Process envelope and void defect analysis in FSW of AA2024, AA5052 and AA7075 aluminium alloys.

IF 2.9 3区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Science and Technology of Welding and Joining Pub Date : 2026-01-09 eCollection Date: 2026-05-01 DOI:10.1177/13621718251413024

Xinrui Liu, Adrian P Gerlich, Patricio F Mendez

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引用次数: 0

Abstract

This article investigates void defect formation in friction stir welding (FSW) of AA2024, AA5052 and AA7075. A total of 159 bead-on-plate welds were performed with real-time monitoring of temperature, force and spindle power. Travel speeds from 25 to 500 mm/min and tool rotation speeds from 300 to 1500 RPM were investigated. Process maps identified critical parameter ranges for different void defects. A new method was proposed to estimate torque from spindle power. Results show that high temperatures ( $> 0.7 T_{solidus}$ ) are necessary but not sufficient for defect-free welds. Torque thresholds can distinguish cavity from tunnel and groove defects, while power input below 1000 W (AA2024) or 1050 W(AA7075) is generally necessary and sufficient to avoid voids. These findings enable real-time defect monitoring and process optimisation in FSW.

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AA2024、AA5052和AA7075铝合金FSW的工艺包络和空洞缺陷分析。

研究了AA2024、AA5052和AA7075搅拌摩擦焊中空洞缺陷的形成。在实时监测温度、受力和主轴功率的情况下，共进行了159次板上焊。行程速度为25 ~ 500mm /min，刀具转速为300 ~ 1500rpm。工艺图确定了不同空洞缺陷的关键参数范围。提出了一种从主轴功率估计转矩的新方法。结果表明，对于无缺陷焊缝，高温（> ~ 0.7 T固相）是必要的，但还不够。扭矩阈值可以区分空洞、隧道和沟槽缺陷，而低于1000 W（AA2024）或1050 W（AA7075）的功率输入通常是必要的，足以避免空洞。这些发现使FSW中的实时缺陷监控和过程优化成为可能。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Science and Technology of Welding and Joining 工程技术-材料科学：综合

CiteScore

6.10

自引率

12.10%

发文量

审稿时长

1.7 months

期刊介绍： Science and Technology of Welding and Joining is an international peer-reviewed journal covering both the basic science and applied technology of welding and joining. Its comprehensive scope encompasses all welding and joining techniques (brazing, soldering, mechanical joining, etc.) and aspects such as characterisation of heat sources, mathematical modelling of transport phenomena, weld pool solidification, phase transformations in weldments, microstructure-property relationships, welding processes, weld sensing, control and automation, neural network applications, and joining of advanced materials, including plastics and composites.