Abstract
An innovative double-side friction stir Z shape butt-lap welding (DS-FSZW) process was proposed for welding medium-thick Ti/Al dissimilar metals. It suggests that the DS-FSZW joint eliminates the weak bonding zone and adds a lap joining surface compared to the traditional double side friction stir welding (DS-FSW) joint. The DS-FSZW joint also forms a thinner IMCs layer between the Ti/Al interface, and this increases the effective bonding strength of the interface. In addition, the DS-FSZW reduces the axial force during the DS-FSW of the second-side weld. The tensile strength of the DS-FSZW joint is 313 MPa, reaching about 70% of the AA2024-T4, which is increased by more than 18% compared to the DS-FSW joint. This indicates that the innovative DS-FSZW enhances the joint performance.
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