Effect of friction stir welding on microstructure, tensile and fatigue properties of the AA7005/10 vol.%Al2O3p composite

Several studies have been recently focused on friction stir welding of aluminium alloys and some data are also reported on FSW of aluminium-based composites. The application of this solid state welding technique to particles reinforced composites seems very attractive, since it should eliminate some typical defects induced by the traditional fusion welding techniques, such as: gas occlusion, undesidered interfacial chemical reactions between the reinforcement and the molten matrix alloy, inhomogeneous reinforcement distribution after welding. The present work describes the effect of the FSW process on the microstructure and, consequently, on the tensile and low-cycle fatigue behaviour, of an aluminium matrix (AA7005) composite reinforced with 10 vol.% of Al2O3 particles (W7A10A). The microstructural characterization evidenced, in the FSW zone, a substantial grain refinement of the aluminium alloy matrix (due to dynamic recrystallization induced by the plastic deformation and frictional heating during welding) and a significant reduction of the particles size (due to the abrasive action of the tool). Tensile tests showed a high efficiency of the FSW joints (about 80% of the ultimate tensile strength). The low-cycle fatigue tests evidenced a fatigue life reduction for the FSW material respect to the base composite, particularly for high values of total strain range. The fracture mechanisms for the FSW specimens were those typical of metal matrix composites: interfacial decohesion, void nucleation and growth, as well as fracture of reinforcing particles, as shown by SEM analyses of the fracture surfaces.