Abstract
Alclad 2024-T4 aluminum alloy was successfully joined by friction stir lap welding (FSLW) assisted by external stationary shoulder in the present study. Joint surface appearances, cross-sections, microstructure and lap shear failure loads of the joints were mainly studied. The assisted external stationary shoulder is beneficial to the joint formation, by which arc corrugation, flash and void can be eliminated or diminished. Compared with the conventional FSLW joints, FSLW joints assisted by external stationary shoulder own smaller effective sheet thickness of cold lap (ESTC), bigger effective lap width (ELW) and better lap shear failure strength. Lap shear failure loads of the FSLW joints assisted by external stationary shoulder do not agree with ESTC or ELW due to different fracture modes. Fracture morphologies of the FSLW joints assisted by external stationary shoulder indicate ductile fracture.
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