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The main objective of this investigation is to study the microstructure, tensile properties and fracture toughness of friction stir welded (FSW) butt joints of 10 mm thick AA7075-T651 plates. The microstructural features of stir zone (SZ), thermos-mechanically affected zone (TMAZ), heat affected zone (HAZ) were analyzed using optical microscopy technique. The tensile properties were evaluated using smooth and notch tensile specimens and compared to base metal properties. The microhardness survey was done across the weld cross section and correlated to the failure of tensile specimens. Compact tension (CT) specimens were used to evaluate the fracture toughness of welded joints. The fractured tensile and CT specimens were analyzed using scanning electron microscopy (SEM). Results showed that the FSW AA7075-T651 specimens welded using axial load of 12 kN, tool rotation speed of 750 rpm and welding speed of 30 mm/min exhibited 412 MPa tensile strength and 9% elongation. It showed 88 and 89% of base metal strength elongation. The joints showed fracture toughness of 23 MPa m 1/2  which is 80% of base metal fracture toughness. The superior tensile and fracture toughness properties of joints are mainly attributed to the evolution of finer grains in SZ due to the stirring action of FSW tool.

Microstructure, tensile properties and fracture toughness of friction stir welded AA7075-T651 aluminium alloy joints