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Similar aluminum alloys (AA5086-H32 with AA5086-H32) were welded by friction stir welding (FSW) using three different values of linear speeds; namely 50, 75 and 90 mm/min.and different and rotating speed namely 680, 920 and 1500 rpm. Tensile test was used to determine the joint efficiency of welded samples. The microstructure, hardness, tensile tests and fatigue properties were studied for the welded sample which gave the highest tensile strength. The fatigue test was carried out at a constant stress amplitude cantilever fully reversed( R=-1) in the stir zone of weld and nearby zone or region at a distance of 5, 10 and 15 mm from the welding line. The fracture fatigue surface was analyzed using SEM. It was found that the maximum joint efficiency of 80% was obtained at rotating speed of 680 RPM and linear speed of 75 mm/min. The maximum value of hardness was at the stir zone center of the weld and started to decrease away from it. Fatigue strength of the FSW welded samples was less than the parent or base alloy.

Analysis of fatigue properties in similar friction stir welding joints of aluminum alloy ( AA5086-H32 )