High-Speed Friction Stir Lap Welding of Al Alloys

  • Piyush UpadhyayEmail author
  • Xiao Li
  • Tim Roosendaal
Conference paper
Part of the The Minerals, Metals & Materials Series book series (MMMS)


Friction stir lap welding (FSLW) with linear speed of 1 m/min or higher can open up opportunities for industrial implementation. This paper will provide an overview of several challenges and mitigation strategies to produce effective joints between several Al alloys. FSLW of Al alloys at high speed presents challenges including interface hook features and defects at the interface. 5xxx, 6xxx, and 7xxx Al alloys were joined and characterized. Load-bearing capacity in excess of 80% of base material strength has been demonstrated at the welding speed of 2 m/min for 6xxx and 5xxx similar lap joints. The effects of parameters like welding speed, RPM, tool geometry in material flow features, void volume, and hook geometry is investigated and this knowledge base is applied to improve the joint strength of 7xxx lap welds.


Friction stir lap welding High speed AA7xxx AA5xxx AA6xxx 



PNNL is operated by Battelle Memorial Institute for the U.S. Department of Energy under contract DE-AC05-76RL01830. This work was sponsored by S. Kleinbaum in association with the U.S. Department of Energy Office of Vehicle Technologies as part of the Lightweight Materials program along with contributions from participating entities including Honda R&D Americas, and Arconic Inc.


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Copyright information

© The Minerals, Metals & Materials Society 2019

Authors and Affiliations

  1. 1.Pacific Northwest National LaboratoryRichlandUSA

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