Reducing the Hook Defect of Friction Stir Lap Welded Ti-6Al-4V Alloy by Slightly Penetrating into the Lower Sheet

Abstract

For the purpose of reducing the hook defect in friction stir lap welding joint, Ti-6Al-4V alloy was lap welded by slightly penetrating into the lower sheet. Hook feature, microstructure and mechanical properties of the lap joints were mainly discussed. Results show that using slight penetration, plastic material mainly concentrates above the lap interface, which is beneficial to suppress the primary hook and broaden the stir zone (SZ) width. Simultaneously, a very small secondary hook is formed. The void-like defect, which is formed due to high peak temperature and big temperature gradient along thickness, can be eliminated by decreasing the rotating speed. Microstructures along thickness show much difference due to big temperature gradient. SZ hardness of both the upper and lower sheets is higher than the base material due to finer grains. Bigger lap shear failure load can be obtained using 150 rpm, which is 17.1 KN. Lap joints fracture along the secondary hook and present ductile fracture mode.