AA6061-T6 Aluminum Alloy Research Articles

An enhanced Hosford–Coulomb fracture model for predicting ductile fracture under a wide range of stress states

In this study, an Enhanced Hosford–Coulomb (EHC) fracture model is proposed, which suits a wide range of stress states. The model is validated by quantitatively investigating the ductile fracture behaviors of Ti-6Al-3Nb-2Zr-1Mo titanium alloy through experiments and numerical simulations, and the fracture morphologies are characterized using scanning electron microscopy. The results show that the EHC model has higher accuracy in predicting ductile fracture strain for Ti-6Al-3Nb-2Zr-1Mo alloy compared to the original Hosford–Coulomb (HC) model. Finally, the accuracy and material applicability of the EHC model are further verified with X80 pipeline steel and AA2024-T351 aluminum alloy, demonstrating its advantages.

Effect of Process Parameters on the Mechanical Properties of Simultaneous Double-Sided Friction Stir Welding Joints

Currently, conventional single-sided friction stir welding is primarily suitable for joining thin plate aluminum alloys, and its application to thick plates is still challenging in terms of welding efficiency and joint mechanical properties. Simultaneous double-sided friction stir welding (SDS-FSW) is a high-efficiency joining technique specifically developed for welding thick plates. However, there is little research on the influence of SDS-FSW process parameters on the joint mechanical properties. In this study, a 12 mm thick AA6061-T6 aluminum alloy and dual robot welding equipment are used to conduct SDS-FSW experiments exploring the influence of rotational speed ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} and welding speed v on the mechanical properties and microstructure. The results show that when the welding parameters are ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} = 800 r/min and v = 60–80 mm/min, smooth and defect-free thick plate aluminum alloy SDS-FSW joints can be obtained, and the macroscopic morphology of the joints is distributed in a “dumbbell” shape. The grain size in the weld nugget zone increases with increasing welding heat input. The microhardness distribution in the joint displays a “W” shape, and the hardness value of the weld nugget zone can reach 67% to 86% of that of the base metal (BM). The junction between the thermo-mechanically affected zone and the heat affected zone is the weakest region of the joint, with the lowest hardness being approximately 51% of that of the BM. When the welding parameters are ω\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\omega$$\\end{document} = 800 r/min and v = 140 mm/min, the SDS-FSW joint has the highest tensile strength, reaching 78.43% of the BM strength and exhibiting ductile fracture characteristics. This research indicates that acceptable weld strength in thick aluminum alloys can be achieved via the SDS-FSW joining mechanism, highlighting its significant potential for industrial applications.

Numerical investigation of patch geometry effect on the fatigue life of aluminum panels containing cracks repaired with CFRP composite patch using XFEM and CZM approach

This study investigated numerically the effect of using composite patches with various geometric shapes to improve the fatigue life of aluminum panels of AA7075-T6 and AA2024-T3 containing cracks and compared with the available experimental results. The Cohesive Zone Model (CZM) and Extended Finite Element Method (XFEM) were applied to static and fatigue analyses. Four types of rectangular, trapezoidal, left-oriented triangular and right-oriented triangular composite patches were used in the numerical analysis. With the combination of XFEM and CZM methods, and using the Paris equation, the fatigue crack propagation and fatigue life of aluminum panels containing cracks can be reasonably predicted. A composite patch with a suitable shape and geometry, fatigue life of the repaired panel can be improved considerably. With a 204 % improvement in fatigue life in comparison to the unrepaired panel, the repaired sample made of aluminum alloy AA2024-T3 alloy achieved the most significant improvement in fatigue life. In AA7075-T6 alloy samples repaired with composite patches, the samples repaired with rectangular and trapezoidal patches experienced the highest fatigue life increases, respectively with 342 % and 290 % compared to the unrepaired samples. The comparison of numerical simulation results with the available experiment results shows a good agreement.

Effect of Alkaline Etching on Formation Behavior and Corrosion Resistance of a Cr-Zr-Ti TCP Conversion Coating on AA2024 Aluminum Alloy

Trivalent chromium process conversion coating is considered to be the ideal alternative to traditional chromate conversion coating due to its high corrosion resistance and low toxicity. However, achieving a high corrosion resistance trivalent chromium conversion coating on 2xxx aluminum alloys has been a great challenge. Herein, based on a newly developed trivalent chromium conversion solution (CN patent, ZL 202210804263.2), the effect of alkaline etching on the formation behavior and corrosion resistance of the coating on AA2024-T351 aluminum alloy was investigated. It was found that under the same conditions, the mechanically polished sample and the sample alkaline etched for 30 s showed the highest corrosion resistance. When the alkaline etching time was too short or too long, the corrosion resistance of the coating deteriorated. This is ascribed to changes in the surface microstructure of the alloy during alkaline etching, i.e., reduced number of intermetallic particles and formation of a copper enrichment layer. Reducing the number of intermetallic particles on the alloy surface is beneficial for uniform growth of the coating. However, the copper enrichment layer participated in formation of the coating, resulting in doping of copper species in the coating, which is detrimental to the corrosion resistance of the coating.

Ultrasound-Enhanced Friction Stir Welding of Aluminum Alloy 6082: Advancements in Mechanical Properties and Microstructural Refinement

This study examines the effects of ultrasound-enhanced friction stir welding (USE-FSW) on the mechanical properties and microstructural characteristics of aluminum alloy AA6082-T6, commonly used in automotive, aerospace, and construction industries. The investigation included tensile and bending tests, as well as detailed microstructural evaluations using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and energy-dispersive X-ray spectroscopy (EDS). The results indicate that USE-FSW led to an approximately 26% increase in tensile strength compared to similar samples produced by conventional friction stir welding (CFSW). Additionally, the elongation at break improved by around 52%, indicating better ductility. Flexural strength also showed a notable improvement of over 70%. Microstructural analysis revealed a finer grain structure in the stir zone, contributing to these mechanical enhancements. However, the changes in texture and grain orientation were relatively modest, as shown by EBSD and Kernel Average Misorientation (KAM) analyses. Overall, USE-FSW offers incremental improvements in weld quality and mechanical performance, making it a promising technique for producing joints with slightly enhanced strength and ductility.

A generalized, computationally versatile plasticity model framework - Part II: Theory and verification focusing on shear anisotropy

Shear-dominated deformation (SHDD) is pivotal in sheet metal forming; however, comprehensive modeling of plastic anisotropy in SHDD, specifically shear anisotropy considering both yield stress and plastic flow, has been inadequately addressed in existing literature. In this work, a generalized constitutive framework is introduced on the basis of stress triaxiality-dependent state variable to accurately emulate plastic anisotropy and the physics-based shear constraint in SHDD. The framework is capable to seamlessly integrate with existing yield criteria, preserving computational efficiency and versatility. Notably, the yield function, anisotropic parameters, and their optimization or analytical determination for the non-shear deformation state remain unaltered. When integrated with the Hill48 yield function, featuring either one or two anisotropic parameters within the generalized constitutive framework, precise characterization of yield strength and plastic flow in SHDD is achieved. The applicability of the framework extends to various anisotropic yield functions such as the widely employed Yld2k-2d and the sixth-order polynomial (Poly6) function as a class of associated flow rule-based yield functions, and one non-quadratic yield function for non-associated flow rule scenarios. Experimental validation with two engineering sheet metals, high-strength dual-phase steel DP980 and high-strength aluminum alloy AA7075-T6, was conducted. Comparative analyses with several recently proposed yield criteria, especially Poly6–18p, highlighted the efficiency of the proposed constitutive framework. Furthermore, this study explores intrinsic shear constraints, particularly the absence of through-thickness strains under in-plane shear stress. Additionally, it offers an enhanced description of plastic anisotropy in shear yield stress within the general framework, providing valuable insights into the complexities of SHDD.

Process optimization of refill friction spot stir of AA6061-T6 aluminum alloy for thick plate

To investigate the process parameters of refillable friction stir spot welding for AA6061-T6 aluminum alloy with a 3 mm plate thickness, and to extend the applicability of this technology, experiments were conducted using custom-made tools under varying rotational and penetration speeds. This study aimed to produce well-formed welds and analyze the metallurgical structure, tensile shear strength, and microhardness of the welded joints. The experiments were performed at rotational speeds of 1000, 1200, 1400, and 1600 rpm and penetration speeds of 20, 30, 40, and 50 mm/min. These conditions were found to facilitate effective refillable friction stir spot welding. The results indicated that at lower rotational speeds, the joints failed at the interface, while at higher speeds, failure occurred through the plug. Optimal tensile shear strength was achieved at a rotational speed of 1400 rpm and a penetration speed of 30 mm/min, with a peak force of 9.27 kN and a joint surface fracture mode. Microstructural examination revealed a significant refinement of grains in the weld zone compared to the base metal. Microhardness measurements showed a concentric ring pattern on the upper surface with higher hardness at the center, decreasing toward the edges. The cross-sectional hardness demonstrated a vertical gradient, being higher at the top and decreasing toward the bottom. Notably, the welded area exhibited signs of annealing with a reduced hardness compared to the base metal, where the maximum value was recorded as HV79.

Synergetic effect of hybrid surface treatment on the mechanical properties of adhesively bonded AA2024-T3 joints

ABSTRACT Improving the surface properties of AA2024-T3 aluminium alloys is crucial for achieving durable and sustainable joints. For this purpose, AA2024-T3 alloys were first sandblasted at 4, 5 and 6 bar pressures using aluminium oxide and glass sphere abrasives. Then, the sandblasted samples were subjected to the chemical surface treatment resulting in a hybrid surface process. The surface properties of sandblasted and hybrid surface-treated AA2024-T3 alloys were characterised by 3D image analysis, contact angle and roughness measurement. Additionally, single-lap joints were fabricated using adhesives with low and high viscosity. The effect of changes in the viscosity of adhesives and the surface properties of the AA2024-T3 on the mechanical properties of the joints has been analysed in detail. It was found that both sandblasting and hybrid surface treatments applied to AA2024-T3 alloys caused significant improvement in the mechanical properties of the joints. AA2024-T3 alloys, which were chemically surface treated after being sandblasted with glass spheres at 6 bar pressure, were joined using low and high viscosity adhesives, and the failure load of these joints increased by approximately 110% and 68%, respectively, compared to untreated samples. In the case of aluminium oxide usage, the increase rates were determined to be 93% and 43%.

Influence of travel speed on porosity and liquation cracking in cold wire pulsed gas metal arc welding of aa7075-t651 aluminum alloy

Influence of travel speed on porosity and liquation cracking in cold wire pulsed gas metal arc welding of aa7075-t651 aluminum alloy

Hot Ductility Behaviour of AA7075-T651 Aluminium Alloy

Abstract This study focused on examining the hot ductility characteristics of aluminium alloy 7075-T651. Hot ductility is the capacity of a substance to undergo deformation at high temperatures without fracturing. Aluminium alloys typically demonstrate favorable hot ductility, rendering them appropriate for a wide range of high-temperature applications. The investigation entails performing hot tensile tests for AA7075-T651 aluminium alloy at different deformation temperatures (350°C-525°C), followed by fractography to ascertain the fracture mode. The ductility of the AA7075-T651 alloy was greatly enhanced during this procedure. The findings indicate that the hot working range of the aluminium alloy 7075-T651 can be expanded to 525°C instead of a liquidus start temperature of 477°C with a maximum of 30% ductility. The fractography results demonstrate that the fracture mode remains ductile. The AA7075-T651 aluminium alloy exhibits excellent thermal stability, allowing it to be hot worked at temperatures as high as 525°C without experiencing any sudden alterations in its characteristics or fracture behaviour.

Breakthrough in aluminum protection: Electrochemical and wear insights into sol-gel sealed PEO-coated AA2024-T3 and AA2198-T851

In consideration of the intrinsic porosity in layers generated via the plasma electrolytic oxidation (PEO) process, sol-gel coatings have gained a lot of attention for their environmentally friendly and robust protective qualities when applied as a post-treatment. The sealing capabilities of the sol-gel layer were scrutinized for the PEO coating applied on AA2024-T3 and AA2198-T851 aluminum alloys. Electrochemical Impedance Spectroscopy (EIS) and Field Emission Scanning Electron Microscopy (FE-SEM) confirmed that for the same operating conditions, the morphological properties of the PEO coating depend on the substrate nature and play a key role in the corrosion protection given by such duplex coatings. Furthermore, the findings indicated that the use of a sol-gel enhances the wear resistance compared to the blank substrates and the PEO coatings.

Assessment of aluminium alloys’ formability by elevated temperature testing

Abstract This work presents an investigation of the warm formability of AA7075-T6 aluminium alloy sheets using both experimental and numerical methods. Forming limit diagrams (FLDs) can be created by plotting the failure criteria on a graph with two axes representing major and minor strains. Sheets with a grid can be used to quantify both large and minor strains. General techniques available for the grid involve regular patterns of circles in this experiment. Experiments were conducted at various temperature levels, including room temperature, 100, 120, 140, 160, and 180 °C, as well as different strain rates. The investigation has revealed a significant impact of temperature on formability, while the effect of forming speed is quite insignificant across the whole range studied. At an ageing temperature of 140 °C, the distribution of precipitates is evenly balanced, resulting in improved mechanical strength. To offer accurate numerical models for warm-forming processes, a proposed constitutive model is introduced for aluminium alloy sheets. The present model incorporates plastic anisotropy and the effects of temperature and strain rate dependence. An investigation was conducted on the stress-strain behaviour of thin sheets composed of AA7075-T6 aluminium alloy under elevated temperatures and different strain rates. The objective was to ascertain the appropriate fitting parameters. It was associated with ABAQUS finite element modelling. The recommended material model was utilized to build finite element models, which were subsequently compared to the experimental data. The findings obtained from simulated isothermal uniaxial tensile tests were compared to the empirical measurements. The models used in the tensile test accurately predicted the material’s mechanical response. The predicted failure location, punch forces, and strain distributions for all three forming processes were found to be in close agreement with the experimental results. During deep draw operation, the warm forming limit curves were utilized to precisely predict both the pierce depth at which failure occurs and the precise location where the failure initiates.

Friction stir process parameters optimization in the fabrication of agate particle reinforced AA6061-T6 aluminum alloy surface composite

The main objective of this study was to optimize the friction stir process parameters to fabricate agate particle reinforced AA6061-T6 Aluminum alloy surface composite for hardness and tensile strength. The surface composite samples were made using a CNC milling machine based on Taguchi’s mixed L16 orthogonal array. The process parameters such as tool rotational speed, traverse speed, percent of reinforcement, number of passes and pin profiles were selected in this study. The optimal properties for the developed surface composite were obtained when surface composites having 18% reinforcement were fabricated by a two-pass FSP using a squared pin tool with a rotational speed of 1400 rpm and traverse speed of 60 mm/min. At the optimal process parameters, the tensile strength and hardness of the fabricated surface composite were found to be 312.23 MPa and 74.82 HRB respectively. ANOVA analysis performed at a 95% confidence level revealed that all process parameters were significant and the contribution of the number of passes on the properties of surface composite was higher than other process parameters. Microstructural analysis revealed that medium rotational speed and high traverse speed produced a uniform distribution of agate particles which helped to improve the properties.

The influence of molecular weight on the anticorrosion properties of chitosan coatings

The effort to replace toxic compounds with natural alternatives led to intensive investigations on the use of polysaccharides as coatings for corrosion protection. Biological macromolecules, such as chitosan, demonstrate great potential for the development of sustainable anticorrosion coatings. However, the role played by important properties, such as molecular weight, on the performance of the coatings, remains unclear. In this paper, the influence of molecular weight on the anticorrosion properties of chitosan coatings is investigated using AA2024-T3 aluminum alloy as substrate. Chitosan of three different molecular weights were used for the preparation of coatings and free-standing films, and their properties (morphology, swelling degree, and water contact angle) were evaluated. The corrosion performance of the coated samples was investigated by an atmospheric corrosion essay and by electrochemical impedance spectroscopy, in NaCl 3.5 % solution. The results show that the low-molecular-weight chitosan coatings present the lowest swelling degree (603 %), highest water contact angle (86.4°), lowest porosity, and superior performance in both corrosion tests, reaching impedances close to 105Ωcm2 even after seven days of exposure to corrosive solution.

Humidity-induced curing and anti-corrosion properties of GPTMS-modified polyorganosilazane functionalized silica coating on AA2024-T3 aluminum alloy

Relative humidity (RH) is one of the key parameters that significantly affect the curing kinetics and final properties of polysilazane-based coatings. Thus, the paper discusses the effect of relative humidity during the curing process and the anti-corrosion properties of (3-glycidyloxypropyl) trimethoxysilane (GPTMS)-modified polyorganosilazane (OPSZ) functionalized silica coatings on AA2024-T3. Modified polyorganosilazane sol was prepared and then deposited on AA2024-T3 substrates varying the curing conditions. After the deposition, the coated aluminum substrates were exposed to different RH levels; 15%, 40% and 80%, and then cured at 120 °C for 2 h. Transparent and crack-free GPTMS-modified polyorganosilazane coatings with a thickness of around 15–17 μm were obtained. The exposure to the relative humidity increased the crosslinking and hydrolysis-condensation reactions of the OPSZ and GPTMS molecules, showing more Si-O-Si bonds. The incorporation of GPTMS affected the crosslinking structure, enhancing the corrosion protection properties of the coating. GPTMS-modified polyorganosilazane coatings cured at 40%RH had the best anti-corrosive properties after immersion in 3.5 wt% NaCl solution. The impedance modulus of ∼109 Ω.cm2 at a low frequency was obtained, which was five orders of magnitude higher than that for the AA2024-T3 alloy.Graphical

A comparative study on mechanical properties between linear and zigzag pattern holes reinforced with tialite particles during FSW of AA6082 alloy

In this study, a comparison between linear and zigzag patterned holes is carried out where the holes in the pattern are incorporated with tialite/aluminium titanate (Al2TiO5) particles at the weldment region during friction stir welding of AA6082-T6 aluminium alloy. Different values of tool rotational speed (TRS: 1000, 1200 and 1400 rpm) and welding speed (WS: 35, 40 and 45 mm/min) are considered for the fabrication of joints by both patterns. Visually, no defects are found in all the welded samples. Microstructural analysis has proven that the uniform distribution of particles along the weld region can be obtained by using a zigzag pattern. Maximum hardness is found in the stir zone (SZ), whereas minimum hardness is found in the heat-affected zone (HAZ) for all the samples. The maximum ultimate tensile strength (UTS: 268 MPa), maximum yield strength (YS: 200 MPa) and relatively higher elongation (EL: 7.89%) are exhibited by the Z5 sample, whereas minimum UTS (206 MPa) and minimum YS (142 MPa) was exhibited by L3 and Z7 samples, respectively.

Investigating the effect of stress ratio on fatigue crack growth rate behaviour in friction stir welded AA7075-T651 aluminium alloy plates

This study examines the characteristics of Fatigue Crack Growth Rate (FCGR) in AA 7075-T651 Friction Stir Welded (FSW) joints with a thickness of 16 mm. Compact tension (CT) specimens from both the base and the FSW joints were utilized to assess FCGR under various stress ratios (0.2 to 0.5). Additionally, the study involved analyzing the transverse tensile characteristics of both the based and the welded joints. The microstructures of the welds were inspected using optical and transmission electron microscopes. Findings indicate that the FSWjoint critical stress intensity factor range (ΔKcr)is lower than the unwelded base, that can be related to precipitates dissolving in the weld zone when the friction stir welding process. Consequently, in contrast to the unwelded base, the fatigue life of AA 7075-T651 aluminium alloy FSW joints is significantly reduced. A scanning electron microscope carried out microstructural analyses of the fracture surfaces of the FSW and base under various stress ratioconditions. The results showed that, in contrast to the parent material, the FSW joint has ultra-fine grains resulting in intergranular cracks in the propagation zone.

Assessment of the Thermomechanical Behavior and Microstructure of AA 7075-T6 Aluminum Alloy Lap Joints at Optimal Predicted FSW Process Parameters

The lap joints of AA 7075-T6 aluminum alloy were assembled using the friction stir welding (FSW) technique. Experimental studies were performed to characterize the thermomechanical properties of these welds. The main goal of this research was to comprehensively assess the thermomechanical behavior of AA 7075-T6 aluminum alloy under FSW conditions. Tests were carried out at a tool rotational speed of 1320 rpm and at two advancing speeds of 70 mm/min and 120 mm/min, selected based on a previous study aiming to optimize the heat input during the FSW process. The experimental investigations involved the characterization of temperature profiles during welding, mechanical properties such as microhardness and tensile strength, and microstructure examination at the two advancing speed conditions. This study revealed that the welding speed has an obvious influence on the material thermal behavior during the FSW process. Indeed, the peak temperature obtained with a lower welding speed (70 mm/min) was higher by almost 10% compared to that obtained with a higher speed (120 mm/min). Moreover, by increasing the welding speed, the mechanical characteristics, such as microhardness and tensile strength, were increased by almost 5% for the mean microhardness and 6% for the ultimate tensile strength. Additionally, the microstructure examination demonstrated that, by decreasing the welding speed, more interaction between the tool and the material is observed, resulting in a deeper stir zone due to increased heat dissipation downwards into the material, affecting the thermal profile and influencing the resulting mechanical properties of the welded joint.

Comprehensive analysis of mechanical properties, wear, and corrosion behavior of AA7075-T6 alloy subjected to cryogenic treatment for aviation and defense applications

It is important that the parts to be used in the aviation and defense industry have high wear, fatigue and corrosion resistance. AA7075-T6 alloys are increasingly used in every field due to their advantageous physical and mechanical properties. However, some of the materials of this alloy types exhibit excellent fatigue strength and ductility, but their surface hardness and surface roughness after processing may be poor. For this reason, the wear resistance of AA7075-T6 aluminum alloy expected to be improved in order to increase their corrosion resistance properties. In this work, cryogenic treatment was applied to AA7075-T6 alloy and the mechanical characteristics, wear and corrosion behaviors of these samples were examined. As a result of the experiments, it was determined that cryogenic treatment improved the wear behavior of AA7075-T6 alloy. The untreated sample was found to have the highest wear rate, whereas the sample with deep cryogenic treatment (DCT) had the lowest wear rate. The hardness of the DCT process increased by 5.79 %, according to macro hardness measurements, making the AA7075-T6 alloy harder from 80.16 HRB to 84.8. The SEM images revealed that, the shallow cryogenic and deep cryogenic operations had substantial effects on the microstructure by modifying the size and distribution of precipitates in the AA7075-T6 alloy. In addition, tensile and hardness tests were carried out to assess the mechanical characteristics of the samples. Accordingly, the maximum tensile strength and hardness values were obtained in the deep cryogenically treated sample. The tensile strength of the DCT sample was approximately 544.18 MPa, a considerable 11.5 % increase above the untreated sample's 488.07 MPa strength. In potentiodynamic polarization testing, the DCT treated sample was determined to have the maximum corrosion resistance. Among the materials tested, the DCT sample showed the strongest corrosion resistance, with a corrosion potential of −0.689 V and a corrosion rate of 0.021 mm/year. Wear rate analysis revealed that DCT samples experienced the least material loss, demonstrating improved abrasion resistance. Enhanced hardness and the formation of stable oxide tribo-layers contributed to these superior wear characteristic.

Comparison between Mechanical Properties and Joint Performance of AA 2024-T351 Aluminum Alloy Welded by Friction Stir Welding, Metal Inert Gas and Tungsten Inert Gas Processes.

The aim of this work is to study joining Al 2024-T3 alloy plates with different welding procedures. Aluminum alloy AA 2024-T351 is especially used in the aerospace industry. Aluminum plates are welded by the TIG and MIG fusion welding process, as well as by the solid-state welding process, friction stir welding (FSW), which has recently become very important in aluminum and alloy welding. For welding AA2024-T35 with MIG and TIG fusion processes, the filler material ER 4043-AlSi5 was chosen because of reduced cracking. Different methods were used to evaluate the quality of the produced joints, including macro- and microstructure evaluation, in addition to hardness and tensile tests. The ultimate tensile strength (UTS) of the FSW sample was found to be 80% higher than that of MIG and TIG samples. The average hardness value of the weld zone of metal for the MIG- and TIG-produced AA2024-T3511 butt joints showed a significant decrease compared to the hardness of the base metal AA2024-T351 by 50%, while for FSW joints, in the nugget zone, the hardness is about 10% lower relative to the base metal AA2024-T3511.