Assessing the role of friction stir welding tool shoulder profile and parameters on mechanical performance of Al5083 weld joints pre- and post-corrosion exposure

Abstract

Al5083 alloy sheets were joined by friction stir welding (FSW) by using three different tools having different shoulder profiles (flat, concave and convex) at three different tool rotational speeds. From the cross-sectional microstructures, weld joints obtained at 1120 rpm with three different shoulder profiles were observed as defect free. XRD analysis confirms the development of texture that was dominated with close packed planes. The weld joint mechanical performance was assessed by conducting tensile tests before and after exposing them to 3.5% NaCl solution for 24 h. Combination of concave shoulder profile with 1120 rpm tool rotational speed has given higher strength in the weld joint, compared with base alloy and the other weld joints. The weld joints produced by using flat and concave shoulder profiles exhibited higher mechanical strength even after corrosion attack compared with the base alloy. From the potentiodynamic polarization studies, the three defect free weld joints (processed at 1120 rpm) were measured with lower corrosion current density. The results demonstrate the promising role of FSW to retain the strength against the corrosion initiated mechanical failure of Al5083 alloy by selecting appropriate combination of the shoulder profile and welding parameters.