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Abstract
This paper examines the effect of three friction stir welding process parameters on the residual stresses, hardness and distortion for butt welded aluminium–lithium AA2199 alloy, a novel, low density high strength alloy with potential in the aerospace sector. A systematic set of nine trial welds is examined at different tool rotation and traverse speeds as well as tool downforces. The tensile residual stresses (∼50% of parent material yield strength) and the hardness drop in the weld line varied little with any of the friction stir welding process parameters. However, their breadth increased with rotation speed and downforce and decreased with increasing translation speed, which is consistent with increasing heat input. Weld distortion took the form of a saddle with the longitudinal bending distortion correlating strongly with the width of the tensile zone consistent with it being driven by the magnitude of the tensile buckling forces in the weld region.
