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AA6061 and AA7075 aluminum alloys were successfully joined by using single-pass and multiple-pass friction stir welding techniques after which the effects on the nugget zone evolution from a second overlapping pass and its welding direction, were investigated. In comparison to single-pass friction stir welding, the application of a second overlapping pass prolonged the dynamic recrystallization time, and the grains of the nugget zone became finer with increased high angle grain boundaries. Moreover, reversing the welding direction of the second overlapping pass enhanced the vertical flow of materials, increasing the strain of the friction stir welding in the nugget zone. As a result, the efficiency of the grain refinement and mixture of dissimilar materials during the second overlapping pass were significantly elevated. The tensile strength of the nugget zone was improved after the second overlapping pass due to both the grain refinement and mechanical interlocking of the AA6061/AA7075 alloys. The nugget zone, which was fabricated via the multiple-pass friction stir welding technique using an opposite welding direction, exhibited a 23% increase in yield strength as compared to the sample using the single-pass friction stir welding technique.

The Evolution of the Nugget Zone for Dissimilar AA6061/AA7075 Joints Fabricated via Multiple-Pass Friction Stir Welding