The reliable joining of ultra-thick aluminum alloy plates remains a critical technical challenge in modern industrial manufacturing, often hindered by defects such as porosity and excessive distortion associated with conventional fusion welding. The novelty of this work lies in the characterization of the intermediate layer overlapping zone in 110 mm ultra-thick plates, which has rarely been reported. The motivation is to overcome the limitations of single-pass FSW for thick plates, such as insufficient material flow and high tool forces, by adopting a sequential double-sided strategy. Furthermore, this technique may help moderate the through-thickness heat input variation, although no direct thermal measurements were made. The weld nugget zone consists of uniformly fine, recrystallized α-Al grains. In contrast, the heat-affected zone displays distinctly laminar grain structures. The overlapping regions within the intermediate layer, which undergo two thermal cycles, exhibit refined grain sizes. A well-defined interface is evident between the advancing-side weld nugget zone and the thermo-mechanically affected zone. The overall tensile strength of the FSW joint is approximately 81% of the base material, and the tensile specimen fractured at the interface between the thermo-mechanically affected zone and the heat-affected zone. Along the thickness of the weld joint, a “W”-shaped microhardness distribution is observed at the surface and subsurface, whereas the intermediate layer exhibits a distinct “V”-shaped profile. The lowest microhardness value is located in the intermediate layer overlapping area due to the insufficient heat input and limited grain growth in this region. In summary, under the specific welding parameters tested (130 rpm, 15 mm/min, 110 mm thick), double-sided friction stir welding produces defect-free joints in AA 5052-H32, suggesting its potential for thick-plate applications, offering a practical and effective solution for manufacturing high-performance aluminum alloy structures. Potential industrial applications include pressure vessels for chemical storage, ship hull structures, and heavy-duty transportation components where ultra-thick aluminum plates are required.
Shao et al. (Fri,) studied this question.