The Effect of Brushing on Residual Stress and Surface Roughness of EN AW-2024-T3 Aluminum Alloy Joints Welded Using the FSW Method

This article presents the influence of the brushing process on residual stress and surface roughness of EN AW-2024-T3 aluminum alloy joints welded using the Friction Stir Welding (FSW) method. Butt joints with thicknesses of 2 mm were brushing with using ceramic brush. The aim of the study was to find optimal parameters of the brush-ing process, which would significantly improve the functional properties of welded joints. The experiments were carried out in two steps. In the first stage of the research, the feed rate was changed in the range f = 40 divided by 120 mm/min with a constant brushing depth d = 0.5 mm. The roughness decreased from Sa = 5.285 mu m for the specimen after welding to Sa = 2.460 mu m for the f = 120 mm/min and d = 0.5 mm. The change in the parameters of the brushing process did not have a significant impact on the state of residual stresses. Hence, in the second step, the brushing depth was increased in steps of 0.1 mm. The best properties were obtained for f = 120 mm/min and d = 0.6 mm (variant 6A), where roughness was Sa = 0.443 mu m and compressive stresses sigma =-118 MPa.