Friction Stir Welding of Various Aluminium Alloys to Titanium

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Aluminium and titanium are currently in demand as lightweight materials. However, their combination is challenging due to their significantly different thermo-mechanical properties. Here, solid-state joining processes such as Friction Stir Welding open up new opportunities. Within this study, four commercial aluminium alloys (AA2024, AA5754, AA6056 and AA7050) were welded to Ti6Al4V. The results show a direct relationship between the solidus temperature of the aluminium alloys, the process temperature, energy input and resulting lap-shear strength. Regardless of the process parameters, AA5754 and AA6056 with higher solidus temperatures (600 °C and 555 °C) show superior bonding strength compared to AA2024 and AA7050, having a lower solidus temperature of 500 °C and 490 °C, respectively. Therefore, it is assumed that the maximum process temperature, proportional to the solidus temperature, has a major influence on the bonding. This, conversely, would imply that there is a physical limitation in the achievable joint strength between aluminium and titanium alloys as the required process temperature would exceed the solidus temperature of certain alloys. This assumption is verified for AA7050 by systematic variation of the rotation speed and therefore process temperature.
Original languageEnglish
JournalKey Engineering Materials
Pages (from-to)49-54
Number of pages6
Publication statusPublished - 29.11.2023

    Research areas

  • Engineering - aluminium, difussion, friction stir welding, intermetallic, titanium