Rotary Friction Welding Parameters Effects upon Mechanical Properties and Microstructure of AA2024 Weld Joints

The present work investigates Rotary Friction Welding (RFW) of AA2024 similar joints, where the welding operations were carried out using an adapted device to a column-drilling machine (SUPEMEC J320). This work aims to determine the optimal RFW parameters from an experimental study based on mechanical tests and microscopic observations of weld joints. The best compromise, which offers the highest tensile strength value (499 MPa) corresponds to the joint obtained by using a rotational speed of 2000 rpm, a friction pressure of 12 MPa, and a forging pressure of 17 MPa. The EDX results indicate the presence of the intermetallic compounds (IMCs) in each zone of the weld joints, with varying sizes and a random distribution. This study focuses also on the microscopic analyses of the interface of weld joints and the fracture surfaces that indicates a dominant ductile fracture mode.