1. State Key Laboratory of Precision Welding & Joining of Materials and Structures, Harbin Institute of Technology, Harbin 150001, China;
2. Zhengzhou Research Institute, Harbin Institute of Technology, Zhengzhou 450046, China;
3. AVIC Manufacturing Technology Institute, Beijing 100024, China;
4. Shanghai Aerospace Equipment Manufacturing Factory Co., Ltd., Shanghai 200245, China
To address the deformation issue in friction stir welding (FSW) of aluminum alloy thin-walled structures, a novel method of in-situ rolling friction stir welding (IRFSW) is proposed. The effects of IRFSW on the welding distortion, microstructure and mechanical properties are studied. The results show that the IRFSW can eliminate the flash and ensure the high-quality forming of the joint. The surface grain size of IRFSW joint was obviously refined and a gradient structure with a thickness of about 282 μm was formed on the surface of the IRFSW joint. The surface microhardness of the joint was improved by grain refinement. The tensile strength of the IRFSW joint was 3.3% higher than that of conventional FSW joint. In addition, the distortion degree of IRFSW joint was reduced by 84.8% compared with conventional FSW joint.
2025, 
