| Summary: | 2198 aluminum–lithium alloy was friction stir-welded with a KUKA Robot integrated with a compact friction stir-welding head with a rotation speed of 800 rpm at different welding speeds. The real-time tool force in the three directions of Fx, Fy and Fz was measured with a load sensor. Mechanical properties and microstructure evolution were investigated systematically. The results showed that Fz force increased from 3.2 kN to 8.5 kN as welding speed increased from 50 mm/min to 500 mm/min. Ultimate tensile strength of 383 MPa, 88% of base metal, was obtained when the welding speed was 100 mm/min. The nugget zone consisted of refined grains with an average size of 4 μm. TEM investigation demonstrates that T1 precipitation predominated in the base metal and disappeared in the nugget zone, as a small amount of δ’ was retained. The W-shape hardness profile in all weldments and higher welding speed lead to a higher hardness value.
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