Effect of Friction Stir Welding Mode and its Direction Relative to the Rolling Direction of 2024 Alloy on the Structure and Mechanical Properties of its Weld Joints

Introduction. Friction stir welding conditions determines character of thermomechanical impact on welded material, so a critical alteration of even one of condition parameters can result in formation of defects and strength decrease of welded joint. Also an important factor is an orientation of welded material relative to a welding direction since it determines kinetics of material deformation and consequently its final structure and properties. Research efforts of friction stir welding properties generally consist in analysis of final properties of obtained weld joints and its correlation with parameters of welding condition. But to solve a problem of obtaining of weld joints with strength and quality, it’s also important to estimate a welded material resistance to deformation from welding tool impact which could be achieved by monitoring a number of parameters directly in process of welding. The purpose of the work is to research an impact of welding condition parameters and an orientation of welded material’s structure on friction stir welding process behavior and also on structure and strength of weld joints of 2024 aluminum alloy. Results and discussion. By monitoring the torque and welding force, it is shown that as the tool penetration force increases, the material's resistance to deformation increases. When welding is longitudinal to the direction of base metal rolling a torque and a welding force parameters decreases in value of 5-20%. An increase of welding speed provides a growing of material resistance to welding tool movement, at that, a direction of welding doesn’t have a significant impact. With an increase of welding tool rotational speed, a material resistance to deformation decreases, a welding temperature grows and it results in growing of material’s plasticization degree and in improvement of its mass transfer conditions. It is also shown that the welding conditions, which allows welding the 2024 alloy at a temperature of 450 – 500 ºС, provides the degree of plasticization of the material, at which welded joints with a high-quality structure and high mechanical properties are obtained. In this conditions a direction of welding in relation to the direction of base metal rolling has an impact: when welding is longitudinal to the direction of rolling the tensile strength of weld joints reaches a value of 92%, and when welding is transverse - 95% of base material tensile strength.