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<p>Novel and original results have been obtained in underwater friction stir welding (UFSW) of AA7075/Ti6Al4V dissimilar lap joints using an FSW tool fabricated of a nickel superalloy. The effects of axial load and tool rotation rate on the morphology of an interface and, consequently, on the lap joint strength have been studied. A combination of high axial forces (2700 to 3600 N) with a low rotation rate (375 RPM) leads to the formation of complicated morphology interfaces, where titanium alloy/intermetallic fragments penetrate the aluminum alloys and provide effective mechanical interlocking that allows withstanding tensile loads as high as 1000 N. Using a low axial force (3000 N) and rotation rates (400 to 450 RPM) results in the formation of a flat interface with a thin intermetallic layer, which additionally reduces the joint strength in the absence of any mechanical interlocking. The underwater FSW allows reducing both the size and quantity of intermetallic compounds, while their morphology depends on the welding regimes. The fact of interest is that the UFSW regimes with a constant rotation rate of 375 RPM and higher axial forces correspond also to higher energy inputs as compared to those with higher rotation rates and a low constant axial force.</p>

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Characterization of dissimilar Ti6Al4V/AA7075 joints produced by underwater friction stir welding

  • 期刊论文

  • 发表日期：

    2025年10月14日

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  • Alihan Amirov,
  • Sergei Tarasov,
  • Andrey Chumaevskii,
  • Nickolai Savchenko,
  • Evgeny Kolubaev

摘要

Novel and original results have been obtained in underwater friction stir welding (UFSW) of AA7075/Ti6Al4V dissimilar lap joints using an FSW tool fabricated of a nickel superalloy. The effects of axial load and tool rotation rate on the morphology of an interface and, consequently, on the lap joint strength have been studied. A combination of high axial forces (2700 to 3600 N) with a low rotation rate (375 RPM) leads to the formation of complicated morphology interfaces, where titanium alloy/intermetallic fragments penetrate the aluminum alloys and provide effective mechanical interlocking that allows withstanding tensile loads as high as 1000 N. Using a low axial force (3000 N) and rotation rates (400 to 450 RPM) results in the formation of a flat interface with a thin intermetallic layer, which additionally reduces the joint strength in the absence of any mechanical interlocking. The underwater FSW allows reducing both the size and quantity of intermetallic compounds, while their morphology depends on the welding regimes. The fact of interest is that the UFSW regimes with a constant rotation rate of 375 RPM and higher axial forces correspond also to higher energy inputs as compared to those with higher rotation rates and a low constant axial force.