Friction Stir Welding of 5754 Aluminum Alloy with Cover Sheet

Friction stir welding can realize high-strength aluminum alloy joints. In this study, friction stir welding with cover sheet (CFSW) is proposed to solve the thinning caused by the tool shoulder and reduce the heat-affected zone. The microstructures and mechanical properties of CFWS were also studied. After the cover sheet was added, a reinforcement was formed on the weld surface, which compensated the thinning caused by the friction of the tool shoulder. As the cover absorbed heat from the shoulder, the width of the heat-affected zone of the welded sheet became smaller than the diameter of the shoulder. Without milling the cover sheet, the tensile strength of the 5754 aluminum alloy joint reached 94% of that of the base metal. The fracture position was the heat-affected zone of the forward-side weld joint. After the cover sheet was added, the stress concentration shifted from the thinning area of traditional friction stir welding to the outside of the welding seam.