Use of threaded cylindrical pin tools to reduce macroscopic defects in dissimilar welded joints of AA7075-T6 and AZ31B alloys by the FSW process

Abstract

The continued increase in greenhouse gas emissions has had dire consequences for the global climate. In order to reduce such emissions, several efforts have been made by researchers in the transport sector, such as the development of electric motorization, the development of hybrid engines, the use of biofuels and the use of light alloys. The use of light alloys such as aluminum and magnesium in vehicles can reduce the emission per kilogram of vehicles drastically, however, it is still necessary to develop effective and more agile methods of the dissimilar joints of these materials. Some authors have studied the friction stir welding of AZ31B magnesium alloys and AA7075-T6 aluminum alloys in order to determine better process parameters to enable this bond, however, few articles have been published in order to evaluate the influence of tool geometry on such properties. In this sense, this article aims to evaluate the influence of friction welding tool pin geometry as smooth cylindrical pin, threaded cylindrical pin, conical and hexagonal pin configurations in the formation of the mixed zone of welds manufactured by the FSW process. For this purpose, AZ31B and AA7075-T6 alloys were welded by FSW with welding speed of 75 mm/min, tool rotation speed of 565 rpm, offset of 0.5mm and inclination of the tool geometry in relation to the plates to be welded of 3º, the joints were evaluated for their macro and microstructures and Vickers hardness with a load of 100 gf. It was possible to observe that the joints welded with the threaded cylindrical pin tool presented stir zones free of macroscopic defects, similar hardness values for the four tools studied and the presence of a thin layer of intermetallics between TMAZ and SZ on the AZ31B side.