Friction Stir Welding of AA2099-T83 and AA2060-T8E30 Aluminium Alloys with New Cr-Free Surface Treatments and Sealant Application

The feasibility for friction stir welding (FSW) surface-treated AA2099-T83 aluminium extrusions with AA2060-T8E30 sheets in the overlap configuration and using a sealant at interface was investigated this work. New Cr-free surface treatments such as thin film sulphuric acid anodising (TFSAA) sol–gel were applied to parent materials, before applying FSW process. welds produced several combinations of application no significant influence on process stability performance. metallographic examination showed that good protection crevice achieved some accumulation edges overlapping region. microstructural analysis remnants but presence oxide zone (SZ) welds, especially TFSAA treated material cases. However, these did not show any effect static pull-out strength joints failures most stressed outside weld region consistently obtained.