Process envelope and void defect analysis in FSW of AA2024, AA5052 and AA7075 aluminium alloys.
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| Title: | Process envelope and void defect analysis in FSW of AA2024, AA5052 and AA7075 aluminium alloys. |
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| Authors: | Liu, Xinrui1 (AUTHOR) xinrui19@ualberta.ca, Gerlich, Adrian P.2 (AUTHOR), Mendez, Patricio F.1 (AUTHOR) pmendez@ualberta.ca |
| Source: | Science & Technology of Welding & Joining. May/Jun2026, Vol. 31 Issue 3/4, p139-149. 11p. |
| 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. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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