Failure Analysis of AA 7075 Joints Processed by FSW and SFSW

This paper presents a failure analysis of AA 7075 Aluminium 7075 joints processed by Friction Stir Welding (FSW) and Submerged Friction Stir Welding (SFSW) techniques. AA 7075 is a high-strength aluminium alloy commonly used in aerospace, automotive, and other industries due to its excellent mechanical properties. Understanding the failure mechanisms in these joining processes is essential for ensuring the structural integrity and reliability of AA 7075 joints. The study investigates the failures encountered in FSW and SFSW joints of AA 7075. Macroscopic and microscopic examinations are conducted to analyse the root causes of these failures. Macroscopic observations include visual inspection, dimensional measurements, and identification of fracture locations. Microscopic investigations utilize techniques scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) to examine the microstructure, fracture surfaces, and elemental composition of the failed joints. Based on the failure analysis findings, recommendations are provided to enhance the quality and reliability of AA 7075 joints processed by FSW and SFSW. The results of this failure analysis contribute to the understanding of AA 7075 joining processes using FSW and SFSW methods. By identifying the failure mechanisms and proposing preventive measures, this research aids in improving the quality and performance of AA 7075 joints, thereby ensuring the integrity and reliability of joined structures in industries that rely on aluminium alloys for critical applications.