Dissimilar friction stir welding and post-weld heat treatment of Ti-6Al-4V and AA7075 producing joints of unprecedented strength

Dissimilar welding of Ti and Al alloys is challenging due to the potential formation of brittle intermetallics, which can compromise weld strength. Friction stir welding (FSW) is an advanced joining method with the potential to drastically reduce or prevent the formation of intermetallic phases because melting is avoided. However, in previous studies, dissimilar joints of Ti-6Al-4V and EN AW-7075 with satisfactory strength could not be achieved. Thus, we investigated friction stir welding of these two materials in a butt configuration, and analyzed the effects of post-weld heat treatments on the mechanical properties. Tensile strengths of 441 MPa in the as-welded condition and 505 MPa after heat treatment were achieved, significantly surpassing strength values reported in earlier studies. Microscopic investigations showed no evidence of formation of brittle intermetallic phases, and ductile fracture was observed. Our results show that FSW is a very promising candidate for future aerospace applications requiring dissimilar joining of Ti and Al alloys.