Abstract
Through-thickness friction stir welding of 3″ thick 7050-T7451 Al alloy was performed as some aerospace applications require welding of thick sections of high strength Al alloys. Detailed microstructural characterization using scanning (SEM) and transmission electron microscopy (TEM), weld hardness mapping and location-specific mini-tensile testing of all weld zones were carried out. Grain boundary precipitates, intra-grain precipitates size and distribution and precipitate-free zones of various zones were characterized using SEM and TEM. Extensive precipitation along grain and sub-grain boundaries and severe precipitate coarsening were common in all weld zones. A minimum hardness of ~77 HV0.3 was registered in the heat-affected-zone region. Strength values from the location specific mini-tensile tests were similar to mapped weld hardness.
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