Abstract
Herein, we report the effects of gap variation upon the joint quality and thermomechanical behaviour of 2A14-T6 aluminium alloy friction stir butt welding. Based on the optimal weld pitch, gap-free and variable gap (from 0 to 2 mm in the weld) friction stir welding (FSW) experiments were conducted. The results indicate that welds without metallurgical defects were obtained up to a butt gap of 0.8 mm; however, voids and tunnel defect occurred at gap widths of 1.6 and 2 mm, respectively; moreover, the results showed that joint efficiency began to sharply decrease when the gap exceeded 1.6 mm. Furthermore, the thermomechanical model of varied gap FSW showed when the gap exceeded 0.8 mm, the material transferred by the tool would not completely fill the cavity formed by the pin’s forward motion. Finally, the gap-tolerance window for FSW was evaluated in terms of welding defects, joint efficiency, and thermomechanical behaviour.
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