirred weld. Metall Mater Trans A2015; 46: 300–314.
29.
GallaisCDenquinABréchetY, et al.Precipitation microstructures in an AA6056 aluminium alloy after friction stir welding: characterisation and modelling. Mater Sci Eng A2008; 496: 77–89.
30.
SchmidtHHattelJWertJ. An analytical model for the heat generation in friction stir welding. Model Simul Mater Sci Eng2004; 12: 143–157.
31.
SunHZhangWLiQ, et al.Deformation behavior and microstructure evolution of Al-Zn-Mg-Cu alloy under low-frequency vibration-assisted compression: considering the relative amplitude. J Mater Process Technol2024; 330: 118487.
32.
ChenJMiuraTUshiodaK, et al.Elucidating the role of ordered phases and carbides in the mechanical performance of friction stir welded high aluminum low-density ferrite steels. J Mater Process Technol2025; 343: 118959.
33.
XieRChenPShiY, et al.Effect of feeding material shape on microstructures and mechanical properties in friction rolling additive manufacturing. Mater Des2024; 241: 112952.
34.
WangXXiaoZZhouT, et al.Deformation mechanism and properties evolution of a copper alloy with ultra-high strength after cold drawing and subsequent aging treatment. Mater Sci Eng A2024; 912: 146952.
35.
HuXZhaoHNiS, et al.Grain refinement and phase transition of commercial pure zirconium processed by cold rolling. Mater Charact2017; 129: 149–155.
36.
GuoFDuanSPanY, et al.Stress corrosion behavior and microstructure analysis of al-zn-mg-cu alloys friction stir welded joints under different aging conditions. Corros Sci2023; 210: 110821.
37.
SidharHMishraRS. Aging kinetics of friction stir welded Al-Cu-Li-Mg-Ag and Al-Cu-Li-Mg alloys. Mater Des2016; 110: 60–71.
38.
CaiBZhengZQHeDQ, et al.Friction stir weld of 2060 Al-Cu-Li alloy: microstructure and mechanical properties. J Alloys Compd2015; 649: 19–27.
39.
ChenYCFengJCLiuHJ. Precipitate evolution in friction stir welding of 2219-T6 aluminum alloys. Mater Charact2009; 60: 476–481.
40.
HansenN. Hall–Petch relation and boundary strengthening. Scr Mater2004; 51: 801–816.
Supplementary Material
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
