Process optimisation and mechanical properties of friction stir lap welds of 7075-T6 stringers on 2024-T3 skin

Abstract This paper focuses on the results of process optimisation and mechanical tests that were used to ascertain the feasibility of using friction stir welding (FSW) to join stringers to skin. The effects of process parameters on weld quality of 1.5-mm 7075-T6 stringers lap-joined on 2.3-mm 2024-T3 skins were investigated. Advancing and retreating side locations on the joint configuration were alternated to determine optimal design arrangements. The effects of travel and rotation speeds on weld quality and defect generation were also investigated. Weld quality was assessed by optical microscopy and bending tests. It was found that: (i) the increase of the welding speed or the decrease of the rotational speed resulted in a reduction of the hooking size and top plate thinning but did not eliminated them, (ii) double pass welds by overlapping the advancing sides improved significantly the weld quality by overriding the hooking defect, and (iii) change of the rotational direction for a counter clockwise with a left-threaded probe eliminated the top sheet thinning defect. Subsequently, FSW lap joints were produced using optimum conditions and underwent extensive mechanical testing program. Several assembly configurations including discontinuous and continuous welds as well as single and double pass welds were produced. The results obtained for cyclic fatigue performance of FSW panels are compared with riveted lap joints of identical geometry. S – N curves, bending behaviour, failure locations and defect characterisation are also discussed. It was found that: (i) the tensile strength of FSW joints approached that of the base material but with a significant reduction in the fatigue life, (ii) the probe plunge and removal locations served as the key crack nucleation sites in specimens with discontinuous welds, and (iii) double pass welds with overlapping advancing sides showed outstanding fatigue life and very good tensile properties. The present work provided some valuable insight into both the fabrication and application of FSW on stringer/skin lap joints.