Effect of Friction Stir Process Parameters on the Mechanical and Thermal Behavior of 5754-H111 Aluminum Plates

A study of the Friction Stir Welding (FSW) process was carried out in order to evaluate the influence of process parameters on the mechanical properties of aluminum plates (AA5754-H111). The process was monitored during each test by means of infrared cameras in order to correlate temperature information with eventual changes of the mechanical properties of joints. In particular, two process parameters were considered for tests: the welding tool rotation speed and the welding tool traverse speed. The quality of joints was evaluated by means of destructive and non-destructive tests. In this regard, the presence of defects and the ultimate tensile strength (UTS) were investigated for each combination of the process parameters. A statistical analysis was carried out to assess the correlation between the thermal behavior of joints and the process parameters, also proving the capability of Infrared Thermography for on-line monitoring of the quality of joints.