Effects of Partial-Contact Tool Tilt Angle on Friction Stir Welded AA1050 Aluminum Joint Properties

This study aims to investigate the impact of partial-contact tool tilt angle (TTA) on the mechanical and microstructure properties of the AA1050 alloy friction stir weld (FSW). Three levels of partial-contact TTA were tested, 0°, 1.5°, and 3°, compared to previous studies on total-contact TTA. The weldments were evaluated using surface roughness, tensile tests, microhardness, microstructure, and fracture analysis. The results show that in partial-contact conditions, increasing TTA decreases the generated heat in the joint line and increases the possibility of FSW tool wear. This trend was the opposite of joints that were friction stir welded via total-contact TTA. The microstructure of the FSW sample was finer at higher partial-contact TTA, while the possibility of defect formation at the root of the stir zone in higher TTA was more than in lower TTA. The robust sample prepared at 0° TTA had 45% of AA1050 alloy strength. The maximum recorded heat in 0° TTA was 336 °C and the ultimate tensile strength of this sample was 33 MPa. The elongation of the 0° TTA welded sample was 75% base metal, and the average hardness of the stir zone was 25 Hv. The fracture surface analysis of the 0° TTA welded sample consisted of a small dimple, indicating the brittle fracture mode.