Metallurgical and mechanical properties of underwater friction stir welds of Al7075 aluminum alloy

Travel speeds between 25–300 mm/min and tool rotational speeds of 800 and 1250 rpm were employed for this study. The microstructure, mechanical properties and fracture surfaces of the joints were studied. Underwater environment and an increase in travel speed significantly increase the precipitates’ volume fraction, reduce the average grain and precipitate sizes of the weld nugget zones. A critical travel speed of 150 mm/min is attained in underwater welds beyond which the average grain sizes remain relatively the same. Average grain and precipitate sizes have linear relationships with the tool rotational and travel speed ratio. Optimum weld strengths of 396 and 360 MPa were obtained in the underwater and air-cooled welds at tool rotational and travel speeds of 800 rpm and 50 mm/min respectively.