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Dissimilar friction stir welding (FSW) between 6101-T6 and 7075-T651 aluminium alloys was conducted. Three different parameters each were investigated for rotational speed and travel speed, and the effects of these parameters on the tensile behaviour, hardness and wear were evaluated. The results indicate that the ultimate tensile strength increases with an increase in the feed rate. However, the increase in rotational speed decreases the ultimate tensile values. The fractured analysis of the tensile samples shows similarities in the fractured pattern as all the samples failed at heat affected zone close to the 6101-T6 alloy. The hardness varies across the heat affected zones and nugget zone both at constant rotational speed and welding speeds. The highest resistance to wear occurred at 65 mm min −1  and 1850 rpm welding speed and rotational speed respectively while better material mixing was achieved at the nugget zone of the welds at 1250 rpm and 110 mm/min.

Effects of processing parameters on mechanical, material flow and wear behaviour of friction stir welded 6101-T6 and 7075-T651 aluminium alloys