Void Formation in Friction Stir Welding of AA5052 Butt Joining


Mohanad Kadhim Mejbel *, Heyam Razaq Atwan, Isam Tareq Abdullah


†Middle Technical University, Technical Engineering College-Baghdad, Iraq.

Corresponding Author Email: mohanad@mtu.edu.iq,

This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Friction stirs welding (FSW) mechanical joining properties are dramatically pushed into deterioration when a void (tunnel) defect is formed. Due to improper heat input and insufficient plasticized material flow, defects in the weld are generated at certain variations in welding parameters. In this study, the void formation in FSW of AA 5052-H34 butt joints was studied using three cases of welding parameters. The effect of void formation was evaluated by implementing tensile, bending tests, and adopting (ANSYS software) to determine the stress concentration factor. Cases 2 and 3 reported the formation of voids at the welded zone. No voids were presented at case 1, which revealed the best results with an increase of 65% more than those of friction stir welded samples. At case 1, the highest bending force of 3.7 KN was obtained. To avoid voids and tunneling formation, the relation between tool circulation and traverse velocities should be well-taken care of to control the thermal energy, which is the most critical factor in this flaw.