Abstract
<p>The third generation of Al-Li alloy is a significant material, primarily applicable in the aerospace sector due to its low density, high strength, and increased fatigue crack growth resistance properties. In this study, three tools with different pin geometries, such as triangular, threaded taper, and hybrid tool pins (coupled triangular and threaded taper), are used to join Al-Li alloy at a specific set of process parameters to assess the tool design affects the joint’s surface roughness (SR) and tensile strength. The surface roughness values of the friction stir welded samples were measured on different sides [advancing side (AS), retreating side (RS), AS to RS, and the weld centre (WC)]. At the same rotational speed (1400 rpm), welding speed (180 mm/min), and tilt angle (2°), the experimental results revealed that the HTP weld has a lower surface roughness value than other tools while having higher joint efficiency (78.44%) and tensile strength (418.98MPa).</p>
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