Influence of Tool Offset Distance on Microstructure and Mechanical Properties of the Dissimilar AA2024–AA7075 Plates Joined by Friction Stir Welding

In the present study, the effect of tool offset on microstructure and mechanical properties of dissimilar friction stir welding of Al2024 and Al7075 alloys were investigated. In this regard, base metals were welded by FSW under different tool offsetting conditions, 1.5 and 2 mm shifted into Al2024 and Al7075 alloys, respectively, in addition to constant rotation rates and traverse speeds named as 710 rpm and 28 mm/min respectively. The microstructure of different welding zones and fracture surface were investigated by an Optical Microscope (OM) and Scanning Electron Microscopy (SEM), respectively. The results showed that by tool offsetting from the weld center through Al2024, an onion-shaped area has been created and mixture happens completely. However, by tool off-setting towards Al7075, onion-shaped microstructure fails to be formed in the stirred area. From the results of the tensile test, it is presented that maximum tensile strength is obtained in samples with a tool offsetting into the Al7075. With 1.5 mm tool offsetting into Al2024, first, joint tensile strength increases by 22.2 % in comparison to non-offset condition, and then, with more tool offset as much as 2 mm, tensile strength decreases by 22.2 %. In addition, by tool offsetting towards Al7075 by 1.5 and 2 mm, joint tensile strength decreases by 4.5 and 28.5 %, respectively. It is also concluded that in the offset samples towards the 7075 alloy, the microhardness in the HAZ area decreased compared to the microhardness of the offsets samples towards the 2024 alloy. Finally, the best mechanical behavior and microstructural properties were obtained in the sample with the tool offset of about 1.5 mm towards the welded Al2024 base metal (70215 samples) alloy.