Abstract
Static shoulder friction stir welding (SSFSW) offers a promising solution for joining Al6061 and Ti6Al4V by addressing material mixing and intermetallic formation encountered in conventional friction stir welding (CFSW). SSFSW effectively suppresses material mixing and Al-Ti interdiffusion, leading to an Al5Ti2 – Al3Ti sequence through an exothermic reaction. Comparative analysis with underwater friction stir welding (UWFSW) highlights SSFSW's effectiveness, showing a significant reduction in intermetallic layer thickness compared to UWFSW. The intermetallic layer thickness of SSFSW is measured at 2.169 µm, while UWFSW exhibits a thickness of 3.731 µm, and CFSW shows the highest at 5.485 µm. The inverse pole figure confirms reduced material flow and intermetallic formation in SSFSW compared to UWFSW and CFSW.
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