Microstructural and corrosion behaviours of dissimilar friction stir welded aluminium alloys

Benjamin I. Attah, Rasaq O. Medupin, Tertsegha D. Ipilakyaa, Uzoma G. Okoro, Oyewole Adedipe, Gowon Sule, Omolayo Michael Ikumapayi*, Katsina C. Bala, Esther T. Akinlabi, Sunday A. Lawal, Asipita S. Abdulrahman

*Corresponding author for this work

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In this study, the friction stir welding (FSW) process was employed to investigate the effect of tool geometry on the corrosion behaviour and microstructure of friction stir welded AA7075-7651 and AA1200-H19 using Central Composite Design. The workpieces were machined and welded, and the interfaces were milled. A 2-level full factorial experimental design was deployed using Response Surface Methodology (RSM). A rotational speed of 1500 rpm, welding speed of 30, 60, and 90 mm/min, and a 2 tilt angle of the tool with a plunge force of 7 kN were utilized. The results show that regardless of the tool geometry, multi-response optimum weldment can be achieved at 60 mm/min welding speed and a tilt angle. The microstructure of the optimal weldments presents an 'onion ring'pattern, indicating proper mixing of the alloys during FSW. Analysis of the corrosion behaviour revealed a decrease in the polarization resistance when the transverse speed increased from 30 to 90 mm/min, as polarization resistance has a direct relationship with corrosion rate. It can be concluded that FSW ensures excellent weldment, as evident in the microstructural evolution of the resulting weldments, and that tool geometry plays a significant role in the corrosion inhibition efficiency of the alloys.

Original languageEnglish
Article number7
Pages (from-to)1-11
Number of pages11
JournalManufacturing Review
Publication statusPublished - 19 Mar 2024

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