Friction stir welding of aluminium hollow extrusion: Weld formation and mechanical properties

Abstract

Novel friction stir welding (FSW) technique, characterised by big concave upper and small convex lower shoulders, for aluminium hollow extrusion was studied. Assisted with the lower shoulder, root flaws due to the lack of tool penetration have been eliminated. The tensile strength increased with increasing welding speed. As the welding speed increases from 50 to 200 mm min⁻¹, the width of the welding nugget zone (WNZ) decreases, and the ductile fractured location occurred at WNZ instead of heat affected zone (HAZ) adjacent to thermomechanically affected zone (TMAZ). The interface between the TMAZ and HAZ exhibited the lowest microhardness. The results indicated that the novel FSW method has the potential to join tubular structures and hollow profiles widely used in transportation industries.