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Mechanical and microstructural characterization of friction stir welded skin and stringer joints

A microstructural and mechanical investigation on lap joints welded by friction stir welding and made out of a 7075-T6 stringer and a 2024-T4 skin is presented. In particular, the metallurgical and mechanical properties of joints have been studied at different tool feed rates (V = 35, 50, 100 mm/min) and constant rotation speed (R = 500 r/min). Temperature distributions have been monitored during the process. It is found that in the welded area, the recrystallized zone (nugget) has an average grain size of about 3 µm and exhibits coarsened MgZn2 particles on grain boundaries. The maximum values of microhardness in the welded skin increase with the process temperature, while they just slightly vary with process temperature in the stringer. From the mechanical point of view, the joint welded at R = 500 r/min and V = 50 mm/min exhibits both the highest strength and average microhardness value in the welded area.