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<p>The 2024 Al-Cu alloy is extensively used in aerospace, automotive, and structural applications due to its remarkable properties, such as a higher strength-to-weight ratio and lightweight nature, making it a popular choice across various industries for various applications. Therefore, in the present study, the effect of varying process parameters, such as tool traverse speed (TTS) and rotational speed (TRS), on force and torque, ripple formation during the joining of surfaces, surface morphology, surface roughness, and hardness of friction stir-welded AA2024 Al-Cu alloy was investigated. The materials were joined at different TRS of 600, 900, and 1200&#xa0;rpm and TTS of 3, 5, and 7&#xa0;mm/s using a taper-threaded friction stir tool at a constant tool tilt angle. The results reveal that the low ripple distance occurred at higher TTS. Further, at a constant TRS, it is observed that the TTS is increased, and the ripple distance on the welded samples is also increased. Moreover, the higher surface roughness (SR) values at the weld center (9.82&#xa0;µm) and 4.38&#xa0;µm from AS to RS at TRS of 900&#xa0;rpm and TTS of 3&#xa0;mm/s and higher micro-hardness values are observed (125HV<sub>0.1</sub>) at the same process parameters.</p>

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Effect of Process Parameters on Force, Torque, Surface Morphology, and Hardness of Friction Stir-Welded AA2024 Alloy Plates

  • 期刊论文

  • 发表日期：

    2026年2月14日

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  • Debraj Das,
  • Sanjeev Kumar,
  • Jitendra Kumar Katiyar,
  • Barnik Saha Roy

摘要

The 2024 Al-Cu alloy is extensively used in aerospace, automotive, and structural applications due to its remarkable properties, such as a higher strength-to-weight ratio and lightweight nature, making it a popular choice across various industries for various applications. Therefore, in the present study, the effect of varying process parameters, such as tool traverse speed (TTS) and rotational speed (TRS), on force and torque, ripple formation during the joining of surfaces, surface morphology, surface roughness, and hardness of friction stir-welded AA2024 Al-Cu alloy was investigated. The materials were joined at different TRS of 600, 900, and 1200 rpm and TTS of 3, 5, and 7 mm/s using a taper-threaded friction stir tool at a constant tool tilt angle. The results reveal that the low ripple distance occurred at higher TTS. Further, at a constant TRS, it is observed that the TTS is increased, and the ripple distance on the welded samples is also increased. Moreover, the higher surface roughness (SR) values at the weld center (9.82 µm) and 4.38 µm from AS to RS at TRS of 900 rpm and TTS of 3 mm/s and higher micro-hardness values are observed (125HV0.1) at the same process parameters.