Influence of distinct tool pin geometries on aluminum 8090 FSW joint properties

Abstract

Aluminum Lithium alloys are recuperating substantial interest from automotive and aerospace industries owing to their extraordinary specific strength as compared to conventional aluminum (2xxx, 6xxx, and 7xxx) alloys. The goal of the present investigation is to study AA 8090 joints produced with the unique solid-state welding technique friction stir welding (FSW). Tool pin profile induces remarkable influence on friction and further plastic deformation during FSW. Therefrom, the influences of three distinct but constant dynamic area conditioned tool pin geometries namely, square trapezoidal, hexagonal trapezoidal, and threaded taper on the resulting material flow patterns, mechanical properties, and the microstructure have been studied and discussed in detail. The FSW joint produced with hexagonal trapezoidal pin geometry delivered the highest joint resistance owing to grain refinement and almost flawless microstructure.