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<p>The growing demand for lightweight, high-strength materials in electric vehicles highlights the significance of aluminium research. This study explores friction stir welding (FSW) of AA5083 and AA7075 alloys in a butt joint configuration, using a traverse speed of 100&#xa0;mm/min and rotational speeds of 800, 1000, and 1200&#xa0;rpm. Microstructural and mechanical properties were analyzed using OM, SEM, XRD, and EDS, alongside tensile testing, nanoindentation, and corrosion studies. Base metals exhibited distinct grain sizes—AA5083 (45&#xa0;µm) and AA7075 (20&#xa0;µm)—with varying precipitates. The stir zone (SZ) showed significant grain refinement (5&#xa0;µm at 800&#xa0;rpm, 8&#xa0;µm at 1200&#xa0;rpm). Joints achieved UTS values of 162–205&#xa0;MPa, with elongations of 11.1–16.3%. Fracture surfaces displayed mixed brittle-ductile behaviour. XRD analysis confirms the presence of IMCs such as Mg<sub>2</sub>Si, Al<sub>3</sub>Mg<sub>2</sub>, Al<sub>2</sub>Fe<sub>3</sub>Si<sub>4</sub>, and AlFe<sub>2</sub>Mn in the SZ of all welded specimens, with enhanced hardness (S1: 2.2 GPa, S2:2.3 GPa, and S3:2.6 GPa) due to increased IMC formation. Corrosion resistance was also evaluated, revealing the influence of IMCs on joint integrity. These findings contribute to optimizing FSW parameters for high-performance aluminium joints in EV applications.</p>

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Effects of processing parameter on mechanical, metallurgical, and corrosion characteristics of dissimilar AA5083-AA7075 alloy through friction stir welding

  • 期刊论文

  • 发表日期：

    2025年11月4日

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  • J. Ashok,
  • A. V. S. S. Kumara Swami Gupta

摘要

The growing demand for lightweight, high-strength materials in electric vehicles highlights the significance of aluminium research. This study explores friction stir welding (FSW) of AA5083 and AA7075 alloys in a butt joint configuration, using a traverse speed of 100 mm/min and rotational speeds of 800, 1000, and 1200 rpm. Microstructural and mechanical properties were analyzed using OM, SEM, XRD, and EDS, alongside tensile testing, nanoindentation, and corrosion studies. Base metals exhibited distinct grain sizes—AA5083 (45 µm) and AA7075 (20 µm)—with varying precipitates. The stir zone (SZ) showed significant grain refinement (5 µm at 800 rpm, 8 µm at 1200 rpm). Joints achieved UTS values of 162–205 MPa, with elongations of 11.1–16.3%. Fracture surfaces displayed mixed brittle-ductile behaviour. XRD analysis confirms the presence of IMCs such as Mg2Si, Al3Mg2, Al2Fe3Si4, and AlFe2Mn in the SZ of all welded specimens, with enhanced hardness (S1: 2.2 GPa, S2:2.3 GPa, and S3:2.6 GPa) due to increased IMC formation. Corrosion resistance was also evaluated, revealing the influence of IMCs on joint integrity. These findings contribute to optimizing FSW parameters for high-performance aluminium joints in EV applications.